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By Alex Doll, Derek Barratt

"There is a number of comminution tests commonly used in the mining industry. Many of the tests are used for a particular grinding model or mill sizing program and are incompatible with other tests of different models. This paper provides an overview of the commonly used grinding and crushing tests, which models (or practitioners) use a particular combination of tests and draws some relationships between the incompatible tests based on the DJB Consultants Inc. database of projects.Case studies will demonstrate similarities and differences between major mining districts with some comments about homogeneous and heterogeneous behaviour within the grindability results.INTRODUCTIONThere are a number of bench-scale grindability tests in use for sizing and predicting throughput for grinding circuits. Part of the reason for this variety is there are a number of different grinding models in use in the Industry, and those models operate using incompatible test results as input (Doll and Barratt, 2008).By using the database of testwork in the DJB Consultants, Inc. (DJB) Millpower 2000 database (see Table 1), some of the more commonly used tests are compared and relationships will be drawn."

Jan 1, 2011

By Iann Bouchard

Introduction à l?abrasion et l?érosion Avec le temps, tout solide va éroder et user les métaux les plus durs; de plus, la Corrosion va aussi laisser une couche mince et faible d?oxydation qui sera rayée du substrat. Solutions et guide de sélection Les polymères de Henkel Loctite® peuvent: ? Réduire l?abrasion par glissement ? Protège contre les agents corrosifs ? Prévenir la cavitation ? Augmenter l?efficacité ? Réduire la turbulence ? Résister aux hautes températures?

Feb 1, 2008

By Silvana Costa

In the last two decades, there have been nearly no new mining towns built in Canada. Governments and mining companies have viewed long distance commuting (LDC), commonly known as fly-in-flyout or fly-in mines, as a way to avoid problems associated with building a new community and providing for its sustainability after mine closure. LDC is also considered more cost-effective than building a mine town. The intensification of the use of LDC in the Canadian mining sector has been quite rapid, particularly in northern regions. However, LDC has implications to employees, their families and communities, which deserve further examination, particularly considering the significant expansion in Northern mining and Aboriginal participation in this sector. This paper presents a review of the major issues in long distance commuting, both from an industry and community perspectives. It is a result of preliminary investigation for a PhD research project that will be pursued by a Bridge Fellow and UBC Mining Sustainability Working Group member, and guided by an interdisciplinary research team at the University of British Columbia (UBC). The Bridge Fellowship Program is research-training program linking the UBC?s Faculties of Medicine, Engineering and Graduate Studies. Its mission is to develop creative evidence-based prevention measures for public, environmental and occupational health problems. The SWG is an interdisciplinary student group based in the UBC Department of Mining Engineering, committed to respond to the complex sustainability-related challenges currently faced by the mining industry. In other to pursue this project, it is paramount that industry and local communities alike participate in the development and clarification of research questions as well as in the research design. It is hoped that this paper will function as an invitation for industrial and community partners for such study. The main themes identified for this research are occupational health and safety of LDC employees, family life impacts and community health impacts of this model of resource development.

May 1, 2004

By K. Meyer

"The largest cost centres of the David Bell Mine concentrator are grinding, leaching and effluent treatment. Optimizing results during the 6th year of operation are listed below: o SAG mill slurry density control and operating strategies improved liner life and media consumption by 10 and 25%, respectively.o Poly-met liners clad the SAG mill except for the feed end. Lower noise levels and reduced mill downtime have resulted in an improved and more efficient workplace (time required for liner changes is 2 to 3%).o A comparative grinding media study using seven different marked media at the same time showed media wear rates range 120 to 198 mg/kWh and ball mill charge replacement frequencies of 8.3 to 13.1 per year, and that a meaningful wear test must include all media to be tested at the same time in the same mill. High quality carbon steel cylinders had the best economics.o Pre-aeration, using pure gaseous oxygen is accomplished in pipe reactors. Small bubble generators provide oxygen in the first three leach tanks. 1500 to 3000 kg of oxygen is consumed per day. Leach kinetics have improved and trends indicate increases in gold recovery of three to seven ounces per day at reduced costs. Effects of reduced cyanidation of accessory metals on the effluent treatment plant will be discussed in a separate paper."

Jan 1, 1991

By Jennifer Pell

Dunsmuir Ventures? Nanuq diamond project is located approximately 250 km northeast of Baker Lake and 170 km north of Chesterfield Inlet. It occurs at the intersection of the Wager Bay shear zone with the Keewatin Arch, a major long-lived crustal uplift. The newly discovered diamondiferous kimberlites at Rankin Inlet, Repulse Bay and on Melville Peninsula also occur along this arch. Kimberlite indicator mineral (KIM) sampling has outlined a distinct KIM train more than 35 km long and 6 km wide. Geomorphological studies, boulder displacements and dispersion of magnetite in tills suggest that glacial transport distances were on the order of 4 to 6 kms only. The presence of multiple sources within the main Nanuq indicator train would account for its length and breadth. A second train has been located on the west central part of the property and anomalous concentrations of KIM occur elsewhere. Pyrope garnets (G9?s and G10?s), diamond inclusion field (DI) eclogitic garnets and DI chromites were confirmed by microprobe analyses. Clinopyroxene thermobarometry indicates a cool geotherm, approximately 35 mW/m2, and that mantle within the diamond stability field was tapped. An aeromagnetic survey has identified a number of anomalies. Those with down ice KIM support will have ground geophysical follow-up and will be tested in a spring 2004 drill program. Dunsmuir is optimistic that this will lead to the discovery of a new kimberlite cluster on the Nanuq property.

May 1, 2004

By Sam Palombo, James José Varela

"Washing can be defined as the process used to eliminate or reduce the dirt (presence of fines or slimes) of one material. It is also the basic and oldest process applied to ore preparation for further concentration. This process, in combination with commnution and screening, form the so called washing plant and in many cases produce end products. This work describes the factors that influence the performance of the washing process and main washing technologies used in the mineral processing industry.The Hydro-Clean represents, since 1998, a state of the art technology in this area and is comprised of one of the most innovative solutions developed at HAVER & BOECKER. HAVER & BOECKER design and manufacture technology for mining and related industries. Today the Hydro-Clean is manufactured and sold throughout the Haver Screening Group (HSG) which is comprised of HAVER & BOECKER Maschinenfabrik Münster, HAVER & BOECKER Latinoamericana – Brazil and W.S. Tyler Canada.The Hydro-Clean is a washing technology based on utilization of high pressure water jets. To follow we will discuss how the Hydro-Clean’s different modes of operation result in several advantages related with mine waste reduction, recovery of saleable product, lower capital costs, superior washing results, less stress for the material, a wider range of application and less maintenance cost. Aside from these positive factors, its lower operation costs related to the consumption of energy and water are presented. It is important to note that the quantities, tonnages, data and management concepts presented in the paper are accurate for the time of writing and are subject to change and modification as operations progress."

Jan 1, 2009

By V. N. Bryant

"1.0 SYNOPSISThe Colomac property, located 137 miles by air northwest of Yellowknife in Canada's NWT. will recover gold from 10,000 tons per day of open pit ore.The decision to proceed with the project was based on a mineable ore reserve of 16 million tons (including dilution) averaging 0.064 oz/ton. After an in-fill drilling program in the latter half of 1988, Colomac's mineable, proven and probable ore reserves were increased to 28 million tons averaging 0.056 oz/ton of gold.A feasibility study completed by Wright Engineers for Neptune Resources in December 1987 examined the possibility of vat leaching followed by C.l.P. and electrowinning. A second feasibility study completed by Wright in February 1988 demonstrated that a conventional agitated leach circuit using a finer grind justified the higher capital cost of this process. This study was accepted and formed the basis of the project authorization.Preliminary engineering commenced in April 1988 and detailed engineering was started in September of that year with the objective of a mine/mill start-up by early 1990.The short time period available to meet the project deadline was additionally challenging, as site access is either by plane year round, and winter road from early February to late March. Normal lead times for equipment design, specifications, quotations and bid analyses were not possible, if the winter road time-slot was to be met."

Jan 1, 1990

By Robert J. Kuhne

The Iron Ore Company of Canada has successfully employed advanced process control (APC) to optimize the operation of their induration machines. A significant increase in machine throughput and a reduction in fired pellet quality giveaway were observed following the APC implementation on all six machines. This paper discusses the opportunity for process control optimization in induration, reviews the property estimation and multivariable control technologies, and describes how the IOCC control strategy captured this opportunity. APC performance data is presented. The dependence of APC performance on control room operator acceptance, process equipment and instrumentation is highlighted.

May 1, 2007

By S. Makni, A. Faucher, F. Robichaud, A. Bouajila

"Optimizing the ball charge in a grinding mill may be needed to maximise throughput or alternatively, to achieve proper product size in more challenging situations. Efforts to optimise the ball charge however are essentially empirical and suffer from the lack of appropriate, accessible and reliable tools. To address these limitations, a new model-based technology was developed that relies on 3D Discrete Element Method and population balance techniques: it takes on the form of a simulator that aims to significantly decrease the time required to optimise the size distribution and the grinding media load within a ball mill. This paper summarizes the research work related to the development of this simulator. The calibration of the different constituting sub-models will be highlighted. The successful use of the simulator to predict the effect of ball make-up on the grinding product size distribution in one plant is also reported.INTRODUCTION Adjusting the characteristics of the grinding media charge in grinding mills holds significant potential for optimisation of mill performance. For example, properly adjusting the ball size distribution in a ball mill can help achieving specified targets for final product size distribution and/or throughput capacity. However, several problems appear when reviewing the process and the available tools to optimise ball mill load: • The current empirical simulation tools are lacking with regard to the ability to predict the performance of grinding when changes to mill ball make-up are made; • Generally, these tools estimate the top size of the charge so it is difficult to predict the effect of mixed ball make-up; • As the quality of prediction of these tools is low, the operators try to optimise the ball charge by a ""trial and error"" method and proceeding with conservative changes. The influence of these changes on grinding performance is often less than the measurement precision and the improvements then remain imperceptible; • A change in ball make-up may require an average of about 6 months waiting period before reaching the stationary state of mill ball load. This exercise is due to be costly if applied change decreases the mill performance. In its effort towards the comminution process optimisation, COREM R&D portfolio had addressed the herein described opportunity during the last five years This paper describes the technology already developed for the optimisation of ball charge. It takes on the form of a simulator that aims to predict the evolution of the grinding media load, the grinding energy available in the ball mill and the final product size distribution. The simulator was first validated in a pilot scale ball mill and then applied in an industrial case."

Jan 1, 2012

By Christoph Broeckmann, Andrew Gardula

"The adoption of high-pressure grinding throughout the cement industry has yielded enormous savings in energy and wear material costs. There are also a number of installations, which are applied in iron ore and kimberlite processing operations. High pressure grinding offers the same potential for energy and media savings, as well as opportunities for improved, downstream metallurgical performance, in hard rock mineral processing. This paper focuses on developments in machine design and wear surface engineering for high-pressure grinding of the hard rock ores in the mineral processing industry.INTRODUCTIONIn the early eighties 3.4 % of the world electric energy was consumed for crushing and grinding operations of minerals and 0.6 % in the ore dressing industry. During that time using a laboratory press Prof. Schönert found that interparticle comminution at high pressure requires remarkably less energy as conventional grinding technologies. In grinding of cement clinker he expected energy savings between 33 and 50 % compared to ball mills [1]. Piston presses are limited in throughput. Thus, the principle of interparticle comminution was adapted by the use of high pressure grinding rolls (HPGR) to a continuous plant process. Figure 1 shows the main components of a roller press: The roller nip of width s is formed between the floating roller (1) and the fixed roller (2). The diameter of the rolls will be denoted with D, the width with B. The total press force F can be adjusted using a hydraulic system with two or four pistons (3). In order to compare machines with different roll geometries the specific pressing force p is introduced:"

Jan 1, 2005

By D. Turk, P. Lefebvre, J. Sargent, K. Major

"Stillwater Mining Company recovers platinum and palladium from their Nye Montana operations. Mining first commenced at Nye in 1987 at a milling rate of 455 t/d (500 stpd). The plant was expanded in 1995 with the replacement of the ball mill and the addition of flotation capacity to increase mill throughput to 1820 t/d (2000 stpd). The applications for platinum and palladium have increased in recent years particularly in the automotive industry and the supply of the metals has remained fairly constant with prices for both platinum and palladium increasing and remaining very stable. In 1997 Stillwater initiated the expansion of their operations to increase production of platinum and palladium. Projects were initiated to expand production at the Nye operations, increase smelter and refining capacities at the Columbus facilities and to develop the extension of the orebody at the East Boulder site. This paper will discuss the changes at the Nye concentrator which were completed to increase production from 1820 t/d (2000 stpd) to 2730 t/d (3000 stpd) and eliminate some of the process bottlenecks.IntroductionStillwater Mining Company is mining the only significant primary source of PGMs outside of South Africa. The J-M Reef is an extensive mineralized zone containing PGMs that has been traced over a strike length of about 43 km (27 miles) in the southwest region of Montana. Stillwater controls the entire PGM mineralized zone.Johns-Manville geologists discovered palladium and platinum in the early 1970’s. In 1979, a Manville subsidiary entered into a partnership with Chevron, USA to develop the project. In 1 987, operations at the Stillwater property near Nye, Montana commenced."

Jan 1, 2000

By Richard Maurice

RÉSUMÉ La restauration du site minier Poirier, à Joutel s?est déroulée entre 1998 et 2001. Le principal élément des travaux a été la restauration du parc à résidus et des zones d?épanchement qui totalisaient 4,5 millions tonnes de résidus répartis sur une superficie de 74 hectares. Les résidus sont fortement générateurs de drainage minier acide. La première partie de la présentation consiste en un bref rappel du concept de restauration suivi d?une description des principaux éléments de travaux avec l?emphase sur les leçons apprises de l?exécution des travaux. La deuxième partie de la présentation est axée sur les résultats du programme de suivi en cours depuis la fin des travaux en 2001. Les éléments de suivi se rapportent à la baisse du niveau de la nappe phréatique à l?intérieur de la cellule, au tassement des résidus dans la cellule, aux mesures de température et d?oxygène à l?intérieur de la cellule et finalement à l?amélioration dans la qualité de l?eau de surface. ABSTRACT The reclamation of Poirier Mine, in Joutel, was carried out between 1998 and 2001. The main component of the works has been the reclamation of the tailings basin and tailings spill area which contained a total of 4,5 million tonnes of tailings and occupied some 74 hectares of ground surface. The mine tailings are highly acid-generating. The first part of the presentation will deal with a brief review of the reclamation plan followed by a short description of the main work components laying emphasis on experience gained during construction. The second part of the presentation will deal with the results obtained from the environmental monitoring program still in progress since the end of reclamation work in 2001. The aspects discussed include the drawdown of pore water inside the covered tailing pile, the settlement of mine waste material, the monitoring of moisture, temperature and oxygen underneath the liner and finally, the reduction of loadings in surface water.

Nov 1, 2002

By K. G. Thorne, D. R. Lentz, A. F. Park

"The Main zone of the Clarence Stream gold deposit is hosted by a shear zone adjacent to the Saint George batholith in southwestern New Brunswick. The mineralization history relates to progressive deformation in the shear zone and the intrusion of the Magaguadavic granodiorite.Of three phases of deformation that have affected the area (D1-D3), D1 is not observed in the Clarence Stream shear zone. Two suites of igneous rocks intrude the shear zone: post-D2, pre-D3 gabbro; and granitic dikes, which crosscut the gabbros. Granitic dikes show a diverse range of relationships to D3 features, from pre-syn-D3 mylonitic fabrics in transposed and highly deformed enclaves, to nondeformed and entirely discordant dikes (post-D3).A variety of veins occur within this shear zone. Zoisite-bearing and later, crosscutting epidote-bearing veins are preserved as relics in quartz-mylonites, and predate quartz veins that host gold mineralization. The epidote-bearing veins are associated with pseudotachylitic cataclasite dikes, consistent with transient brittle failure during ductile deformation.Deformation relates to right-lateral strike-slip motion across the shear zone, and subhorizontal and near-vertical stretching lineations imply transpression. A late (late- or post-D3) dip-slip phase of motion is also apparent, and cooling followed a metamorphic peak early in D2-D3 history. Deformation of the shear zone, and more localized transient brittle failure, provided the permeability for fluid movement and vein emplacement. This scenario is similar to the findings of other studies, in which geochemical, tracer isotopic, and age-dating (U/Pb, 40Ar/39Ar) results suggest that the adjacent Magaguadavic granodiorite provided heat and metals. La zone principale (Main zone) du gisement d’or de Clarence Stream est encaissée par une zone de cisaillement qui longe le batholite de Saint George dans le sud-ouest du Nouveau Brunswick. L’historique de la mise en place de la minéralisation accorde un rôle important à la déformation progressive dans la zone de cisaillement et à la mise en place de la granodiorite de Magaguadavic.Des trois phases de déformation à avoir affecté la région (D1-D3), les effets de D1 ne sont pas observés dans la zone de cisaillement de Clarence Stream. Deux suites de roches ignées se sont mises en place dans cette zone de cisaillement : un gabbro post D2, pré-D3 et des dykes granitiques qui recoupent le gabbro. Les dykes granitiques montrent une grande diversité de relations avec les structures D3, allant de précoces à synchrones aux fabriques mylonitiques D3 dans des enclaves transportées et fortement déformées à des dykes complètement discordants et non déformés (post-D3).On note diverses veines dans cette zone de cisaillement. Des veines contenant de la zoisite ainsi que des veines d’épidote sécantes plus tardives, lesquelles sont préservées comme reliquats dans les mylonites à quartz et sont plus vieilles que les veines de quartz contenant la minéralisation aurifère. Les veines d’épidote sont associées à des dykes de catacalasite à texture de pseudotachylite, compatibles avec une rupture cassante épisodique durant la déformation ductile.La déformation résulte d’un mouvement décrochant dextre le long de la zone de cisaillement et les linéations d’étirement subhorizontales et quasi-verticales impliquent de la transpression. Une phase tardive (tardi- ou post-D3) de mouvement selon le pendage est aussi apparente, et le refroidissement succède à un pic métamorphique tôt dans l’histoire D2-D3. La déformation de la zone de cisaillement et la rupture cassante épisodique ont fourni la perméabilité nécessaire au mouvement des fluides et à la mise en place des veines. Ce scénario est similaire à celui proposé par d’autres études, dans lesquelles les résultats de géochimie, de traceurs isotopiques et de géochronologie (U/Pb, 40Ar/39Ar) suggèrent que la granodiorite de Magaguadavic avoisinante a fourni la chaleur et les métaux."

Jan 1, 2008

By G. Couture

"The Glencore Raglan mine Concentrator, located in Quebec’s Nunavik region, has been in operation since 1997. The nickel metallurgical plant was originally designed to process 100 tonnes per hour of ore to produce 130 000 tonnes of nickel concentrate per year at 16% Ni. The increased grinding capacity and the discovery of rich ore bodies have increased the annual production to more than 190 000 tonnes of concentrate at 19% Ni. In 2014, the Metallurgical group, with support from BBA, implemented an expert control system on the flotation circuit. This project was initiated to cope with the high variability of the concentrator’s feed. Increasing the plant recovery and final concentrate grade were also important project objectives. The implementation of the expert system ensures better control of concentrate inventory while maintaining maximum plant throughput. This paper describes the successful implementation of the new control system, the control technology selection and the flotation circuit optimization. It will also discuss the performances obtained with this new approach and the improved process stability.IntroductionThe Raglan Mine is located in Northern Quebec along the 62th parallel. It has been in operation since 1997 and was originally designed to produce 130 000 tonnes of concentrate annually at 16% Ni. The increasing of the grinding capacity and the discovery of rich ore bodies have increased the annual production to more than 190 000 tonnes of concentrate between 18 and 20% Ni."

Jan 1, 2015

"Air Products approached LAC Minerals in 1987 to initiate trials with pure oxygen in the leach circuit at several LAC facilities in Canada. This paper gives an overview of oxygen use and covers specific operating data from the Doyon and Terrains Aurifères mills near Val D'Or in northwestern Quebec. LAC also uses oxygen at the Macassa mill in Kirkland Lake, Ontario.In addition to the LAC facilities, oxygen is currently in use for test purposes at the Holt McDermott mine in Kirkland Lake, Ontario and the Camflo mine near Val D'Or.There are two requirements for oxygen in the cyanide leach mill. Firstly, oxygen is required in the familiar gold dissolution reaction as follows:(1) 4 AU (s) + 8 NaCN (aq) + 02 (aq)+ 2H 20(aq) - 4NaAu(CN) 2(aq)+ 4Na OH(aq)Of the reagents on the left side of the equation, the availability of gold is fixed by the ore in question. Obviously, water is available in excess, 1eaving cyanide and oxygen as the limiting constituents in the process. Most mills operate with an excess of cyanide, which is fairly closely monitored. Dissolved oxygen levels, however, are not normally watched very closely and find their own level based on the temperature, the availability of compressed air and the ability of the ore to consume oxygen.Typical D.O. levels are in the 3-8 ppm range, however levels less than 1 ppm are not uncommon for refractory ores.With pure oxygen, dissolved oxygen levels as high as 30 ppm can be achieved. (Figure #1). This greatly accelerates the kinetics of the leach reaction and may also shift the reaction further towards completion thus increasing gold dissolution slightly."

Jan 1, 1990

By Shahram Tafazoli

This article presents a novel technology for sensing the size of rocks after blasting in hard rock mines. Blast engineers require rock size statistics to carefully adjust the blasting parameters. The rock fragmentation requirements vary depending on the ore type and crusher specifications. The most popular statistical parameters in the industry are the so-called P numbers (e.g., P80 and P100). A machine vision based system is introduced here for automatic image collection and fragmentation analysis of the material right inside the bucket or dipper of mining shovels. A heavy-duty camera provides the required imaging data to an embedded computer mounted inside the cab. A custom machine vision software continuously analyzes the captured bucket images and stores the suitable ones in local storage which are then fed to a Desktop software for automatic fragmentation analysis. This technology has been developed by Motion Metrics International and is commercially available as FragMetrics?.

May 1, 2009

By Costa

The fly-in-fly-out (FIFO) mining model has significant implications for the industry as it plays an important role in fulfilling the economic, social and workforce needs of the contemporary mining industry. It has increasingly been adopted in countries such as Canada and Australia, but is the current nature of the FIFO model challenging the place women have achieved in the mining workforce? Research in the mining and oil and gas industries reveals that major sources of stress for fly-in-fly-out mining workers are the times of parting and of reunion, the challenges in defining roles within the family, parenting, and conflict between spouses over the use of the leave time and money. So how are women in the industry coping with the FIFO schedules and consequent intermittent relationship with families and partners? How is the mining industry adapting to recruit and maintain female employees in FIFO operations? This paper describes an exploratory study conducted in Canada, which intended to provide some initial insights that might help us answer the questions above. There are several inferences made from this exploratory study. It is clear that FIFO poses significant challenges for both female and male workers. It is largely seen as rigid, extremely challenging for employees with young families and workers who are single mothers, and it is generally incompatible with starting a family and caring for small children. FIFO creates severe stress on relationships and on workers psychological well-being. It seems to be indeed harder for women, since they are often in lower paying positions and therefore have less financial reward for the FIFO lifestyle. On the other hand, FIFO creates the opportunity for young women, including Aboriginal women, to jump-start their careers, as well as opportunities for mature women to work while pursuing other personal interests during their time off. This paper concludes with recommendations to improve the FIFO system in order to increase the ability of mining companies to hire and retain women

May 1, 2006

By Jason J. Crowder

Presentation Outline ? Introduction ? Costs of ground support and rehabilitation ? Why post-failure rock mass properties are necessary ? The Rock Mechanics Problem ? Present State of Modelling and Instrumentation in Mining ? Case Study Background ??Williams Mine ? Deriving Parameters for Modelling from Instrumentation ? Results from Case Study ??Back Analyses ? Discussion of Research Impact t Summary

May 1, 2006

A comprehensive axial test program has been undertaken at the WASM Dynamic Test Facility on the performance of 20mm threadbar. The threadbar tests had a double embedment configuration, with variation to the encapsulation lengths, debonded length and surface hardware and fixtures to examine failure mechanisms. Performance was significantly affected by the collar embedment length and type of fixture nut used. Results ranged from thread shearing occurring between the nut and bar at 1kJ of energy dissipated, to control plastic deformation of a central debonded length dissipating 22kJ.

May 1, 2009

By M. Melashvili

"The SART Process was introduced to the gold mining industry in the late 1990s and several commercial plants were built over the following 10 to 15 years. Most of these plants have operated well and enjoyed plant performance in line with expectations based on the underlying chemistry of the process. However, two of the plants have consistently suffered from high reagent consumption and poor product quality, which has motivated a re-examination of the process fundamentals in the hope of understanding the reasons for poor performance when it occurs, and developing mitigating strategies.This testwork along with a review of the relevant literature has demonstrated that the amount of sulphide added to the primary reactor, relative to the copper concentration, is the most critical parameter dictating plant performance, with pH and residence time important secondary factors. The primary product in the SART Process is synthetic chalcocite, Cu2S, and the stoichiometric requirement for sulphide addition is therefore 0.5 moles per mole of copper in solution. Testwork shows that when sulphide is added in excess of this amount (generally with the express purpose of lowering residual copper in solution) it not only fails in its intended purpose, but can have a negative impact on the settling and filtration characteristics of the copper sulphide product, as well as the final product quality. Moreover, these problems are exacerbated the higher the selected operating pH in the pH 3 to 5 range, and the longer the residence time of slurry in this pH range.Freshly precipitated copper sulphide compounds are known to be very fine and slimy, with poor settling and filtration characteristics. It is therefore important to engineer the SART Process in such a way as to encourage growth in the average particle size of the precipitate crystals. This was the rationale for recycling a portion of the thickener underflow to the primary reactor when the SART Process was developed. The theory of crystallization predicts that compounds of extremely low solubility, such as chalcocite (Cu2S: KSP = 10-48), are likely to experience growth in crystal particle size through aggregation rather than heterogeneous nucleation. On this basis, the SART practice of recycling a portion of thickener underflow to the primary reactor in the commercial plants is unlikely to lead to crystal growth via nucleation, and could in fact promote breakage of the aggregates that formed in the thickener. Recycling thickener underflow could therefore have the opposite of the desired outcome. The result of testwork that is reported here lends credence to this theory and questions the wisdom of recycling in the SART process.There is evidence to suggest that operating the copper sulphide thickener in the SART Process without flocculants may be beneficial. Thickener underflow densities could improve from the current 10 - 15% range to 40 - 50%. This will not only reduce the flowrate of slurry to the filter, but the filtration properties of the slurry (filtration rate, filter cake moisture content) will also improve. This is one of the most critical engineering and design aspects of the SART Process, and the achievement of high solids density in the thickener underflow will not only improve the health and safety aspects of the operation, but also has the potential to lower capital costs and improve the quality of the final product."

Jan 1, 2016