Search Documents

By J. Stiksma, R. Kalanchey, M. J. Collins, G. Owusu, R. Raudsepp, K. R. Buban, L. A. Barta, I. M. Masters

This paper describes the results of testwork for the treatment of Ambatovy laterite ore by a pressure acid leach process, with recovery of the soluble nickel and cobalt values as mixed sulphide intermediate by precipitation with hydrogen sulphide, and subsequent refining of the mixed sulphide to nickel and cobalt metals. These process development studies were carried out primarily in 2004, as part of a bankable feasibility study for the Ambatovy Nickel Project. The Ambatovy orebody is located in Madagascar. The mini pilot plant testwork was carried out in the Dynatec metallurgical laboratory in Fort Saskatchewan, Alberta. The results of the testwork were very encouraging, including nickel and cobalt extractions in the range of 95.5% to 97.0%, and 94.0% to 97.0%, respectively, in the ore leach step with sulphuric acid. High recoveries of nickel and cobalt were achieved throughout the remaining process steps, yielding separate nickel and cobalt metal powders with better than acceptable purity.

Jan 1, 2005

By Robert J. Brison

On the basis of experience accumulated during the completion of some 150 gold/silver process development projects, general guidelines are presented for developing the most cost effective process for a specific project. Steps involved in process development for lode ore deposits generally include a review of pertinent background information on the ore deposit, sample procurement and preparation, sample characterization, study of concentration possibilities, investigation of leaching and metal recovery methods, economic evaluation of alternative processes, optimization of the selected process, a pilot plant program if warranted, and finally, process design and feasibility studies. Each of these steps is discussed, with emphasis on the relation between technology and economics.

Jan 1, 1984

By Hiddlestone D. C

Effective exploration, testing and analysis is essential for good process design and optimisation of coal preparation plants. Coal processing relies on the sizing and washability characteristics of the particular coal to define the most cost effective design to meet the market requirements. Flowsheet development and equipment selection is dependent on the natural quality characteristics of the coal, its physical properties and the value of the final product in its market. The methodology of process selection and the key elements in design are discussed. Coal is consumed in two general markets: ò steaming coal - both domestic and export, and ò metallurgical coal. This paper discusses the typical economic analysis required to evaluate the potential for, and cost benefit of, providing the flexibility to switch coals between markets. A case study illustrates the methodology of process selection in a typical high value metallurgical coal.

Jan 1, 1997

By J. T. Hanks

Process development is one of the principal tasks required in the course of turning an exploration discovery into a mine. Exploration geologists should have an understanding of the more important metallurgical processes and the test work required for each process. The paper discusses the important metallurgical processes, the test work and sample requirements for each, and the costs and time requirements to accomplish the testing. The limitations of reverse circulation drill samples for metallurgical testing are discussed. The level of process definition required to support engineering studies: scoping, pre-feasibility and feasibility studies are also described.

Jan 1, 1997

By S. Dicarlo

"In late 1985, B-zone ore was first processed through the Eldor Mines mill at Rabbit Lake. Extensive modifications had been completed in order to mill this ore. In-plant process development was initiated to tune up the new circuits and concentrated on leaching, solvent extraction, impurity and uranium precipitation and tailing and effluent treatment. This process development effort and the results are described.INTRODUCTIONEldor Mines, a division of Eldorado Resources Limited, operates the Rabbit lake mine-mill complex at Collins Bay on the western shore of Wollaston Lake in northeastern Saskatchewan.The first orebody was discovered in 1968 by Gulf Minerals Canada Limited below a small body of water named Rabbit Lake. Ore from the Rabbit Lake (RL) deposit was first processed through the new mill in June, 1975, with depletion scheduled over the next ten years. Continued exploration in the area led to the discovery of four orebodies in the vicinity of Collins Bay: A-zone (1971), B-zone (1977), D-zone (1978) and Eagle Point (1980). Collins Bay is about ten kilometres from the mill facility.In 1982, Gulf Minerals was acquired by Eldorado Nuclear Ltd., who continued the development effort to bring the B-zone deposit into production. The RL pit was mined out in May, 1984 with stockpiled ore providing mill feed until startup on B-zone ore, which was scheduled for November, 1985."

Jan 1, 1988

By Shijie Wang

The metals of value in tetrahedrite are copper, antimony and silver. A new hydrometallurgical process is proposed to recover these metals from tetrahedrite. The process consists of leaching concentrate with ferric fluoborate, solvent extraction, electrowinning and residue treatment. Products from this process are high-purity SX-EW copper and antimony and a high-grade silver residue that will be further treated in a hydrometallurgical process for early release of silver. The process has advantages, such as achieving rapid leaching rates at modest temperatures with high metal recovery. Most pyrite is not attacked. Thus, it remains in the leach residue along with elemental sulfur.

Jan 1, 2003

By Sui Xue

A process has been developed from laboratory-scale experiments for the aqueous processing of various lead-bearing wastes. The process exploits the limited solubility of lead in sulfate-rich solutions to effectively separate lead from other metals. The lead sulfate is then completely converted to lead carbonate using sodium carbonate and ammonium carbonate. The effectiveness of this conversion was observed to be sensitive to the solution pH and carbonate concentration. The final stage of the process uses low temperature calcination of the lead carbonate to form PbO. Yellow lead oxide (massicot) is readily formed if calcination is conducted at a temperature at or iibove 50G°C, wlule red iead oxide (iitharge) is formed at temperatures near 450°?C. A complete economical analysis of the process will be discussed.

Jan 1, 1996

By J. L. Coburn

The Huari-Huari ore body is located in Southern Bolivia, at an elevation of approximately 3,800 meters above sea level. The ore is a complex massive sulfide, slightly marmatitic sphalerite, in a fault fissure filled hypo- thermal vein in Paleozoic shales and quartzite-altered sandstone. The sphalerite has common associations with pyrite and quartz and is frequently intricately intergrown with stannite, chalcopyrite, and pyrrhotite. The sphalerite also contains numerous inclusions of pyrite, marcasite, galena, boulangerite, jamesonite, quartz, arsenopyrite, and cassiterite. A research program was undertaken to develop a flowsheet for the recovery of separate silver, zinc, and tin concentrates by selective flotation. Based on this experimental work and subsequent flowsheet development, engineering and construction of a 500 metric ton per day concentrator was undertaken. This paper describes the process that was developed for the Huari-Huari ore and the unique aspects of the Huari-Huari concentrator.

Jan 1, 1977

By John Turney, John Gathje, Donald Gale

The Eskay Creek deposit, located in northern British Columbia, is a high-grade gold/silver ore associated with complex polymetallic sulfides. Process development began in 1989 and continued through 1993. Because of the refractory nature of the ore, options including roasting and smelting were investigated. The selected process of pressure oxidation was the basis for basic engineering design until a re-evaluation of economics and risk indicated a preference for toll smelting. Although well proven in many industrial applications, pressure oxidation of the Eskay Creek ore dictated several innovations to solve problems associated with silver jarosite formation, preg-robbing, and high soluble copper and zinc concentrations.

Jan 1, 1995

By P Dunn

Following civil war in Sierra Leone, London Mining Plc obtained the mining license in 2006 and commenced activity to redevelop the Marampa mining and processing operations. The Sierra Leone Marampa mine is a brownfield development effort, having been operated by a few companies since the 1930s until low iron ore prices forced closure. Peak production of the preceding operations was approximately 2.5 Mt/a in the 1960s. There are two virgin ore deposits of interest for development as well as a resource comprised of tailings accumulated from previous operations. The Marampa tailings operation (Phase 1a) is being implemented first with a 1.8 Mt/a plant producing 66 per cent Fe sinter feed, expandable to 3.6 Mt/a in a Phase 1b. The first phase is currently under construction with start-up expected in the third quarter of 2011. Further expansion (Phase 2) that includes the development of the virgin deposits is currently under prefeasibility study and targets a final 16 Mt/a concentrate production. Outotec partnered with London Mining to develop the magnetic separation flow sheet using SLon VPHGMS machines to process the Marampa tailings (haematite) material. The flow sheet development process started with sample characterisation and detailed parametric investigations to evaluate SLon performance. The final flow sheet configuration, including expected circuit recoveries and concentrate quality, demonstrates the performance of the SLon VPHGMS circuit for iron ore tailings.

Jul 11, 2011

By I Ritchie, A Johnston, D Yataco

Marcobre SAC (Marcobre) is developing the Mina Justa copper mine project, located in the Ica region of Peru. The Mina Justa IOCG orebody comprises of a sulfide mass overlain by an oxide cap with a sharp transitional zone between the sulfide and oxide masses. The primary target metal is copper, but there are minor amounts of gold and silver. The oxide will be treated by HPGR, crushing and vat leaching, whereas the sulfide will be treated by HPGR, milling and froth flotation. The processing selections are due to some unusual ore characteristics which have required relatively unconventional solutions.Vat leaching was chosen over heap leaching and other processes after detailed trade-off studies found it to be the most attractive, primarily due to the high acid consumption of the ore. The sulfide flotation produces a wide range of concentrate grades due to the complex nature of the mineralogy. The selection of HPGR circuits for both the oxide and sulfide ore is due to the extremely hard and competent nature of the deposit. These factors and others have contributed to a unique process selection for this resource.The selection process for the oxide and sulfide ores, and an overview of the technology, equipment selection and geometallurgy, will be discussed.CITATION:Johnston, A, Ritchie, I and Yataco, D, 2017. Process development for the Mina Justa project, in Proceedings MetPlant 2017, pp 207–217 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 11, 2017

By P. Keller, T. E. Lister, G. G. Clark, L. A. Diaz

As electronic technology continues to evolve there is a growing need to develop processes which recover valuable material from antiquated technology. This need follows from the environmental challenges associated with the recovery of raw materials and fast growing generation of electronic waste. Although present in small quantities in electronic devices, the availability of raw materials such as rare earths and precious metals becomes critical for the production of high tech electronic devices and the development of green technologies (i.e. wind turbines, electric motors, and solar panels). Therefore, the proper recycling and processing of electronic waste presents an opportunity to stabilize the market of critical materials, providing a proper disposal and treatment of a hazardous waste stream. This paper describes the development and techno-economic assessment of a comprehensive process for the recovery of value and critical materials from electronic waste. This hydrometallurgical scheme aims to selectively recover several value streams (base metals, precious metals, and rare earths) present in electronic waste. The economic feasibility for the recovery of rare earths from electronic waste is mostly driven by the efficient recovery of precious metals, such as Au and Pd (ca. 80 % of the total recoverable value). Rare earth elements contained in magnets (speakers, vibrators, and hard disk storage) can be recovered as a mixture of rare earth oxides which can later be reduced to the production of new magnets.

Jan 1, 2016

By Earl L. Rau

Although the Sagasca deposit has been known for 76 years, the property was never put into successful operation because of various adverse factors including low market price for copper, legal entanglements, unsuccessful financial arrangements, and an inadequate metallurgical process. Late in 1963, Continental Copper & Steel Industries, Inc., obtained legal control of this property. Since that time there has been a concentrated effort to complete the necessary mine appraisal, process development, and engineering design, and to solve the legal and financial problems to bring this property into production.

Jan 1, 1970

By M. S. Prasad

In earlier work it has been shown that paper filler clay products can be obtained from primary kaolin deposits of Minnesota. The objective of the current work was to reduce silica and iron contaminants and to maximize kaolin recovery to higher value products suitable for paper coating. This results in achieving a finer and cleaner product conforming to paper coating specifications. Cationic flotation and high gradient magnetic separation were used to remove free silica and iron, respectively, while attrition grinding and ultrasonics have been examined for particle size reduction. The results of this work are presented and discussed particularly with respect to application-oriented product properties. Budgetary estimates are presented for a 200,000 ton/year processing plant based on the process flowsheet developed and optimized by the study.

Jan 1, 1991

By S. Acar

"In recent years the gold mining industry has been challenged by declining metal prices as well as having to treat ores that have low grades and are refractory in nature. Many factors must be considered when metallurgical studies are designed to develop process design criteria for these type of ores. These factors are mostly related to the mineralogical and chemical compositions of the ores, the geological setting of the deposit and how the ore/waste will be mined, such as whether openpit or underground, the mine schedule, and the mine fleet type and capacity. The purpose of this paper is to provide an experience-based practical approach to how to select and characterize test samples as well as devise process development metallurgical studies for both oxide and refractory gold ores, and to provide insight into some of the matters that might go wrong during the course of the studies. This paper is intended as both a guide for someone new to the field and also as a reminder for those familiar with the field. IntroductionThe recent decline in ore grades and metal prices have challenged mining companies to reduce capital and operating costs associated with developing new mineral resources. In some cases, metallurgical studies have been sacrificed to prevent cost overruns resulting in inadequate mineralogical, chemical and metallurgical characterization. Consequences have included longer construction schedules, higher initial and working capital, higher operating costs and less than desirable plant performance (Whincup, 2010; Torres, Chaves and Meech, 1999).Mineralogy, geology, mining type and sequence, and the metallurgy of an orebody will determine the process development metallurgical study requirements and eventual process plant design. Therefore, once the geologist has an early indication of a prospective orebody, geologists, metallurgists, mining engineers, and social and environmental responsibility scientists should convene and devise a plan on how to exploit the orebody economically (Lunt, Ritchie and Fleay, 1997).Geologists may find a prospective orebody solely based on grade. However, if the orebody cannot be mined and processed economically, then it is deemed not to be a deposit. An example of this could be a refractory gold deposit, either sulfidic, carbonaceous or siliceous refractory or any combination of those, that may not be mined and processed economically due to reasons such as the physical location of the deposit, depth of the ore lode, or social and environmental concerns. Therefore, an early collaboration between all disciplines must be established.Each orebody may have its own unique mineralogical, geological and chemical characteristics (Guresin et al., 2012). These unique characteristics should be effectively sampled to reduce risks associated with process design and engineering efforts for the process development metallurgical studies. If the sample or samples are not representative of these unique characteristics, then the studies performed will be pointless. The project metallurgist in charge of conducting metallurgical studies should also possess general geology, mineralogy and mine engineering knowledge. Recommended readings are a book on understanding mineral deposits by Misra (2000) and articles on heap leach development by Scheffel (2014a and 2014b)."

Jan 1, 2016

By R L. Bowers, D S. Smit

In light of soaring commodity prices, Nkomati has investigated the potential of processing additional low grade nickel ores to add to their reserves. The Chromititic Peridotite Mineralised Zone (PCMZ) was identified as one ore type with the potential of producing a high grade nickel concentrate. In addition to the nickel, copper, cobalt and PGM?s, the ore also contains a significant amount of chromite which adds substantial value to the project. Pyrrhotite, pentlandite, chalcopyrite and chromite are the dominant minerals within the ore, which on average grades around 0.23% Ni and 12% Cr2O3. The PCMZ ore contains excessive amounts of fibrous silicates which makes it a challenging float, with gangue control as the key element to success. Extensive laboratory testwork, which eventually led to a pilot plant campaign, was undertaken with the aim of developing a process route for treating the PCMZ ore. Several flotation circuit configurations were tested and results from the optimal circuit indicated that a nickel concentrate grading at 8.5% is achievable at a recovery of 78%, with substantial recoveries for the copper, cobalt and PGM co-products. The chromite concentrate, grading at 45%, was extracted from the flotation rougher tailings via a spiral plant. These promising results were incorporated into the plant design and are currently being evaluated in a bankable feasibility study, which will see the current 100ktpm MMZ concentrator being upgraded to a 250ktpm PCMZ concentrator as part of Nkomati?s Phase II expansion.

Jan 1, 2007

By Matsumura T, Takematsu T

The Brown Coal Liquefaction Process (BCL Process) has been developed by Nippon Brown Coal Liquefaction Co., Ltd. (NBCL), and a 50-ton-per -day Pilot Plant has been partially completed and put into operation by Brown Coal Liquefac- tion (Victoria) Pty., Ltd. (BCLV) at Morwell, Victoria, Australia. This Project has been sponsored by New Energy Development Organization (NEDO), an or- ganization associated with MITI, and has been promoted as a National Project with funding by the Japanese government. This project has also been conducted as a cooperative technology de- velopment project between the Japanese and Aus -tralian governments since 1980 and has been supported by the Victorian state government and

Jan 1, 1987

By Jerome P. Downey

Technologies developed within the field of extractive metallurgy to recover, concentrate, and purify metals and industrial minerals from ores, have served as the foundation for all of the subsequent environmental remediation, materials recycling, and waste management technologies. This paper discusses the application of classical extractive engineering principles to the development of a thermal process for the recovery of mercury from solid wastes. Process development is presented as a series of logical stages, which begin with a thorough characterization of the site-specific waste, move on to bench and pilot scale testing of the process options, and end with a functional process flowsheet. This paper also presents thermodynamic data on many mercury species of interest to the minerals, power, and chemical industries. These data can be used to model the speciation and recovery of the mercury as a function of various process parameters.

Jan 1, 2003

By J. Stiksma, R. Kalanchey, M. J. Collins, G. Owusu, R. Raudsepp, K. R. Buban, L. A. Barta, L. Masters

This paper describes the results of testwork for the treatment of Ambatovy laterite by an acid pressure leach process, with recovery of the soluble nickel and cobalt values as mixed sulphide intermediate by precipitation with hydrogen sulphide, and subsequent refining of the mixed sulphide to nickel and cobalt metals. These process development studies were carried out primarily in 2004, as part of a bankable feasibility study for the Ambatovy Nickel Project.

Jan 1, 2004

"Metallurgical process development in greenfield projects must define the comminution flowsheet and establish the equipment sizes that are required to deliver the project design criteria. These are critical steps that heavily influence the financial performance of the project, requiring a detailed understanding of the ore properties of the project resources and the best practice methods to size comminution machines. This paper reviews current practices for determining the ore characteristics relevant to comminution circuit design. Particular attention is given to the design of sampling and testing programs, and the methods commonly applied to size crushers and mills for conventional size reduction applications in mineral processing. IntroductionMetallurgical process development in greenfield projects requires the selection of a comminution flow sheet and must establish the equipment sizes required to deliver the project design criteria. This necessitates a detailed understanding of the ore properties that define the project resource. For brownfield projects the same objectives may apply for plant expansions, or the project objective may be simply to define the capacity and operating cost of an existing facility for a new ore source. The process development phase in either instance will typically comprise the following key activities:• Geometallurgical classification and sampling of the ore deposit or deposits.• Determination of comminution energy requirements.• Benchmarking similar projects.• Identification of flow sheet options.• Equipment selection and sizing.This paper is concerned specifically with process development testing and will as such focus on the first two activities on the list: sampling and testing of the deposit. The discussion will focus on testwork programs to support the design of comminution circuits commonly in use in mineral processing today, specifically crusher, tumbling mill and stirred mill technologies.It is important that any testwork program is designed giving consideration to the types of flow sheets that are viable for the project, and the data that will need to be generated to support the final equipment sizing. Designing a testwork program to only provide information about one particular type of flow sheet will not allow sufficient information to be generated for a rigorous trade-off analysis of options, and may therefore preclude financial optimization of the project. Testing programs should be designed to collect sufficient data to ensure that any backtracking at a later stage to fill in missing information is minimal."

Jan 1, 2016