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By Ian Townsend

A prerequisite for good filter performance is that the total filter installation has been well designed. In this sense, the filtration testwork will provide scale-up data, and an insight into the relationship between operating parameters that may then be optimised, and used in the development of a control strategy. A good understanding of the filter’s operating principles will ensure correct selection and sizing of ancillaries, allowing in particular for the difference between instantaneous and average flow rates.

Sep 13, 2001

By D P. Murphy, R F. Dewhirst

Traditionally closure has been seen by the Resource sector solely as a green or an environmental issue, focused primarily on the requirement to rehabilitate the site following cessation of production activities. In addition to operational, maintenance and production aspects of processing plant design, future design teams will need to take a more holistic view and consider an increasing number of sustainability issues including safety in design and cleaner production as well as closure itself. Sustainability principles being adopted by industry such as the Minerals Council of AustraliaÆs Enduring Value Framework are now broadening our understanding of closure. While issues around the closure of tailings dams and associated infrastructure have been widely studied, few investigations have looked closely at the implications of closure on the design of minerals processing plants. It is likely that design teams may be able to make a significant contribution to meeting industry objectives by adopting innovative designs which, in addition to meeting production objectives, deliver sustainable and cost effective plant closure outcomes. This presentation explores the opportunity for innovative design of mineral processing plants through the assessment of alternative closure objectives. This assessment specifically looks at current industry standards and statutory requirements, as well as potential risks and opportunities associated with each objective. Alternative design strategies to meet these objectives are discussed.

Jan 1, 2006

By O. J. R. Baena

Mining activity in the Segovia region in NE Colombia is the main source of employment in the local economy. This has created major problems of illegality and informality mining associated with a high social and environmental impact, as inefficient technologies are used and high consumption of toxic substances required in the process of gold recovery by amalgamation and cyanidation. In this work is presented mineralogical characterization of six local mills and studied beneficiation processes developed in them. With the results presented a proposed plant design that eliminates the use of mercury by replacing gravity concentration processes taking advantage of the characteristics of the treated material. Significant results were obtained regarding the recovery of precious metals and present a methodology that can be replicated in other mineral beneficiation plants that use gold amalgamation processes. This implies a significant reduction in mercury use and decreased risk of human contamination associated with this.

Feb 23, 2014

By Majorkiewicz A

Engineering of gold treatment facilities complete with infrastruc- ture in a remote location such as Papua NewòGuinea present unique problems to the design team. Site location, topography, ground conditions and infrastructure are some of the major hurdles to overcome when setting out on the design of such plants. This paper discusses two such plants, located in two distinctly different areas of Papua New Guinea and the solutions evolved in order to design successful operating facilities.

Jan 1, 1991

The complete life cycle of a production facility has many phases requiring many different skills and many different personalities. It is not unlike the life cycle of a person and many parallels can be drawn from it. I leave some of these analogous situations to your fertile minds. The author, having worked in operations, plant design, plant commissioning, marketing and many other interesting situations through the industry has drawn from this experience and examples given by many associates in the industry.The phases seen are as follows: Concept Studies û someone has a bright idea of how to make a dollar. Scope Studies û what possible processes/options that could make a dollar. Prefeasibility Study û the æviableÆ scope options are studied to develop feasible options. Feasibility study û defines the concepts that should be designed to make a viable project thus enabling financing and project commitment to be made. Detailed Design û an intermediate step that consolidates the inputs to give a robust plant that can be constructed.Construction û people can see what they thought was going to occur and start to understand the plant. Commissioning û the hand-over of æownershipÆ from the conceiverÆs to the operators. Operations û the ætoyÆ has become reality and money must be made. De-commissioning û the plant has seen out the useful life of the ore deposit, it now goes through a further process required by society.Across these phases of plant design run several countervailing management requirements that can influence the outcome of the plant design. Some of the management rigours that have to be applied to the various phases are as follows: costing basis of the various phases; operational and maintenance reviews; sustainable development; risk assessment; reliability reviews; equipment availability; commissioning time; and environmental review.This paper endeavours to awaken people to the phases that projects require for a successful outcome and the management rigour that has to be applied throughout the phases to ensure the correct intellectual horsepower is applied at the right time to ensure the best outcome.Many of you would be parents and realise this is not unlike the development of children, teenagers, adults, retirees and ongoing.

Jan 1, 2002

By V. Fred Swanson, J. Patrick Glynn

The environment for process engineers today is very different from 20 years ago. The ideas and mathematical description of models for a multitude of different unit operations is an ongoing development. The computer tools to deal with the mathematics are readily available and specialist companies have developed, tested and verified their models. The challenge for the process engineer is to know which package to use and to know whether a particular application is the most accurate for the specific process. Metallurgical simulation programs today are well known and proven. Certain programs are specialized while others are broader based. The needs of each user are dependent on the application. Typically, most users require the following operations: • Comminution • Flotation • Hydrometallurgy • Pyrometallurgy • Additional requirements could be defined as: • Thermodynamic capabilities for solids, phases, and gases • Dynamic simulation • Data analysis tools • Coal oriented operations • Diamond oriented operations

Jan 1, 1997

"In today’s world of complex projects, where engineering and execution are supported by a high level of project management and systems, how critical is the human factor in design engineering. Based on his involvement on a variety of projects, Tony Lipiec will relate his experiences as the impact of 4 factors: the ‘team’ involved in the design and execution of the project; the project and information systems supporting the project; the impact of scope, time, and budget; and finally the selection of the proper success criteria to judge the project and the people who have enacted the project.The discussion of the team will relate to the quality of people and the impact of their knowledge, attitude and experience. It will also look at the relationships and interests of the various stakeholders. Decision making and taking responsibility will be discussed.Supporting the team are the management, document and information systems. The value that these systems bring to the project as a whole will be examined. How project size impacts the applicability of the systems will be discussed.Scope, time and budget are recognized as critical. Reference will be made to the interplay between these components which are vital to project success. The issue of iterative design and whether it is necessary will be considered together with the development of supporting technical information.Finally the selection of the proper success criteria and the awards provided to the team can have a big impact on the final, production success of the project. The author will discuss his views on the impacts of these on EPCM projects."

Jan 1, 2016

By William R. Yernberg

The Mineral Processing Plant Design, Practice and Control Conference was held from Oct. 20through 24, 2002, at the Fairmont Hotel, Vancouver, British Columbia, Canada. The conference was attended by nearly 400 of the world’s top mineral-processing specialists, including plant-design engineers, mineral-processing consultants, academics, suppliers and equipment manufacturers. The meeting was sponsored by SME and cosponsored by the Canadian Mineral Processing Division of the Canadian Institute of Mining, Metallurgy and Petroleum (CIM). The conference covered all aspects of mineral-processing design, construction and operation. The meeting included more than 130 technical presentations. Topics included sampling programs, feasibility studies, design criteria, process technologies, construction, start-up operations and shutdowns. To stimulate interaction and discussion throughout the five-day conference, the sessions were presented consecutively. Attendees had the opportunity to attend every session.

Jan 1, 2003

By J. C. Motz

The advantages of producing a fine mill feed have been recognized for many years. The extent to which fine crushing can be carried out will vary and depends on the ore characteristics, plant and crusher design. Unfortunately, the ore characteristics are generally beyond our control, so the concentration of effort lies primarily on the plant arrangement, equipment design and operation Where fine crushing should stop and grinding begin is controversial and is influenced greatly by personal opinions and experiences. Often, this break point will be different if consideration is being given to a new plant in comparison to a modest expansion. Most new plant designs employ the largest and most efficient equipment. The modification of existing plants becomes more complex because of the space requirements and the related equipment already in operation. Fine crushing is, of course, a relative term. Obtaining a final crusher product of minus 3/4" is commonplace today and can occasionally be obtained in an open circuit final crushing stage.

Jan 1, 1980

By Ben Murphy, Alejandro Yanez, Tatu Miettinen

"Flotation using large volume cells has grown in importance during recent years, particularly given the increasing demand for minerals whilst ore grades are decreasing. Outotec introduced the TankCell® e300 in 2007 to enable concentrator plants to process these higher tonnages. From the beginning, TankCell® e300s with FloatForce® mixing mechanisms have demonstrated good metallurgical performance with decreased operating costs and high availability. This paper deals with specific engineering challenges that need to be considered when installing these units rather than giving examples of performance. Today there are over 100 TankCell® e300s operational worldwide. As more of these units are installed new technical challenges are encountered and solutions developed to maximize their productivity. Lessons have been learnt by operators, engineering companies and the cell manufacturers on how best to design and layout these cells in modern concentrators to ensure smooth transition from design to installation to operation. This paper presents information on important design considerations and learning that has been obtained through the design, installation and commissioning of the TankCell e300 around the world. Areas pertaining to cells layout such as feed and discharge arrangements along with items of metallurgical concern such as sampling, reagent addition and the potential benefits of installing a variable speed drive on the motor will be covered in depth."

Jan 1, 2014

By A. K. Fallaw, D. L. Taylor, G. Wang, L. R. Moore, S. Dobson, C. B. Parkinson

"Over the years, the decline of high grade ores have become an increasing problem in the global mining industry. As such, techniques and chemistries must change in order to continue to meet the market demand and quality. Reverse cationic flotation of quartz and silicates is one of the most important techniques for generating the industry standard product from minerals such as iron and phosphate ores. Amine collectors are the global standard in such processes. However, as the ore quality continues to decline so must the chemistry change to meet the change in ore composition. This paper will focus on the introduction and full scale application of a novel amine collector towards a cleaner flotation process in phosphate beneficiation with Crago process. The results suggests the collector is capable of improving the phosphate recovery, in this cleaner circuit, to approximately 94% with minimal sensitivity to the everyday changes in feed grade.INTRODUCTION The days of mining high grade minerals are long gone, but the demand continues to increase. Phosphate ore, for example, is most dominantly demanded from the agriculture industry as a fertilizer component (i.e. diammonium phosphate, DAP) (FAO, 2014). Some literature suggests that global food production must increase by approximately 70% by 2050 (Cordell, 2009). It is also suggested that the peak global phosphorus production will occur around the year 2033, which is the period at which the easily accessible reserves have been depleted. Currently, phosphorus is commonly mined with a BPL (Bone Phosphate of Lime) concentration of 12-20% and a remainder typically being gangue minerals such as silica, clays, metal oxides, calcareous minerals, and carbonaceous minerals. These gangue components can lead to various negative processing and utilization consequences. Calcium, from carbonaceous minerals, is problematic due to the elevated levels of sulfuric acid required to convert the phosphate rock to the acid form (SRI Consulting, 2009). Calcium can also lead to elevated dosages of flotation reagents due to the desire of the fatty acid to coordinate to calcium minerals. Carbonate leads to increased levels of foam during the wet acid process. Silica is associated with the level of insols (acid insolubles), which must be less than 10% in the final concentrate that will be transferred to the chemical plant for acidification. Phosphate ore can generally be classified as carbonaceous or siliceous (El-Shall, 2003). Siliceous ores are commonly processed through various sizing steps followed by multi-staged flotation (Figure 1) (FIPR, 2014 & Güven, 2010). Though the higher grade phosphate pebble is declining, many mines are still able to size good enough to produce some amount of such pebble. Unlike most metal flotation processes where grinding is a necessity for an optimal process, Florida phosphate flotation does not generally require aggressive grinding and can typically operate at 0.1-1.0 mm. The rougher flotation step applies pH modification to achieve the optimal pH of 8.8-9.3 followed by conditioning with a fatty acid type collector, which builds a hydrophobic waxy layer on the surface of the particle to assist in the flotation. This generally achieves higher than 85% recovery of a product with 50-60% BPL and 15-30% insols. Unfortunately, DAP production generally requires 3.5 tons of phosphate rock containing greater than 63% BPL to produce 1 ton of phosphoric acid (ArgusMedia, 2014). Thus, further purification is required to achieve the grade by the chemical plant for fertilizer production. After the fatty acid is scrubbed off the phosphate particles using sulfuric acid (pH 2.5-3.5), the pH is generally operationally readjusted to 6.5-7.2 by washing with “fresh” water. A second collector is applied prior to the cleaner, which is a reverse cationic flotation process. This collector is typically a cationic amine based reagent, which should have an affinity for silica containing mineral"

Jan 1, 2015

By Thomas F. Evans

This study shows that statistics on the rate of coal dumping can measure the effectiveness of freeze conditioning agents. The use of appropriately indexed dumping intervals or interval logrithms provides a more sensitive indication of unloading problems than does a simple calculation of average loading time because of the abnormal form of the distribution of dumping intervals. The paper presents information that indicates suitably applied coal freeze conditioning agents are effective in reducing coal handling problems attributable to frozen coal. Graphs and figures show that the severity of coal freezing potential due to subfreezing temperatures is proportional to the exposure time and average departure of the temperature from the freezing point.

Jan 1, 1982

By J. Grignon, C. Fleming

It is possible to reproduce the performance of an operating CIP or CIL plant in the laboratory, in small scale batch kinetic tests, coupled with mathematical models that translate kinetic data into predicted steady state gold profiles across multi-stage adsorption circuits. Once the performance of the commercial plant has been mimicked by the model, the plant operating parameters can be varied systematically in the model, and the likely response of the plant to the step wise change can be determined. In this way it is possible to inexpensively optimize the operating conditions of an existing plant, with no disruption to plant operations and no economic risk to the mining company. This approach had been adopted by IAMGOLD to optimize the performance of their Rosebel CIL plant following several major expansions in mill capacity since 2004.

Jan 1, 2011

By J. C. Monette

Stripping of gold and silver from carbon is effected by means of two main processes (AARL and ZADRA ). The main rate-enhancing parameter in the stripping of gold and silver is temperature. A secondary rate-enhancing parameter is ionic strength. (1) Stripping is usually conducted within a solution containing sodium cyanide (0.1 -0.5% ) and caustic ( 1 -3%). The development of a chemistry that increases the rate of gold and silver stripping from carbon in a manner proportional to its concentration is described. Its use in atmospheric and pressure strips is also outlined.

Jan 1, 1992

By C. F. Davan, C. T. Houseman

The news pages of MINING ENGINEERING and other trade publications have for the past two years carried a great many items about new developments in phosphate and potash, reflecting the surge in world consumption of these products as fertilizer. Today the question often arises concerning how much growth can be further anticipated by the phosphate and potash industries. To answer this question, a 15-year projection of world fertilizer consumption in terms of the three basic plant food nutrients-nitrogen, phosphate and potash-has been prepared. Two of these, phosphate and potash, are basic products of the mining industry. Nitrogen, once an important product of mining, is now mainly a chemical product. Another mineral, sulfur, although not a primary nutrient, depends on the fertilizer manufacturing industry for the bulk of its market. In crop year 1962-63, there began a startling in- crease in world fertilizer consumption. In that year, consumption increased by about 10% and in the following year by 10-12%.

Jan 12, 1965

By Sir Robert Hadfield

(New York Meeting, February, 1913.) THE Hadfield method of producing sound steel ingots has been the subject of a paper 1 read before the Iron and Steel Institute, so that it will be unnecessary to describe it fully here. The object of the method is to make possible the production of steel ingots in which the pipe is almost entirely obliterated, and it is applicable particularly to the production of sound ingots, from which good rails could be rolled. The method in brief consists in casting the ingots on cars, usually with the small end down. Each ingot mold is provided with a sand top, rammed up in the well-known manner. After the mold is filled to the desired height with steel, a layer of slag about 0.5 in. thick is placed upon it and the balance of the mold is then filled with charcoal. Then, through suitable piping, an air blast is directed in numerous jets upon the charcoal, which is burned thereby, the combustion supplying additional beat to the top of the ingot, which helps to keep the top fluid and to retard its solidification, while the lower parts are rapidly losing heat by its transfer to the mold. By-one plan the ingots are cast in molds placed upon bogies, movable trucks, or platforms, in the position A, Fig. 1. The ingots are cast vertically on bogies, say four or more ingots on each bogie, as may be found most convenient, and the upper surface of the steel is maintained in a molted condition during the transit of the ingots from the casting pit to the stripper. This is effected by a series of air pipes, for example, three in number, with jets or holes on the under surface of such pipes, placed preferably horizontally, arranged in such a manner as to cause jets of air to impinge on the upper surface of the ingots. These holes or jets are made throughout the entire length of the overhead pipes, the length of such pipes being

Jan 4, 1913

By Andrew Mayer

EARLY in 1942 National Lead Co. was requested by the War Production Board to construct and operate a plant for the Government to produce magnesium by the ferrosilicon process which had been developed by Dr. L. M. Pidgeon in the laboratories of the Canadian National Research Council. A contract with the Defense Plant Corporation was concluded in May 1942 and Magnesium Reduction Co., a wholly owned subsidiary of National Lead Co., was formed to carry out this project. The capacity of the plant was rated at 10,000,000 lb. of magnesium per year, equivalent to an average production of about 14 tons per day. THE PROCESS The process, in brief, is as follows: The raw materials are dolomite and ferrosilicon, 75 per cent grade. The dolomite is calcined, the calcine and ferrosilicon are ground and mixed and the mixture is briquetted. The briquets are charged into tubular retorts of chrome-nickel steel set horizontally in a furnace with the open ends projecting outside the front wall. The retorts are then closed and evacuated. Magnesium is liberated according to the reaction 2(MgO, CaO) + Si = 2Mg + 2CaO, SiO2 It is distilled from the charge and condensed on a removable sleeve in the throat of the retort. Sodium and potassium, if present, are also liberated, distilled and condensed on a "sodium condenser" in the end of the retort. At the expiration of the distillation period the retorts are discharged and the cycle of operations is repeated. For the rated daily capacity of ±. tons of magnesium there are required approximately 170 tons of dolomite, equivalent to about 85 tons of calcine, and 16.5 tons of ferrosilicon. The retort residue, a bulky powder which at present is waste, amounts to about 87 tons. CHOOSING THE SITE The investigation to select the location of the plant was conducted by the Research Laboratories of National Lead Co. This work included geologic and economic surveys of a number of districts, examination of dolomite samples by chemical, spectrographic and petrographic methods and large-scale tests of dolomite from several of the more promising localities. In the last-named tests 2-ton samples were put through the ferrosilicon process in the pilot plant of the Canadian National Research Council, under the guidance of Dr. Pidgeon. The conclusions drawn from the investigation, in regard to the quality of dolomite to be used in the ferrosilicon process, were: First, the dolomite should contain not less than 21 per cent MgO

Jan 1, 1944

By Harris J. W

The treatment plant at The Great Boulder Proprietary Gold Mines Limited was designed and erected by Chas. Ruwolt Proprietary Limited in 1934 to mill 12,000 short tons per month. The flow sheet called for fine grinding, straking, flotation, roasting of the flotation concentrates and cyanidation of the resulting calcine.In 1937 considerable alterations and additions were made to the plant. The grindin,g section was duplicated with addition of two 8 ft. x 6 ft. Abco Ball Mills to increase the throughput to 28,000 tons per month, and the flow sheet was changed from "straight flotation" to "precyanidation and flotation" neeessitating the addition of thickeners, agitators, Oliver filters and Edwards roasters.A further change to the flow sheet was made in 1942 with the introduction of sulphur dioxide conditioning ahead of the flotation section, to permit the treatment of 500,000 tons of oxidised ore. Since that date no major alterations were made to the flow sheet or equipment until 1950, when the modifications set out in this paper were commenced with the object of reducing costs and increasing plant efficiency.These modifications are dealt with under the section headings and are therefore not necessarily in chronological order.CRUSHING SECTIONThere has been no material alteration in this section although at the time of writing a 650 ton capacity ore bin is being erected ahead of the primary Jaques crusher. This bin will reduc'e the crushing time from a three shift to a two shift basis and reduce the labour force required by two men, giving an annual saving of £2,000.FINE GRINDING SECTIONAlterations to the grinding section were commenced in 1950. Prior to this date the grinding flow sheet calle...

Jan 1, 1955

By Harris J. W

Mr. Gillie and Mr. Harris have given us a wealth of information and food for thought on the vital subject of information and food fo rthought on the vital subject of reducing costs and mention considerable saving in some of the larger items. There are a number of points on which I would like further information, but I will confine my remarks to a relatively small saving which is of particular interest in view of another paper to be presented this afternoon.Mention is made of a 50 per cent reduction in the amount of zinc used in the precipitation of gold slime from the pregnant solution. Would Mr. Harris enlarge on the methods by which they obtained this reduction; and could he give an actual figure of zinc consumption either by ton of ore treated or per ounce of bullion recovered.AuthorsWe consider the reduction of zinc is due to improved clarification of the pregnant solutions. The sand clarifiers used prior to the installation of the 50 ft. -thickener were not satisfactory due mainly to the blending of the hessian and matting under the sand. Under these conditions the leaf clarifiers were fed with overflow solution from the clarifiers and were overloaded in consequence. The addition of Calgon has also been beneficial.The present consumption of zinc per ton of solution treated is 088 lb. per ton.A. L. "Keats (No,rth Broken Hill Limited)In the operation of milling equipment there is a progressive increase in maintenance expenditure during the life of a machine, so that when comparing the cost of operating old equipment with the cost of operating new equip...

Jan 1, 1956

By Larry S. Diaz

The paper considers the selection of control instrumentation for a modern flotation plant, as well as the best interpretation and most effective use of the process data obtained. Process control computer availability is considered from the outset. A general philosophy of control is proposed which leads toward a system that is its own reliability monitor. The bulk of the problems are in grinding and classification. Alternative control methods are described that use particle size measuring devices. Flotation controls, based to a large extent upon on-stream X-ray analysis, are reviewed in detail. Reagent control methods are also examined. Methods to analyze the data obtained from the various measurement devices are introduced. These methods would enable an estimate of the validity of the data and require some redundant information. Another objective of these methods is the protection of operating equipment from possible control malfunctions. Although the discussion generally considers some degree of computer usage, this paper attempts to describe instrumentation and data analysis methods that enable control with or without the process control computer.

Jan 1, 1972