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3366

CONTENTSSEPTEMBER 2011

SEPTEMBER 2011 International Mining 1

AROUND THE WORLD 3 The Leader 4 World Prospects 68 Forthcoming events IBC Classifieds

COVER: Orofino Gold Corp

Material removed from La Azul mine using artisanal techniques is ready to be

processed in the ball mills. Orofino Gold Corp (ORFG) is a Nevada corporation

holding one gold mining concession comprising 500 ha (1,235 acres) of land,

with purchase rights to 11 more concessions totalling 17,260 ha (42,657

acres), all in the heart of one of Colombia’s richest gold producing regions (see

p67). ORFG is a publicly traded company in its early development stage.

Its corporate office is in Dallas, Texas and its exploration office is in Medellín,

Colombia. www.orofinogoldcorp.com

6600

28

8 OPERATION FOCUS: StillwaterThe mine is an innovator and in goingdeeper has chosen an electric truck ramp inpreference to shaft deepening or anunderground conveyor system. John Chadwick visited the operation.

20 FRAGMENTATIONBlast fragmentation should be optimised formaterial haulage, comminution and mineralprocessing. John Chadwick examinessome technologies and the benefitsaccruing.

54 DRIVES AND CONTROLSPowering almost all fixed capital equipmentin mining and mineral processing,electromechanical and hydraulic drivesalong with electric motors are at the heartof site efficiency, reports Paul Moore.

58 HIGH PROFILEThe uptake of man-machine interfacetechnology in the mining industry is poisedto increase exponentially, according toBooyco Electronics’ Managing Director,Anton Lourens

67 HIGH PROFILEOrofino Gold Corp - insights on the goldboom in Colombia.

36 PROCESS DESIGNContributors consider regrind mills, physical separation, new processdevelopment for rare earths and vanadium, and much more.

88

2200

60 SX/EWThe technology is increasingly beingused by the minerals industry toseparate, purify and concentrate metalssuch as nickel, cobalt, copper, zinc,uranium and rare earths. John Chadwick looks at some of thelatest developments.

5544

T 2011:HR 24/8/11 14:52 Page 1

http://www.weirminerals.com

Coal now accounts for 29.6% of global

energy consumption, up from 25.6% 10

years ago. There was much doom and

gloom spread about the future of coal, and the

gainsayers continue their work, but the statistics

tell another story. Global thermal-coal trade is

projected to increase 4% a year to 962 Mt in

2016, underpinned by demand from China and

India. Certainly, it is noticeable these days how

many more coal projects are reported in our

International Mining Project News, every fortnight

Just this week the three join venture partners in

Cerrejón (Anglo American, BHP Billiton and

Xstrata, each with 33%) announced a $1.3 billion

expansion project that will increase its production

and export capacity by 8 Mt/y to 40 Mt/y.

Construction of the P40 project is scheduled to

commence in the third quarter of 2011 and be

completed by 2013, with production progressively

ramping up to reach 40 Mt/y by the end of 2015.

The project will include increasing coal production

and coal handling capacity at the Cerrejón mine and

coal handling and ship-loading capacity at its 100%

owned and operated port, Puerto Bolivar, including

the construction of an additional loading berth.

Cerrejón is an integrated mining and transport

complex in La Guajira, a department in the

northernmost part of Colombia. It currently includes

a thermal coal open-pit mine that produces 32 Mt/y,

a railroad that is 150 km long, and a maritime

port able to receive ships of up to 180,000 t dead

weight. It is the largest private exporter and one

of the most important tax payers in Colombia.

In one of the countries that is a key driver of

coal consumption, Coal India Ltd (CIL) produced

431.32 Mt in fiscal 2010-11. The company has

planned a significant expansion over the next 12

months so for fiscal 2011-12, CIL's targeted

production and coal off-take have been fixed at

452 Mt and 454 Mt, respectively.

In its first move overseas, Coal India Africana, a

wholly-owned subsidiary of CIL, will soon start

exploration and development work at two coal

blocks in Mozambique’s northwest Tete province,

estimated to have a reserve of at least 1,000 Mt.

Mozambique has become one of the new coal

frontiers with the likes of Vale and Rio Tinto very

active there.

Mongolia too is a hotbed of coal activity. In July,

the government chose two coal mining giants,

Peabody Energy from the US and China’s Shenhua

Group, and a Russian-Mongolian consortium to

jointly develop the keenly sought Tavan Tolgoi

coal deposit in the Gobi Desert, 550 km from the

capital Ulaanbaatar. A

government statement

said the companies

agreed to build a 600

MW power station, coal-

to-liquid fuel and coking

fuel plants as well as

north and southbound

rail lines for the project.

Shenhua will hold the largest stake in the project

at 40%, with Peabody taking 24% and the

consortium 36%, the government said. The

agreement is not yet confirmed but the deposit is

described on www.tavantolgoi.mn as “not only

the biggest deposit of Mongolia, it is one of the

10 biggest [coal] deposits in the world.” There it

reports 6,000 Mt of coal of which 2,000 Mt are

coking coal. “Thickness of the total coal is 191 m

and thickness of 16 layers of coal is 74.9 m.”

While Tavan Tolgoi may not yet be set in stone,

Peabody is currently very active elsewhere. Along

with ArcelorMittal it has submitted an all-cash

offer to acquire Macarthur Coal. Macarthur Coal is

a leading producer of low-volatile PCI metallurgical

coal with production and development assets in the

Bowen Basin, Australia, including the Coppabella

and Moorvale Joint Venture, Middlemount and

Codrilla. It holds total coal reserves of 270 Mt and

total resources of approximately 2,300 Mt.

In mid-July, Peabody Energy and the Government

of China’s Xinjiang Uyghur Autonomous Region

entered into a framework agreement to pursue

development of a state-of-the-art 50 Mt/y surface

mine that would operate over multiple decades.

Peabody Chairman and CEO Gregory H. Boyce

said "Peabody is honoured to work with the

Government of Xinjiang to advance a world-class

large-scale surface mine in the world's largest and

fastest-growing coal market."

Under terms of the agreement, Peabody would

construct, manage and operate the mine, which

would be one of the largest surface mines in

China, using best practices in safety, training,

productivity, resource recovery, environmental

standards and land restoration.

The Xinjiang Region is China's largest

administrative region with vast reserves of coal

estimated to account for approximately 40% of

China's reserves. The government expects

Xinjiang's coal output will increase from some

100 Mt in 2010 to more than 1,000 Mt.

John Chadwick

Publisher

[email protected]

THE LEADER VOLUME 7 • NUMBER 9

King coal’s expanding kingdomPublisherJohn ChadwickEmail: [email protected]

EditorPaul MooreEmail: [email protected]

Associate EditorChris CannEmail: [email protected]

Editorial BoardProfessor Malcolm ScobleRobert E. Hallbauer Chair in Mining Engineering., University of BC, Vancouver

Jeff RoschykVice President of Product Management & Marketing, P&H Mining, USA

Peter KnightsBMA Chair & Prof. of Mining Engineering University of Queensland

Stephen StoneWest One ManagementPerth, Western Australia

Dr. Andrew M. RobertsonPresident, Robertson GeoConsultants Vancouver, Canada.

Ed McCordProject ConsultantCaterpillar Global Mining, USA

Jason NitzMining Systems Strategist Newcrest Mining Ltd, Australia

Dr Terry MudderManaging DirectorTIMES Ltd, USA

Simon TarbuttConsultant, Santiago, Chile

Dr. Mike DanielComminution Process ConsultantAusenco Minerals & Metals, Australia

Editorial Enquiries:Tel: +44 (0)1442 870 829Fax +44 (0)1442 870 617

Advertising Sales:Phil PlayleEmail: [email protected]+44 1442 87 77 77

Advertising ProductionEmma SmithEmail: [email protected]

Publishing ConsultantRobin Peach

Design & ProductionTrevor SheldonEmail: [email protected]

Website:www.im-mining.com

Annual Subscription Enquiries:Emma SmithEmail: [email protected]

Annual SubscriptionUK and Europe £160, €230Rest of the world US$270

International Mining is published monthly by Team Publishing Ltd,2 Claridge Court, Lower Kings RoadBerkhamsted, Herts. HP4 2AF, UK

Printed by The Manson Group, St Albans

© Team Publishing Ltd 2011

ISSN 1747 -146X


WORLD PROSPECTS

4 International Mining SEPTEMBER 2011

Development on the KoiduKimberlite Expansion Projectin Sierra Leone is on schedule

and on budget, promising to rampup mining production to 100,000t/month of ore by the secondquarter of 2012.

Some six months into the projectto grow the mine’s output, ownerKoidu Holdings is working withSouth Africa-based lump-sum-turnkey contractors Consulmet anda host of local and global sub-contractors to meet a tight projecttimeline.

The expansion will see the totalmining rate ramped up from300,000 t to 1.5 Mt/month. Toprocess these tonnages, a new 180t/h run-of-mine treatment plant isbeing erected, with associated wastedisposal facilities; and an entirelynew mine infrastructure is also underdevelopment, to cater for the five-fold increase in the scale ofoperations.

A resettlement project isunderway to provide upgraded housing andcommunity for all those living within theaffected area of the mine’s future operations;this includes construction of a new road tofacilitate access around the newly enclosedmining lease.

“The magnitude of each of these sub-projects is considerable,” said Jan Joubert, CEOof Koidu Holdings. “Finding ways tosuccessfully implement these in Sierra Leoneoccupied substantial resources during theproject planning phases.”

In the project area – some 330 km east ofFreetown – the local systems of administrationand infrastructure are weak, he said. “Our nineyears of operating in Sierra Leone has given usthe insight to pre-empt potential shortcomingsand bottlenecks and to draw on strongrelationships developed within the country.

The tender for the process plant, carried outahead of the feasibility study, saw submissionsfrom three of the major plant engineeringcompanies in South Africa. The success of thebid by Consulmet was due to its experiencewith the maintenance of the current 50 t/hplant, its understanding of the kimberlitecharacteristics and recognition of Koidu’soperating philosophies and management style.

The new plant site is located 500 m to thewest of the existing plant, allowing productionto continue uninterrupted during the erectionof the new processing facility. The design of thenew plant follows a traditional kimberlitetreatment process, using proven technologiesappropriate to the operating conditions in

Sierra Leone, with high rainfall, high humidity,fairly limited engineering and electrical skills.

“Our approach to the design was to developa processing plant that is user-friendly and easyto operate in a challenging environment,” saidGavin Boyle, Director of Consulmet. “This wasachieved by keeping the flowsheet simple andincorporating relatively high levels ofredundancy and flexibility into the circuit tocater for the known variability in kimberlitecharacteristics from the various orebodies.Extensive test work on all kimberlite types wascarried out during the feasibility study andthese results guided the plant design process.”

Due to the remoteness of the Koidu site, thevarious plant modules are being fabricated andtrial-erected by Consulmet in South Africa toensure that all components are engineeredcorrectly and that each module is functioningprior to shipment to Sierra Leone. Thisapproach was adopted to detect problems thatcould cause delays in construction andcommissioning on site.

“The Koidu kimberlites contain diamondpopulations with large stone size distributionsand are known for producing some of thelargest rough diamonds ever recovered and,therefore, our process plant has been designedto recover any large stones before they reachthe crushing circuits,” said Boyle.

In final recovery, he explained, the designincluded the latest upgraded Flowsort wet X-ray machines These are fitted with the newoptical box spindle systems. This allows the X-ray machines to run at higher efficiencies, with

better recovery results and generating smallerconcentrate yields reporting to the glove boxes.

“In line with Koidu Holdings’ vision ofcreating a nature conservancy within theirmining lease once operations progressunderground, we paid special attention tonoise reduction, dust suppression and wastedisposal mechanisms,” said Boyle. “This keepsthe footprints of the slimes dam and tailingsdump as small as possible and introduces athickening system to recycle process water.”

The mine infrastructure development projectwas also awarded to Consulmet. This called fora new access control system, change house,mess facilities, workshop, central stores, fueldepot, emulsion storage facility and trainingfacilities. Also included is a generator house,electrical and water distribution systems,accommodation facilities, entertainment areas,waste management systems, drainage systemsand extension of the office complex.

Joubert is pleased with the progress on theproject to date, with half of the plant projectand nearly 40% of the infrastructure projectcompleted. “We have passed some of the mostdifficult phases of the project execution,” hesaid. “When one considers the project timelines ofother recently developed kimberlite operations,this is certainly exceptional performance.”

He said this was largely the result of themanagement team’s experience in Sierra Leone.“The five original members of our management

Expand ing Ko idu d iamond output

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WORLD PROSPECTS


team have already built one mine in SierraLeone and produced diamonds within 17months of the first site visits by the technicalteam,” he said.

“Our depth of knowledge and experience inSierra Leone has grown exponentially and withthe addition of three new members to themanagement committee last year, bringing awealth of specific diamond mining, processingand marketing experience, we have the optimalblend of in-country expertise, qualifications anddrive to implement the Expansion Projectsuccessfully.”

Mining is currently focussed on the K2 openpit; the expansions will bring the K1 open pitcomplex on line with an aggressive wastestripping program to remove the remnants of theK1 vertical pit. The K1 complex includes the mainkimberlite pipe and two dyke zones flanking thenorthern and southern margins of the pipe, aswell as two enlargements on the dyke zonesdeveloped about 200 m on either side of K1.

The new mining fleet is now moving about750,000 t/month from K1, a rate that willincrease to over 1 Mt/month; the targeted K2production rate of 500,000 t/month will bring

the total mining rate to 1.5 Mt/month fromSeptember 2011. This will ensure the requiredoutput by the time the new treatment plant iscommissioned next year.

Koidu Holdings is a mid-tier diamond miningcompany with kimberlite projects located in thediamond fields of eastern Sierra Leone. It isowned by BSG Resource. Koidu Holdings holdtwo mining leases - Koidu and the TongoDiamond Field Project; and an explorationlicence – Panguma, within the main kimberlitefields of Sierra Leone.

Metso offers first recyclable screening media

Hilti has a new range of screw anchors and a new cable bolt system

Metso has proudly announced it hasdeveloped the first fully recyclablemodular screening media – Metso

Trellex LS-Eco, in response to customer requestsfor sustainable and environmentally-friendlyscreening media solutions, and in line with itsown sustainability program. The company hastaken the Metso Trellex LS rubber modularscreening media systems and successfullyreplaced the traditional steel reinforcementwith an environmentally-friendly compositematerial. This makes it possible to effectivelyrecycle customers’ screening media. A uniquesolution.

In the past, screening media modules whichwere no longer suitable for production weretreated as waste and could not be recycled.Metso has introduced a new futureand a sustainable solution. In addi-tion to providing environmentally-friendly screening media panels,Metso will implement a unique pro-gram to provide its customers witha suitable range of recycling services.

The Metso Trellex LS-Eco offers awide range of health, safety and environmentalbenefits. Each screening media panel is up to

40% lighter than standard steel reinforcedTrellex LS panels. This makes handling easierand the working envi-ronment safer.Lighter panels alsohelp to reducethe over-all

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The Trellex 300LS andTrellex 305LS rubber andpolyurethane panels can be

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The Hilti Mining Screw (HMS) anchors areavailable in lengths from 155 to 920 mmand various diameters with undercut-

forming threads to suit different types of rock."These anchors are easy-to-use and extremelyversatile," Hilti Australia spokesman Peter Jonessaid. "Simply drill the hole and drive the anchor- that's all it takes to achieve outstanding loadvalues of up to 20 t." The HMS screw anchorscan be used for a wide range of undergroundapplications including fastening machinery,ventilation systems, water pipes or hoses, andcables. They are available in three versions:HMS-S for soft rock and non-abrasive materialssuch as coal, HMS-MX for medium-hard rocktypes such as shale, and HMS-H for very toughground conditions.

The new Hilti HTT cable bolt system isdescribed as innovative, fast, safe and effec-tive. “The HTT-UX, HTT-UXG and HTT-RX cablebolts feature a torque tension head that candeliver very high pre-tension lev-els, without having to applyhazardous and cumber-some hydraulic ten-sioners,” Jonessaid.

“Simply

install the bolt usingstandard rigs off the

miner or airtrack, then use the torque

of the same rigto tension thenut - done.”

Point-anchored orpost-grouted, the long

tendons suited a widerange of development and

outbye applications, Jones said.This news came from the AIMEX exhi-

bition in Australia where Hilti also showcasedits OneStep rock anchor system, which accord-ing to the company continues to revolutioniserock bolting. The self-drilling system integratesbolt installation components (drill steel, drillbit, resin cartridges and rock anchor) into oneproduct, providing fast, easy, safe and reliableground control. www.hilti.com

Hilti HTT-UXG cable bolt

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Stillwater Mining Co (SMC) is the only US

producer of palladium and platinum,

operating the Stillwater and East Boulder

mines in the foothills of the Beartooth

Mountain Range in Montana. Its recent

production levels are shown in the table.

Second quarter 2011 mined production of

palladium and platinum totalled 142,700 oz,

an increase of 26.7% over the 112,600 oz

produced during the same period last year and

8.8% more than the 131,200 oz produced

during the first quarter of 2011.

Mined production of palladium and platinum

has exceeded original estimates for the first

two quarters of 2011. Production has exceeded

expectations due primarily to more tonnes mined

than anticipated, higher ore grades in the lower

off shaft area of the Stillwater Mine and the

contribution of higher grades from the east

side of the mine. Based on updated estimates,

SMC increased its 2011 annual forecast for mined

palladium and platinum production to 515,000

oz from its original guidance of 500,000 oz.

The Stillwater mine is near Nye, East Boulder

is south of McLeod. Both mines are located on

the J-M Reef. Concentrators are operated at

both mines to upgrade ore to a concentrate.

The company also operates a smelter, refinery

and laboratory at Columbus, Montana to

further upgrade concentrate to a PGM-rich

filter cake. Spent catalyst material is also recycled

at the smelter and refinery to recover PGMs.

The mines have a reputation in North

America and worldwide for innovation. They

have made extensive use of tunnel boring

machines (TBMs), and continue to do so. The

Kiruna Electric truck installation from ABB/GIA

is the first application of this technology in the

‘lower 48’ – the states of the US south of the

Canadian border and excluding Hawaii. As the

first, it is attracting interest from underground

mines elsewhere in the country, like Nevada.

Stillwater mine accesses the eastern portion

of the J-M Reef, a segment more than 10 km

long of the total strike of some 45 km, at

elevations of 700 to 2,195 m above sea level.

The reef is accessed by a 595 m vertical shaft,

and by a system of horizontal adits and drifts.

East Boulder accesses the western portion of

the J-M Reef and is completely independent of

Stillwater.

SMC has moved its mine operations from

mechanised bulk mining methods to less

mechanised but more selective methods. Sub-

level mining is being de-emphasised over time

at both mines. At the Stillwater mine up to

35% of ore will be mined by various captive

cut and fill (CAF) mining methods and 65% by

mechanised ramp cut and fill mining methods.

At the East Boulder mine up to 100% of ore is

mined by various captive CAF methods.

This transitioning of methods emphasises

margin and sustainability. Selective mining is

important to SMC:

■ Increased opportunity to mine with less dilution,

thus increasing the ore grade to the mill

Stillwater runs

deep

The mine is an innovator and, going deeper,has chosen an electric truck ramp inpreference to shaft deepening orunderground conveyor system

A Kiruna Electric truck emerges from under the

Nordic Mine Technology chutes.

Stillwater mine 2010 2009 2008

Palladium 270,600 301,700 268,200

Platinum 81,100 92,100 81,200

Total 351,700 393,800 349,400

East Boulder mine

Palladium 103,500 105,300 116,000

Platinum 29,900 30,800 33,500

Total 133,400 136,100 149,500

Total mining

Palladium 374,100 407,000 384,200

Platinum 111,000 122,900 114,700

Total 485,100 529,900 498,900

SMC palladium and platinum mine production (oz)

OPERATION FOCUS – United States


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■ Increased recovery of the in situ mineral

deposit

■ Decreased primary and secondary

development per ounce of production,

reducing operating costs

■ Decreased reliance on mobile equipment

reducing capital expenditures and mining

support costs.

Ramp-and-fill is a mining method in which a

series of horizontal cuts

are extracted from the

orebody using mobile

equipment. Access to the

orebody is from ramps

driven within or adjacent

to the orebody using

hydraulic drills and LHDs.

In Sub-level stoping,

blocks of the reef some

15 m high and up to 23

m in length are extracted

in 9 m intervals using

longhole drill jumbos and

remote control LHDs. The

reef is mined in a retreat

sequence and mined out

areas are filled with

development waste or

sand backfill as

appropriate.

Traditionally, captive

CAF has been viewed as

being more selective in

nature than either ramp-and-fill or sub-level

stoping, but it also requires miners with special

skills and is generally less productive. Other

factors considered in determining the most

appropriate

mining method

for each area

include the

amount of

ancillary

development

required as

well as the ore grade and ground conditions

expected. The mine determines the appropriate

method to be used on a stope-by-stope basis

using an engineering and economic analysis.

The mine operates an impressively large

trackless equipment fleet. Roof support is

provided by three Sandvik Bolters. There is an

assortment of raiseboring machines; a

Subterranean unit, two Robbins RBM7s and a

Terratec RMB. Longhole drilling is provided by

four Boart Longyear A8s and one Atlas Copco

H157 Simba.

There is a large number of fairly small drill

jumbos, because of the mining methods used –

21 single-boom units and six MTI Driftrunners,

which feature two hydraulic percussion drifters

designed to drill headings 5.49 m by 7.04 m.

The single-booms are 15 Atlas Copco H104s,

giving coverage of 6-20 m2 and six MTI

Veinrunners, which are designed for drilling

vertical, horizontal, and angled holes, feature

one hydraulic percussion drifter, and can drive

headings 5.5 m by 5.1 m.

There is very large LHD fleet of 65 machines,

ranging from 17 MTI LT-270 1.2 m³ machines

with a rated load capacity of 2,722 kg and an all

mechanical powertrain; 21 MTI LT-350s (1.9 m³

with a rated load capacity of 3,636 kg), some

older Atlas Copco ST2D (Wagners in fact) to the

largest units – 21 Caterpillar R1300s (3 m3). The

truck fleet is no less impressive – five MTI D1604s

(8.0 m3, four-wheel drive with a 14.5 t rated

capacity) and 12 Trident C416 trucks with the

same capacity. The large diesel trucks are the four

Caterpillar AD30s that will carry 21 t each.

The mine’s utility fleet includes four Normet

Multimec cassette carriers, three MTI DT1604

fuel trucks, various Getman units – six A-64



Mining

horizontal slices

using jacklegs

and ore mucking

with a slusher

Ramp and Fill mining begins in a horizontal stope. It

employs mechanised drill jumbos and LHDs. Advances

in the stope are made in 2.7 m increments. After the

stope is mined out, it is then backfilled with waste

rock and sand to become the floor for the next

horizontal stope, moving upward in 3 m increments

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flatbeds and a special unit for backfill, a PT-100

– a mixed fleet of Case skidsteer loaders and

five Dux P1 scissor lifts. Caterpillar 120 graders,

a D3 dozer, three MTI DT1604 trucks and a

compactor comprise the underground road

maintenance fleet.

Electric trucksToday, some 60% of Stillwater’s production is

sourced from where the mine refers to as ‘off-

shaft’. That means it is from stopes below the

3200 level (975 m above sea level (asl) –

surface is 1,524 m asl), and below shaft

bottom. Until now, the ore from lower levels

was all hauled to shaft loading facilities using

the mine’s fleet of Caterpillar AD30 diesel

trucks. However, economics dictated that the

mine required a more efficient and cheaper

method to bring ore up from the lower levels

as its share of total mining output was

growing.

SMC undertook a feasibility study into all of

its options for haulage from the deep levels,

which included: extending the existing shaft,

stepping off, using conveyors and expanding its

fleet of diesel trucks as well as the electric

‘trolley’ trucks.

Whilst the study indicated that initial costs



Sub-level stoping at Stillwater involves a ramp along

the footwall of the reef to access to the orebody at

9.1-12.2 m vertical intervals. Ore is removed from the

open stopes byremote-controlled LHDs

For Stillwater’s captive CAF with borehole access, the orebody is accessed from a

footwall lateral to a crosscut. The stopes are accessed by pulling a raisebore level to

level. Horizontal slices are mined using jackleg drills. Blasted ore is transferred to an

orepass using a slusher winch. Following completion of the first lift, access to the next

level is from the top of the raise

Captive CAF with Alimak enters the orebody from a footwall lateral to a crosscut.

Then an Alimak raise is mined from level to level for access to mining stopes.

Horizontal slices are mined using jacklegs and ore is mucked with a slusher

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In China, a number of POLYCOM® high-pressure grinding roll units are already in successful operation grinding iron ore concentrate. Two Chinese companies placed second orders for this type of mill.

A Mexican mining company has placed a order for an iron ore grinding plant with ball mill for a capacity of 450 t/h of iron ore.

In Brazil, the POLYCOM® high-pressure grinding roll is a well known machine in the iron ore mining industry. Now ThyssenKrupp Polysius has received a new order from a Brazilian company for supply of a POLYCOM® high-pressure grinding roll.

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were comparable, according to Chief Engineer,

Curt Jacobs, all options, other than the electric

trucks, meant a capital cost outlay with no

payback for some years. “We therefore opted

in favour of the Kiruna trucks as a ‘pay as we

go’ option,” he explained.

Another good reason for the Kiruna Electrics

is the battle SMC, like all North American

mines making extensive use of diesel

equipment, has to keep Diesel Particulate

Emissions (DPM) within acceptable limits. For

some years it has been using 35% biodiesel

and has been very active in efforts to reduce

DPM from the over 300 diesel powered

machines underground (IM, February 2009,

pp48-50).

Furthermore, these trucks are ‘cool’ in terms

of ventilation requirements, quiet and climb

ramps considerably faster than diesel units. The

Cat AD30s climb ramps at 6 to 8 km/h, while

the Kiruna Electrics climb their dedicated ramp

(which other vehicles can use) at a governed

speed of 16 km/h. They could haul up the ramp

at up to 22.5 km/h. The measured outside

noise level at maximum output is 85-90 dBA.

Currently the mine is exhausting some 40,000

m3/min (1.4 million cfm) through the workings

using a 295 kW fan in each ventilation shaft.

Pat Wilson, the driver with whom I took a

circuit in the truck, used to drive the AD30s. He

noted that he is much less tired at the end of

the shift as he has not been subjected to the

same stresses of noise and heat as in a diesel

machine. “It looks scarey and big,” Wilson

observed, “but it’s easy to drive.”

Produced in Sweden in co-operation

between GIA Industri and ABB, the Kiruna

Electrics operate on a three-phase AC, 690 V

overhead trolley line secured to the roof of the

ramp drift. There is a power collector on the

roof of the truck. These trucks are engineered

(electrically), sold and serviced by ABB in

Canada for the North American market.

It is an all AC electric system with one motor

for each axle, making it a true four-wheel drive

truck. Two electric traction motors drive all four

wheels allowing the truck to maintain high

tramming speeds, resulting in a higher

productivity per truck unit. A single Kiruna

Electric unit can achieve the same production

tonnage as several diesel trucks. Faster speeds

up steeper ramps result in a much smaller total

electric truck fleet size for the same ore and

waste haulage as a larger fleet of diesel trucks.

Electric power also allows easy and smooth

stop/start operations with less strain on the

operator and truck components.

A 75 kW Tier 3 diesel engine automatically

starts up for off line duties such as, for

example, loading, dumping and turning areas.

Similarly, when operating the trucks in tandem

on the ramp, there is no need for an overhead

trolley line in passing areas. The operator simply

drops the power collector which starts the

diesel engine, allowing him to move off the

ramp into a crosscut and allow the oncoming

vehicle to pass.

SMC currently has two Kiruna K635EDs, is

ordering a third and considering a fourth. Once

the three are in operation, two will operate in

tandem with the third as a spare to cover

planned maintenance downtimes. These trucks

offer a haul capacity of 35 t, nominal, and have

been fully operational since March. They are

running up and down a 1,707 m (5,600’) long

ramp between 1,067 m (3,500’) asl and 853 m

(2,800’) asl. The round trip is 3.4 km (some

11,200’) and takes little time (some 15-18

minutes) at 16 km/h, even though the gradient

is 13-17%. Each truck can comfortably haul

1,400-1,600 t/d and a very good shift (achieved

quite often) would be 1,000 t. The total mine is

only hoisting about 2,000 t/d of ore and

development rock.

Next year, the ramp will be extended down

to 762 m (2,500’) asl and then to 670 m

(2,200’) asl. Eventually it will go down 427 m

(1,400’) asl and will really put these impressive

machines through their paces.

ABB supplied all the overhead trolley line and

electrical installations and switchgear that steps

the 13,200 V in, down to the 690 V for the

trolley line. Gerald Rothwell is the SMC

electrical engineer who managed this

installation and the assembly (and wiring) of

the trucks underground. As we all know, a

project of this complexity is bound to have a

few teething problems but overall he was very

happy with the way it went and the support he

received from both GIA and ABB Canada. Joel

DeBruycker, Project Engineer and David

Crabtree, General Foreman, confirmed that

everyone involved in the project was “real

happy.”

The Kiruna Electric ramp is 5 m (16.4’) wide

and 4.9 m (16’) high. The mine used a Wirtgen

road paver to pave the top 152 mm (6”). The

result is a smooth ride, though there is a

tendency to rut because major changes of

direction and breaking points are always in the

same places. There will need to be some

resurfacing eventually. The trucks are loaded

from two separate 2 m x 0.9 m Nordic Mine

Technology chutes – one for ore, the other for

waste, and the trucks tip into one of two

appropriate passes at the top of the ramp.

Machine monitoringThe Kiruna Electric monitoring system sends its

data to a control room in a main workshop

near the top of the dedicated ramp. Rothwell

explains that he can look at 167 separate types

of information – temperatures, voltages,

currents, etc. Tonnage and other production

data are also available. The trucks download

this data automatically every time they pass up

the ramp to the dumping points. For specific

diagnosis, or production monitoring tasks, the

system can be set up to automatically report on

12 data items at any one time.

Kiruna Electric is a well proven technology

with more than 70 trucking years in production

mines, at an availability of over 85%.

Maintenance and operating costs are low

compared with diesel trucks. Continuous

improvements are made, responding to

customer feedback. Summarising their benefits:

■ Relatively low capital cost to access below

shaft bottom



Compared to conveyor belts, GIA says the Kiruna

Electric is flexible, requires no re-loading, the system is

easy to extend, redundancy allows more than one

truck for the production required, a dedicated ramp is

not required. Early start of production and the ability

to re-use the trucks and trolley system in another

mining block without more capital expenditure are

two further advantages

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■ Minimal demands on ventilation systems and

concomitant savings (diesel trucks generate a

significant amount of heat)

■ Fast benefit of production increase and early

return on capital employed

■ Long asset life (electric truck typically gets

>50,000 operating hours)

■ Environmental, health and safety friendly

■ Faster speeds = more production

■ Faster speeds = shorter cycle times = smaller

fleets

■ Reduced risk of underground diesel storage

■ Lower operating costs derive from fewer

trucks for the same tonnage moved (and

fewer drivers; energy costs less than diesel

fuel; dynamic breaking on AC trucks

generates power down ramp and lower

maintenance cost less

■ Can use steep ramps (shorter ramps)

The major cost elements at SMC’s mines

include labour (56%), power (5%) and fuel

(4%), mining materials and supplies (27%) and

contracted services (8%).

Stillwater looking aheadThe basis for the ten-year plan provides for

sustaining the current production profile while

strengthening the developed state and

upgrading infrastructure to mitigate receding

face implications. During this same period,

Stillwater will be developing growth

opportunities to the east within SMC’s present

land package, targeting the Blitz area.

Stillwater began operations in 1986 and has

undergone dramatic changes since that time.

The active mining front has moved deeper and

further to the west, expanding the mine such

that operations now extend laterally more than

8 km east to west and vertically for more than

1,600 m. Today, for example, more than half of

the mining occurs roughly 5 km distant from

the shaft. Operating within a concentrated

mining front would enable SMC to maintain

lower costs and higher productivities.

The mine operates at elevations of 610 and

2,225 m asl. As well as the main vertical shaft

there is a system of horizontal adits and drifts

driven parallel to the strike of the J-M Reef at

vertical intervals of between 46 and 92 m.

Seven main adits have been driven from surface

portals on the west and east slopes of the

Stillwater Valley at various elevations between

1,525 m (5,000’) and 1,800 m (5,900’) asl.

Several additional principal levels have been

developed below the 5000 level down to the

3200 level, accessed from the vertical shaft and

the associated shaft ramp system.

The mine currently uses its 30 footwall lateral

drifts and six primary ramps and vertical

excavations to provide personnel and

equipment access, supply haulage and

drainage, intake and exhaust ventilation

systems, muck haulage, backfill plant access,

powder storage and/or emergency egress.

Additionally, operations have become

increasingly dispersed, so that haulage and

service groups are now required to traverse

distances of up to several kilometres in support

of daily mining activities. No wonder then that

mine personnel make use of 61 Kawasaki

Mules (models 3010 and 4010) and nine

Kubota RTV900 utility vehicles. There is also a

mixed fleet of Ford and Toyota pick-ups.

The new Kiruna electric truck ramp has been

designed to reduce the haulage load and will

initially support Stillwater’s westward

development below the 3200 level and

subsequent production as new stoping areas

come on line. In July of 2011, the ramp began

to be extended deeper into the mine and is

expected to reach the 1400W level by late

2015, providing increased haulage support for

the western mining operations.

Production rates from the mine are expected

to remain flat until the Kiruna haulage system

begins to support mining activity in the far west

via the 1400W level. Complementing the

Kiruna haulage system, the main shaft will be

upgraded to achieve a 20% increase in hoisting

capacity. Development will advance under a



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three primary areas (Off Shaft, Upper West and

Lower West).

SMC says “once these milestones are

achieved, there may be an opportunity to

increase mine production rates, contingent

upon our ability to staff the operation at that

time. At a minimum, this infrastructure

strengthens our operational foundation and will

help to sustain Stillwater in the years ahead.”

SMC controls a considerable length of JM

Reef strike to the east of the existing Stillwater

mine operations, referred to as the Blitz area.

Limited surface drilling in this area suggests its

ore grades may be similar to those in the Off

Shaft area of the Stillwater mine. The company

intends to develop this area over the next few

years in hopes of providing additional mill feed

to sustain current production levels and

potentially grow Stillwater’s production in the

future.

The Blitz project would be accessed from the

5000 level east portal at the mine. A significant

amount of rehabilitation is underway in

preparation for this project and is scheduled to

be completed by the fourth quarter of 2011.


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The project is currently planned to advance two

parallel footwall laterals 4,115 m to the east on

the 5000 rail level and 5600 ‘rubber tyred’

level. Assuming sufficient ore reserves are

found, two new ventilation raises to surface

would be required to provide adequate

ventilation in support of ore production from

this area.

Two options were considered for developing

the Blitz 5000E level – conventional drill and

blast methods or installing a tunnel boring

machine (TBM). SMC has had significant

success with TBM development at East Boulder.

As SMC says, the method “has the advantage

of requiring a different skill set and somewhat

leaner staffing than the conventional drill and

blast method. Staffing Blitz

with skilled miners for

conventional drill-and-blast

development would compete

with our own production

staffing needs, making the

TBM option appealing.

SMC growthIn July SMC and Peregrine

Metals entered into a

definitive agreement

pursuant to which Stillwater

will acquire all of the

outstanding shares of

Peregrine. SMC plans to

further delineate, develop and operate

Peregrine's Altar porphyry copper-gold deposit,

a large, undeveloped open-pit resource located

in the San Juan province of Argentina. Altar has

Canadian NI 43-101 compliant Measured and

Indicated copper resources of 7,400 Mlb of

copper and Inferred copper resources of 4,300

Mlb, both at a 0.3% Cu equivalent cutoff

grade. The property also has significant gold

resources, with 1.5 Moz of Measured and

Indicated resource and an Inferred resource of

880,000 oz. The resources at Altar are open to

expansion laterally in three directions and at depth.

SMC expects that development of the Altar

project will benefit from potential infrastructure

synergies as well as from its strategic location

near key transportation routes across the

nearby Chilean border and proximity to

shipping facilities on the Pacific Ocean.

Frank McAllister, SMC's Chairman and CEO,

said, "For several years, one of Stillwater's

primary strategic goals has been to grow and

diversify our business through the acquisition

and development of high-quality mining assets.

The Peregrine transaction provides us with

broader diversification into copper -- a metal

with favourable long-term fundamentals driven

by growing market demand -- as well as

meaningful exposure to gold.

"In combination with our PGM producing

assets in Montana and the continuing

development of our Marathon assets in

Canada, we are creating a leading mid-cap

diversified mining company with a strong

financial profile and a robust growth pipeline

across attractive commodity classes and

geographies. We believe that the mix of PGMs,

gold and copper provides Stillwater and its

shareholders with a unique and compelling

investment proposition."

Stillwater plans to invest approximately $75

million over the next three years to fully

delineate the Altar resource and to advance

exploration on the property. IM



Stillwater

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Break it better

Blast fragmentation should be optimisedfor material haulage, comminution and

mineral processing. John Chadwickexamines some technologies and the

benefits accruing

FRAGMENTATION


Jack Eloranta of Eloranta & Associates

stresses the importance of timing a blast

properly. “It may take days or weeks to

drill out a pattern and loading might take

hours or days. But, the time span that really

matters is the interval from the detonation of

one hole to the time the adjacent hole fires.

“Modern detonators have revolutionised

blast timing. Not only has precision improved

by an order of magnitude, but complete

flexibility is now a reality. If you want 1 ms or

five seconds of delay – just dial it in.

“So, with timing solved, it is time to focus

on other more pressing blast design problems

– right? Not quite so fast. Just because the

technology is available, it doesn’t mean the

understanding has caught up.

“Recent laboratory work by Katsibanis1 and

computer modelling by Preece2 have confirmed

that the window of opportunity is narrow.

Their findings seems to reconfirm the work of

Rholl and Stagg, done for the US Bureau of

Mines3 in 1987 that “fragmentation improves

above 3.3ms/m and is adversely affected below

1 ms/m or above 26 ms/m”. There is, as well, a

great deal of speculation regarding the

interaction of shock waves. However, there is

little supporting evidence as to the benefits of

colliding shock waves.

“The window of opportunity is short. It is

critical that from the instant of initiation of one

powder column there is a narrow range of

time that the adjacent hole must fire. When

the time is too short, the late work of the first

hole is stopped and the full potential of

creating a fracture network is not achieved.

Conversely, when the delay time is excessive,

the second hole is shooting into a fractured

rock mass with openings between fragments.

In the extreme case, shifting occurs which may

result in offsets and cutoffs of the powder

column. Such disruptions may be much more

Orica Mining Services showcased new blasting

developments designed to improve productivity,

efficiency, safety and environmental outcomes during

AIMEX this month. “These innovative technologies

can be tailored to the specific requirements of

customers,” said Toni Laming, Strategic Marketing

Manager - Australia/Asia, Orica Mining Services. The

company has also launched a mobile device

application for its Blasters’ Handbook. “Our Blasters’

Handbook app for Apple iOS, BlackBerry and Google

Android devices is designed to give blasting engineers

instant access to vital blasting specifications,

calculations and procedures,” she said

Too fast -loss of late work: Crack tip velocity is estimated at 1,000 m/s while shock wave velocity may be three

times faster. This difference has shed doubt on the role of interacting shockwaves as a primary mechanism

underlying the effectiveness of modern detonators.

Too late - offsets and cutoffs: The other ‘bookend’ to blast timing is the long-recognised bugbear of cutoffs. In

the worst case, physical dislocation of the powder column results in a misfired hole. However, there may be

significant losses in blast performance even when no un-shot product is found after the blast. The robust flame

front associated with the detonation of a large-diameter blasthole can fire a fully offset portion of a powder

column. However, as the offset distance increases; full order detonation gives way to low order detonation and

deflagration. In a 16’’ (406 mm) diameter blasthole, avoiding a loss of 9’’ (229 mm) of bulk product would pay

for the changeover to modern detonators

http://www.cubex.net

FRAGMENTATION


prevalent than previously thought. Research by

Rodgers and Lee4 indicates that stemming

decks may need to be at least 10 diameters in

length (as opposed to the old rule of thumb of

six diameters). This means that that a blaster

who is experiencing offsets may not necessarily

be finding un-shot powder in the muckpile.

Powder can be consumed via deflagration

rather than detonation. Such low order

combustion has been shown to contribute to

nitrous oxides and orange smoke. Further

evidence of offsets lies in VODR (velocity of

detonation recorder) data. The success rate for

capturing detonation velocity in the field is

low. The initial hole in a pattern is often the

only clean record.

“To conclude, your timing will be dictated

by several constraints. High on the list will be

avoiding misfires due to cutoffs and avoiding

high ground vibration at neighbouring

properties. Other high priority constraints may

include: minimising movement for dilution

control and matching muckpile profile and

digability to loading equipment. Once these

high priority concerns are met, further timing

tests can be done to optimise downstream

processes such as crushing and grinding where

the greatest savings lie. In the final analysis,

one might say that modern detonators result

in an increased effective powder factor thanks

to full order detonation of more of the powder

column.”

WipWare says that with the introduction of

WipFrag in 1986, it “became the industry

leader in optical granulometry of fragmented

material. Since that time, the company has

built a global reputation for excellence in

software innovation and design.” With

WipFrag, Momentum, Reflex and Solo;

WipWare continues to provide customers with

innovative solutions to optimisation and

automation needs.

With innovative fragmentation analysis

technologies, companies are now able to

establish blast consistencies, and can track

relative changes in ore size, based solely on the

data provided from these systems. The results

include reduced maintenance costs, improved

blasting procedures, and increased throughput.

Gyratory crushers are typically adjusted every

five to seven days depending on the operation.

Now, companies are focusing on real-time

fragmentation data, and using key

performance indicators to determine how

much downtime and maintenance is necessary

when gapping.

At one particular operation, rules were set

to adjust the gap settings automatically using

hydraulic toggle technology along with

fragmentation data from an online system. The

results can show a number of different things,

but most importantly it tells the operator

either:

a) The crusher needs to be gapped on a more

regular basis based on the increased

fragmentation size

b) The crusher is being gapped too often when

it is not required, allowing for less downtime.

Further into the comminution circuit, being

able to adjust the SAG mill feed based on real-

time data has allowed operators to optimise

the size of material going into the SAG. This,

in return, has increased the throughput at

many operations worldwide, and has reduced

liner wear significantly.

Mark Wagner of WipWare notes that “when

monitoring fragmentation at three crucial parts

of the mining process, mining companies have

developed a better sense of what is passing

through their process, and have adjusted

blasting and crushing procedures accordingly.”

I-Blast is blasting simulation engineering

software to help optimise results without

delaying the blasting process. The DNA-Blast

model provides a "holistic" and realistic model

of rock breakage, and consequently of

fragmentation distribution size, taking into

account all key parameters involved such as

geology, explosive features, drilling pattern and

timing sequence.

DNA-Frag is a paradigm shift in

fragmentation simulation versus traditional

purely statistically-based simulation tools.

Furthermore, the DNA-Blast model enables a

new proven approach and sets a new standard

in blast design, thanks to its fragmentation

module and its new simultaneous simulation

capability for vibration, air blast, fly-rocks and

muck-pile shape.

Multiple blast scenarios can be run before

selecting what should be the most effective

combination that best suits operational

objectives. DNA-Blast allows a seamless

quantification and size estimation of the

fragmentation and delivers a size distribution

of rock either in a muckpile or on a conveyor

belt, for a considered hole or for the whole

blast, thanks to a unique image compilation

feature (see the bottom part of the

screenshot).

The DNA_Frag module, takes into account

all the field data at hand to accurately predict

blast results – real burden and spacing face

geometry, rock mechanics characteristics,

explosive hole loading, angle and co-ordinates,

explosive characteristics and behaviour.

The DNA-Frag module shows an average

90% accuracy in the prediction over recent

years. Complete muckpile screening campaigns

even show these figures to be somewhat

underestimated, says the French inventor of

the technology, Dr Thierry Bernard.

Non-disruptive fragmentation analysis technology analyses material as it dumps into

the primary crusher

The fragmentation result is displayed instantly and

can be sent via email to operators throughout the

operation

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The DNA-Blast Energy Optimsation Module

was integrated into I-Blast in early 2011 and

adds a decision aid tool that simulates all the

possible initiation sequences in your

configuration, pinpointing the sequences that

best optimise the energy inside the blast.

Aiming at providing an Optimized Explosive

Energy Release time design, Bernard applies

the principle of mass conservation to the

explosive energy: less energy dissipated in

vibrations means more energy for

fragmentation. “Ask somebody who is using

electronic detonators for vibration control. He

will say that the muck pile is uniform and the

fragmentation has improved. This is exactly the

principle we apply in DNA-Blast Technology”,

says Bernard.

The use of signature hole principles, and

subsequent vibration analysis allows the

mitigation of the energy waste that is

responsible for adverse blast effects such as

vibration, air blast level and fly rock.

The DNA-Blast Energy Optimisation Module

gives you the opportunity to process either a

Far Field or a Near Field Signature hole. Using

a Far field analysis, an average number of

holes per row and an average number of rows

are considered to give you the best trend for

Inter Row Delay and Inter Hole Delay.

Relying on a Near field Signature, the

module takes into account blasting pattern

configuration, the x,y,z hole location, the

number of holes, hole loading and

configuration. It provides the optimum timing

sequence among a screened range of Inter

Hole delay and Inter Row Delay.

The yellow areas show where the amount of

wasted energy is minimized outside the blast.

Selecting the corresponding delays will

optimize your blast which results in less

vibrations and a better fragmentation.

A 35% drop in excavation and comminution

costs through the application of optimised

timing has been reported by one North

American open-pit mining.

“I have successfully used I-Blast at over 35

sites and over 500 blasts and the software

performed as expected with vibration, air

overpressure, and fragmentation results

occurring as predicted”, says John Babcock,

Executive Technical Director at South Technical

Services, based on his experience in providing

engineering and advanced technical services to

the quarries of the East Coast of the USA.

The three most important factors in blasting

are drilling, drilling and drilling, according to

BME. Expecting explosives to provide totally

satisfactory results when preparation and

drilling on site has been poor is not only totally

unrealistic, but can also be expensive. The

result of poorly drilled blast sites is a

substandard outcome, poor fragmentation and

ultimately lost production, says Tony Rorke,

Director of Blasting Technology at BME, one of

South Africa’s leading suppliers of explosives.

“The belief that explosives will compensate

for poor drilling at a blast site is more common

than most people would think,” says Rorke

who says that he is often requested to deal

with requests to use technology and explosives

to solve what miners already know to be

poorly prepared blast sites.

Amongst the most common requests for

assistance are:

■ To do timing designs that will “ensure good

fragmentation and low vibration” when

drilling has already been completed

■ To request the application of electronic

detonators to improve blast results at sites

where poor drilling quality is endemic. The

significant benefits when using accurate

electronic detonators are completely

overshadowed by poor drilling quality.

Most commonly, however, is the claim that

drilling is not the problem. “I am often told

that high bottoms are being experienced on

blasts and that it is the explosives, the blast

design, the initiation system or both the

initiation and blast design that is at fault.

Unfortunately, this is rarely true. Poor drilling

quality or inappropriate drilling patterns are

usually found to be the heart of the problem,”

says Rorke.

The causes of poor blasts are many and can

range from poorly trained drilling crews and

drill foremen, through to teams working with

an insufficient number of drill rigs and having

to work under pressure to try and maintain

production rates.

Other factors that have a negative impact

on drilling results can be drill rig fleets that are

inappropriate for the mining geometry or rock

in an area and difficult environments where

drilling quality and measurement is difficult.

This scenario is most common where handheld

drilling is required in narrow stopes or

development ends.

“I am often asked when on site what the

sources of errors in drilling are,” says Rorke.

Summarised they are distances between holes.

Holes drilled too close together result in over-

fine rock fragmentation. Explosives in nearby

unfired holes may become damaged and not

detonate properly or it may detonate

sympathetically impacting on the quality of

fragmentation.

“Most common are holes being drilled too

far apart resulting in coarser fragmentation

and high floors. This is particularly the case in

harder rock.”

Other problems are collaring caused by the

drill operator drilling in the wrong place due to

a number of reasons. Angle errors result in off

line deflections, most common in smaller

diameter holes, or the boom of the drill rig

being set at an angle different to the desired

hole.

Hole depth is another problem; short holes

result in high floors or capping, or holes that

are too deep cause damage to rock below and

result in drilling problems in the following

bench.

Hole positioning where holes are often

drilled into badly damaged rock from previous

sub-drill damage. “Very often, sub-drill

damage is so high that a re-drill is impossible

and the area ends up without a hole. Missing

holes have a very deleterious effect on floors

and fragmentation in a blast,” says Rorke.

Hole diameters influence the dispersal of

energy and result in either “explosive energy

starvation” or “excessive energy” that lead to

FRAGMENTATION


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FRAGMENTATION

rock damage and a risk of under-filling. “Small

variations in diameter have a very significant

impact on energy in a blast, especially in larger

diameter holes. Again there are many reasons

for these errors occurring,” he says.

“Drilling needs to be given high priority in

the production cycle and should not be treated

as a basic operation where operator training is

minimal and inexperienced foremen are used.

Explosives and blast timing cannot correct poor

drilling. Poor drilling will result in bad blast

results, he concludes.

Of course stemming blastholes can help.

Varistem says its system “reduces processing

costs, with the Varistem achieving up to a

25% increase in fragmentation. Studies also

show the Varistem can reduce blast patterns

by 10% or greater and achieve the same

fragmentation for major savings in drilling and

explosive costs.” (See IM March 2011)

Significant work done in the US was

reported at this year’s SME annual meeting in

Denver. In Improved fragmentation through

data integration, R. Owen reported on work at

the Morenci mine, saying, “An overwhelming

amount of data can be collected around the

blasting process. This information can include

blasting product, pattern design, blast results,

and routing. It is only when these data sources

are combined in a concise and accurate form

that they are of real use in determining the

safety and economic implications of each

parameter. Two key technological aspects of

blasting are drill fleet management (DFM) and

size fraction analysis (SFA). As these

technologies are integrated as near-real-time

measurement and QA/QC tools, the resolution

and realisation of blasting parameters is

significantly increased. Morenci has integrated

these technologies along with other existing

database structures to create a responsive and

sustainable tool for reconciliation, forecasting

and parameter matching. This ability allows

Morenci to customise blast patterns to meet

the criteria most critical to each shot, whether

the impact is influenced by routing and

recovery, equipment maintenance or safety

concerns.”

The current DFM system is running on 12

production drills. It receives pattern layout and

is capable of semi-autonomous drilling over

the entire district. The fleet is capable of

drilling in highly altered intrusive units and

hard granites through the range of

sedimentary and volcanic units at Morenci. The

system brings a level of accuracy not

achievable with earlier paint-marked patterns.

Depth control is also increased along with

more consistent wear and maintenance

patterns due to semi-autonomous drilling.

Morenci invested in imaging and drill fleet

management technologies, and used Mintec’s

MineSight to manage and analyse the data. In

three years, it saved more than $120 million

on horizontal accuracy. In the SME paper

Managing the drill and blast process, Mintec’s

L. W. Berry, commented that “typical planning,

reporting, and information exchange usually

involves large quantities of data collated in a

discordant set of spreadsheets, databases, and

reports. Collecting, analysing, modelling, and

distributing all data necessary for efficient drill

and blast operations is time consuming and

cumbersome. MineSight Axis Drill and Blast

provides an extensible core of functions,

seamlessly integrated with other MineSight

software tools, to make sense of this

information.”

“The primary advantage of the DFM is to

increase the realisation of blast pattern

design,” Owen continued. “This reduction in

variation from design to actual allows for more

accurate blast modelling. Manually surveyed

patterns characteristically have large enough

error to potentially invalidate correlations of

blast parameters and blast results. As a primary

element of successful blasting, energy

distribution is achievable when assisted by the

DFM.”

The SFA captures images of active dig faces

for all large production shovels. Owen explains

that “the images are manually cleaned of

unusable images and automatically processed.

This data is stored on a database where each

image is collated to a GPS coordinate of the

location where the image was taken. This

combination of information has increased the

ability to systematically judge fragmentation

results.

“The SFA reporting allows for very detailed

feedback on blasting performance while the

DFM allows for blastholes to be placed within

a half-diameter error of design. The other

parameters necessary for blast design and

reconciliation are also captured to create a full

process map. This data includes bulk explosives

information, detonation details and accessory

utilisation. These items are combined with the

The two types of angle errors that canoccur. Well-trained drill operators can

minimise this type of error althoughhole deflection errors are more difficult

to eliminate

Hole positioning relativeto damage contour line

caused by sub-drill fromprevious hole positions in

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blasthole location from the DFM to give precise

kilocalorie calculations and high explosive

tracking.

“The bulk explosive data stored in the

system include total weight of product loaded

into the blasthole, the type of product used,

the depth of the blasthole, amount of

stemming loaded and any measured water

levels in the blasthole. This information is

stored for each blasthole. By linking this data

to the exact coordinates of each blasthole, it is

possible to model the kilocalories applied to

the shot.”

He concludes that this integration “improves

the ability of blasting to respond to

geotechnical, economical and safety issues

with high precision. Blast testing conducted

under this blasting model has the advantage of

quick data analysis with more detailed results.

This ability to see impact on multiple variables

with less time allows for greater integration of

these test results into the production

environment. By fully integrating these blasting

aspects, blasting performance will better suit

both upstream and downstream processes.

“The ability of each aspect of the mining

process to adapt in a timely manner to

evolving needs is critical. This integrated

blasting model allows blasting costs and results

to vary as the mine progresses. As mines are

expanded, steepened and new mines are

designed, geotechnical parameters become

more important. Integrated data allows the

blast model to build correlations between

geotechnical parameters and their impacts on

both blast performance from a processing

standpoint and highwall stability standpoint.

This information then allows the blast design

to be best optimised for the current economic

situation. The ability to move blasting results to

adapt to economic situations means real cost

savings with minimum lag time.

“Near-real-time reporting and complete data

analysis ability are critical when evaluating the

safety concerns associated with blasting. The

energy expended with each blast is a key

concern with every pattern. Inability to control

energy adversely affects blast results and may

put personnel and equipment in harm’s way.

By reviewing the design and actual blast

parameters of each blasthole, it becomes

possible to analyse well-shot blastholes and

less than optimal shot blastholes to evaluate

what parameters can be optimized. Blast video

along with recognized success or failure is less

effective without good data collection to

analyse.

“Understanding the interaction of each

variable involved in the outcome of a blast is a

daunting prospect. The amount of data that

can be collected on each blasthole, for each

blast pattern, on each bench, for each

pushback in every corner of a mining district is

immense. The need for a robust and

manageable database is crucial. The

information must be integrated quickly and

with confidence. The information then should

be accessed in a clear and concise manner. The

integrated blast model facilitates this with

ability to grow as technology is advanced and

becomes available.

“The upstream and downstream process

improvements are still being realised. Each

mine site may have different requirements, and

the requirements may change as equipment is

changed. Blasting can accommodate crusher

throughput limitations, contributing to the

mass reduction from the initial blast. This can

easily be evaluated from a cost standpoint

FRAGMENTATION


Using Carlson’s Drill Grade System drill operators can

navigate and position from within the cab without

the need for a surveyor. Blast design can be done

from the office or in the field with easy-to-use

interface. Remote wireless monitoring provides near

real-time system feedback and it enables all-weather

operation, day or night

Accurate production drilling is essential to good

fragmentation. Atlas Copco’s extensive range of

Simba rigs offer hydraulic tophammer rock drills, and

the Rig Control System (RCS) to provide efficient,

productive and high-precision longhole drilling

Independent Blasting Studies ConfirmGreater Pattern Spreads Possible

SURALCO, LLC: Bauxite Mine in Suriname, South America Pattern spread increased 25% for similar fragmentation Fly Rock & Noise Control potentially opens mine reserves

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HOLCIM: Limestone Quarry in Ste. Genevieve, Missouri 14 x 18 spread increased to 14 x 19

reduced fragmentation size 11.6% 14 x 20 spread reduced drilling 10% with equal fragmentation

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FRAGMENTATION


allowing for the money to make the largest

impact: more crusher capacity or more money

spent in the initial blast. In leaching operations

the reduction of ROM material may realize

immediate and significant profit increases.

From total recovery to recovery times, the size

of material in a ROM leach pad is very

influential. In milling processes the ability to

impart micro-fractures and small initial input

size can greatly reduce the energy and time

requirements to realize particle size. Waste

material may not require small size fractions,

but fragments that are too large may cause

unnecessary damage to equipment or loading

hardships for personnel. By optimising these

and many more downstream processes it may

be possible to reduce or streamline the types

and amount of blasting products purchased.

Improved maintenance may reduce work hours

required to keep equipment running and

increase production.

“Blasting is the pillar of open pit mining and

is directly influenced by many factors, both in

design and terrain, and can influence much of

the ultimate mine design and cost realization.

The technology exists to reduce analysis time

and build sufficient models to accurately

predict rock fragmentation. The integration of

data sources and the application of this data

into the process is the key to success. The

future of blasting is here and will only continue

to develop as new technologies are developed.”

K. M. Kim, of ASARCO (Grupo Mexico) and

J. Kemeny, The University of Arizona, reported

on Site specific blasting model for mine-to-mill

optimisation. This blasting model has been

developed for the Asarco Mission mine. “The

main inputs to the model are the in-situ block

size (F80), the post-blast fragmentation (P80)

and the intact tensile strength (To). The output

from the model is the specific blast energy

(ESE). Modern techniques are being used to

obtain the input parameters for the site-

specific blast fragmentation model. In

particular, image processing software is used to

obtain both the in-situ

block size and the post-

blast fragmentation, and

the Schmidt hammer is

used to obtain the tensile

strength at numerous

locations throughout the

rock mass.

An initial model was

developed using five test

shots in one area of the

mine that contains Argillite and is relatively

homogeneous. This also included calibrating

Schmidt hammer readings against actual

Brazilian tensile measurements. The model for

Argillite will be updated as more tests are

conducted, and the model will be extended to

the other four primary rock types at the

Mission mine.

“In modern blast fragmentation modelling,

the parameters must be easily attained at

numerous locations throughout the rock mass.”

“The purpose of the site-specific blasting

model is to optimise blasting for total cost or

total energy, including downstream

comminution and mineral extraction. In

general, increased explosive energy will result

in finer fragmentation and increased rock

damage (microcracking). Thus, even though

the drilling and blasting costs may increase,

the total mine-through-mill costs will decrease.

There is a limit, however, and there is a point

at which further increases in drilling and

blasting costs will increase rather than

decrease the total cost. The site-specific

blasting model developed in this paper can be

used to find that optimum point.

“A preliminary study was conducted to look

at total cost savings vs. blast energy for a hard

and soft rock, and indicated optimum blast

energies of 225 and 175 Kcal/t for hard rock

and soft rock, respectively.”

Better fragmentation through team work at

Dos Pobres mine, Safford, AZ, by D. Brandt et

al, considered this a copper oxide heap-leach

mine where, as mine depth increased, “the

proper fragmentation size became harder to

achieve due to less weathering and different

rock types. Because copper recovery increases

as crusher product size decreases, achieving

the appropriate product size at the crusher is

the operating priority.

“The Engineering Department started a

project to improve fragmentation through

blasting and thus increase throughput in the

crushing system. It soon became clear that

input from other departments was going to be

required to make this a safe and economical

project. Therefore the Crush and Convey and

Ore Control departments worked together to

evaluate all available data on blast patterns

and explosive loads and tracked performance

and results. Using image analysis, Drill Energy

Index and databases, we have been able to

improve fragmentation size and verify the

results while controlling costs.”

They concluded that consistent blasting

practices have resulted in better control and

consistency in fragmentation. “This is evident

from the crusher performance, crusher screen

data and from the camera image analysis data.

The costs associated with the improvements

have not increased overall costs. Costs for

increased drilling have been offset by using less

explosive product or products of lesser

strength. Costs have also been reduced by the

increase in hauling efficiency, crusher

throughput and less crusher wear.”

Effective blast?When evaluating the effectiveness of a blast, it

is important to obtain the rock fragmentation

results as close to the blast as possible to prevent

inaccuracies due to handling of the material.

Motion Metrics International‘s FragMetrics™

solution provides rock fragmentation analysis

from the shovel bucket, which is typically where

the first stage of material handling occurs.

The images used for fragmentation analysis

are automatically captured using a rugged

camera installed on the top of the boom of an

electric rope shovel, or on the stick of hydraulic

face shovels. Specially designed brackets

position the camera to have a clear view of the

bucket during operation and help to isolate

against shock and vibration.

The embedded computer, installed in the

operator’s cab, tracks the bucket as the shovel

is in operation, and automatically logs images

of the contents. Advanced real-time image

processing algorithms are used to filter the images

based on image quality and bucket contents to

select only the images suitable for fragmentation

analysis. A collection of images are sampled

through the face as the shovel excavates to provide

a representative fragmentation measurement.

The logged images can then be accessed over

the mesh network or directly via the on-board

industrial-grade CompactFlash card.

Motion Metrics offers two options to

perform the fragmentation analysis; a stand-

alone tablet computer, FM-Tablet, or a service

contract-based agreement, FM-Service. The

FM-Tablet provides the tools to process and

review the analysed fragmentation results, and

generate automated reports, in a compact

FM-Tablet computer for

Motion Metrics fragmentation

analysis and reporting

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tablet computer. This option is favoured for

performing routine assessment and

maintenance of blasting performance. The FM-

Service employs Motion Metrics specialists to

perform the processing and reviewing of

fragmentation results to provide fragmentation

reports. This option has been popular for

mines that would like to perform a third-party

assessment of a blasting consultant, or carry

out a study on the effects of blast

fragmentation on a particular mine process.

Blast fragmentation has far-reaching effects

on the performance of equipment and

processes throughout the mine. Fragmentation

affects the looseness or diggability of the

bench face, which influences excavation

efficiency, while the throughput and energy

costs of primary crushers are directly related to

the input feed rock sizes.

To provide a more comprehensive collection

of information, the fragmentation data can be

correlated with data from other Motion

Metrics shovel solutions. For example,

correlating the fragmentation data with the

shovel tooth-wear data from WearMetrics™

and shovel productivity information from

LoadMetrics™, allows the mine to monitor the

relation between blasting and shovel operation

efficiencies to optimise future blast practices.

Lowering dilutionA Queensland innovation in electronic blast

detection received Australian recognition for

excellence in the application of Information

and Communication Technology (ICT) at the

iAwards. Judges sited the BMM system’s use of

innovative technology, ease of application and

its potential to significantly reduce ore loss and

dilution at any open-pit mine that uses

selective excavation.

With mines routinely recording a 5 to 20%

loss of valuable mineral in every blast, BMMs

already save mining companies tens of millions

of dollars per mine every year.

The inventors of the BMMs formed a

company, Blast Movement Technologies (BMT),

to commercialise the combined hardware and

software grade control solution in 2005 after

conducting initial research at the University of

Queensland. Since then, the prototype has

been transformed into a robust commercial

product now used in mines across Australia

and in more than 10 countries around the world.

The BMM system works by placing hardened

transponders into drill holes in an orebody

prior to blasting. After the blast a portable

detector is used to locate the new position of

the markers, thereby determining the

movement vector of the blasted ore. Ore has

often moved more than 10 m.

Once downloaded to BMT’s proprietary

software the information is quickly and easily

transformed into accurate, 3D movement

vectors, redefining ore boundaries, and enabling

the most precise identification of ore and

waste available to the industry. BMT claims.

BMT Director and Principal Consultant

Darren Thornton said the award was a highly

valued recognition of the quality of this

advanced system. “The team at Blast

Movement Technologies has worked tirelessly

to lead the mining industry into an age where

the precise measurement of muck pile

movement can now have a significant impact

on improving mine reconciliation.

“When we begin working with a mine we

perform a comprehensive evaluation of

existing blasting practices while training staff

on just how easy it is to use the Blast

Movement Monitors. Most mining engineers

and senior managers accept ore loss and

dilution as a cost of doing business, however

they are always surprised by just how much

money they are losing by unintentionally

dumping high grade ore as waste, and

shipping useless waste to the plant for

expensive processing,” Thornton said.

“All of the mines that we work with have

recorded significantly decreased loss and

dilution, which translates directly to increased

profits. Improved reconciliation of planned

versus actual ore grades enables more control

of the mining process.

“Once the site team is actively using the

system as part of its blasting procedures we

provide ongoing support and maintenance as

required,” Thornton said.

The system is currently being used by

leading Australian and international mining

companies including Barrick, BHP Billiton, Mt

Gibson Iron, Newcrest, Newmont, AngloGold

Ashanti, Goldcorp and Rio Tinto. IM

References1. Katsabanis, P. D.. Kim, S Tawadrous, A. & Sigler, J.

Effect Of Powder Factor And Timing On The Impact

Breakage Of Rocks, 34th Annual conference on

Explosives & Blasting Technique, New Orleans,

International Society of Explosives Engineers

Proceedings, 2008

2. Preece, D.S. and Lownds, C.M., 3D Computer

Simulation of Bench Blasting With Precise Delay

Timing, 34th Annual conference on Explosives &

Blasting Technique, New Orleans, LA, International

Society of Explosives Engineers Proceedings, 2008

3. Rholl, S and Stagg, M, 1987, Influence of Blast

Delay Time on Rock Fragmentation: One-Tenth-Scale

Tests, US Bureau of Mines Circular #9135j

4. Lee, R. A., Rodgers J. A., &. Whitaker, K. C.

Explosives Malfunction in Decked Blasts, 26th Annual

Conference on Explosives & Blasting Technique, 2000,

International Society of Explosives Engineers

Proceedings

FRAGMENTATION


The BMM system enables production controls that were

not possible previously, leading to reduced ore loss and

dilution and improved mine reconciliation. It has also shed

new light on understanding blast dynamics, which in turn

leads to better blast designs. Directional

transmitters (BMMs) are activated,

programmed and installed in

dedicated holes prior to blasting.

After the blast, an operator

walks across the muckpile with

a portable detector to locate

each BMM and record the

signal strength

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The best flowsheet

Contributors considerregrind mills, physicalseparation, new processdevelopment for rareearths and vanadium,and much more

PROCESS DESIGN


Xstrata Technology’s Brenton Burford

notes “modern engineers pride

themselves on being able to design the

most efficient process flowsheet tailor-made

for the deposit. Modern methods of design

based on complex mineralogical data, state of

the art modelling and simulations programs,

backed by a substantive test work arsenal,

surely must be better than the generation

before us armed with their tables, slide rules

and rules of thumb?

He considers regrind mills to be an area that

“is rather neglected in process design” and

some of his colleagues have highlighted some

of the issues noticed in scale up of such mills1.

“On the whole, process design has certainly

come a long way making the most of modern

techniques and tools, providing very energy

efficient plants. However they can be further

improved, particularly in areas where our

understanding is still poor, such as the

regrinding section. Regrind mills play a vital

part in determining the concentrates’ grade

and recovery, no matter what the product. But

despite this importance, the overall

understanding of regrinding from a design and

operational standpoint is startlingly limited.

“A review of publicly available literature and

ongoing plant designs shows many regrind

circuits are less energy efficient than the initial

design. Sometimes the actual energy usage in

a plant is double the design, yet it doesn’t

make a ripple in the process design pond. This

would never be deemed appropriate if it

occurred for SAG mill design – because if the

mills don’t get the tonnes it is easy to

recognise. But for similar design flaws in the

regrind section no one seems to notice.

Whether it’s a case of “you don’t know what

you don’t measure”, or if it is measured, is it

compared to the design data, and then why

the difference? At the end of the day it is very

rare that the design engineer gets back to the

original circuit to close the loop and improve

the next design, hence we are stuck in the rut

of mediocrity.

“So what is lacking in our regrind design

knowledge base? To begin with there is no

industry standard for regrind test work. In

many cases we still rely on the classic Bond

test, yet it is well known that for finer sizes less

than 70µm the more inaccurate it is. A better

approach is to use the Levin test, which is

based on the Bond test, but using finer screen

sizes when the mill is discharged at certain

intervals, and is designed to top up the

undersize fraction which is taken from the mill,

with fresh feed of the top size, at each

screening interval. However at 2 litres of feed

required for each screen size, this takes up a

lot of sample, more than possible for a small

pilot run, but it gives accurate grindability

data.”

“Not all distribution curves are equal. Some

are flatter, others sharper. Just because the P80

size is the same for several grinding methods

doesn’t mean every other point of the

distribution curve is the same. If one

technology was tested, and then another used

in the plant, then a flatter distribution could

have serious implications for leaching, or slurry

handling (i.e. settling in pipelines). Compare

several grinding technologies in the lab first,

check the coarser end, i.e. P98, as well as the

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PROCESS DESIGN


finer end, and then install the one that best

suits the design.

“Even more erroneous is to test with one

ball size, and then use another in the plant.

Neither is it realistic to test a ball size in the lab

scale mill, get great energy efficiency figures,

only to realise that there is no way that ball

size can be used in a industrial mill – certain

mills can only operate with a certain range of

media.

“The lack of a standard test for grinding fine

means the equipment suppliers are responsible

for doing the test work for the client. While

they do their best to achieve accuracy and

make recommendations, it is in the hands of

the customer to question them. So the best

advice is keep asking questions.

“One of the key points that need to be

discussed is how much sample should be

tested. All too often too little material is used

in test work, resulting in an open area in the

mill larger than the actual volume of material

tested and a great bias in what is discharged.

A general rule is the sample size should be

three times the value of the mill volume, which

allows the mill to reach steady state. If

insufficient sample is tested, there is a good

chance that coarse material is left inside the

mill, and significantly underestimates the

power that is really required.”

Another question to be asked is just how

accurate is the scale up test work – does the

manufacturer have any data that compares the

design test work with real world results. Are

the results 100% scale up and if not, why?

How is power measured, is it direct from the

drive shaft, or is through an indirect method?

Also investigate the mill in the lab, check the

variables such as the speed, internals, media

loading, media size, % solids etc. – are they

the same as the full scale version? And what

about shell effects? A large test mill compared

to the particle and media sizing should have

minimal effect, but it needs to be checked.

While operators have a good handle on the

power required per tonne in the primary

grinding circuit, the regrind circuit is harder to

quantify. “The only point to remember is that

the finer the grind, the more power needed on

an exponential basis. And if it is regrinding a

concentrate that is based in pyrite, or chromitic

minerals, more power is needed again, as you

are not grinding the same material as in the

primary feed. So try to find examples of

regrind circuits similar to the one being

designed for, check for published data – some

does exist. And if the mill supplier suggest

something that is too low, and doesn’t sound

right, it probably isn’t right.

“The industry is slowly realising that there

are significant gains to be made in accurately

designing the regrind sections of process

plants. The first step however is to gain an

understanding of what the regrind mills are

doing in plants and how they compare to their

initial design. Through these efforts and also

through programs such as the proposed

JKMRC fine grinding review, it is hoped to

provide the industry with a better

understanding of what it takes to properly

design a regrind circuit.”

Gravity recoveryKnelson reports that throughout 2011 it

continues to advance the patented centrifugal

cone configuration platform known as

CONE*Logic™. It says it “is a key differentiator

that sets the Knelson Concentrator apart as

the most metallurgically efficient and widely

proven technology available in the field of

centrifugal concentration. Recent

advancements in application specific cone

technology focus on ways to simplify

maintenance and increase cone life.”

Over Knelson’s 34 year history, thousands of

Knelson Concentrators have been supplied to

over 70 countries around the globe. This large

installed base has provided extensive

technological data that has helped drive both

internal R&D initiatives and external R&D

programs at leading universities. Among the

many considerable outcomes of this activity is

the successful development of Knelson's

application based approach to gravity recovery

IsaMill scale up at Anglo Platinum Western Limb

tailings retreatment

3D Graphic: Modular Cone (left), and available in any

G series the XR1 Heavy Duty Cone (right) is outlasting

standard urethane cones by 30-50%, Knelson reports

Knelson-Deswik Vertical Grinding Mills (KD-VGM) are...

making advancements across the globe! Continuing the trend of advancement, the KD-VGM has progressed with recent installationsin South Africa and Zimbabwe, and on-going Research and Development in North America.

The KD-VGM is designed with a small footprint and can reduce particle size to <10 micron.

Learn more at www.KnelsonMillingSolutions.com.

Site Photo: KD-VGM500 Installation, South Africa, 2011.

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which allows Knelson to custom configure

each concentrating cone to optimise

metallurgical efficiency.

In addition to customising the ring profile,

fluidisation requirements and the delivery

method, Knelson has also made significant

advances in the cone structure (construction) -

the most notable new option being the

Modular Cone.

The all-new modular cone enables plant

maintenance personnel to quickly and easily

remove and replace the cone liner as part of a

routine preventative maintenance program

thereby ensuring optimum metallurgical

performance and high unit availability.

The Modular Cone features a urethane cone

liner with imbedded reinforcing steel that has

allowed Knelson to advance drill pattern

technology and provide cones that respond

efficiently with lower quality water conditions.

Other features include:

■ A permanent lower section

■ Replaceable upper cone - no shell to exchange

■ Simple one bolt deflector pad

■ Scale resistant surface,

■ Available in a variety of ring profiles and drill

patterns, and able to have large drill hole

patterns for poor water conditions

■ Fit into any XD or QS40” and 48”

concentrator.

Other construction options include the rigid

shell traditional polyurethane lined

concentrating cone supported by the cone

exchange program and the XR1 Heavy Duty

Cone designed for very aggressive slurries. The

XR1 uses highly wear resistant rubber tipped

polyurethane rings and is supported by the

cone exchange program.

Knelson can determine the best cone for the

duty – from coarse gold in grinding circuits to

high g-force fine gold recovery in regrind

circuits. The key considerations used in

Knelson's CONE*Logic selection are:

■ GRG Test data

■ Gold size distribution

■ Target feed stream (primary grinding, flush

flotation, flotation regrind etc.)

■ Water balance

■ Maximum capture area

■ Ore hardness and abrasiveness

■ Target concentrate grade and mass

Physical separationJens-Michael Bergmann of CommodasUltrasort

recently presented a paper2 on different

aspects of sensor based sorting of minerals

and ores by optical inspection and other, more

sophisticated inspection technologies, such as

X-Ray transmission (XRT), Near Infrared (NIR),

Electromagnetic (EM) or Radiometric (RM). Use

of such systems is growing.

Optical sensing is based on colour line scan

CCD-cameras. Pictures are analysed and the

vast number of colours is reduced to a few

clearly identifiable colour classes. Special

features, filters, and parameter settings allow

individual programming for each sorting task.

Several high speed processors process the

huge amount of data in a few milliseconds.

The system is able to evaluate, localise and

eject up to 10,000 objects per second. This

allows successful application of this technology

even in fine material of +2 mm.

One of the limitations of optical sorting is

that the cameras are scanning the material

surface only, so a clean surface is needed to

identify the particles themselves and not its

coating or dust coverage.

Colour detection is simple – as long as the

objects are illuminated correctly and

permanently, without changes to the light

intensity, its colour temperature and with no

shadows. So it has advanced to today’s state-

of-the art: liquid-cooled LED-lamps with a

defined light colour, high intensity, rigid and

durable, providing long term stability without

fading and a lifetime of more than 50,000

hours. To avoid shadows, optical sorters have

up to six lamps installed. To prevent

deterioration of the light quality from dirt,

PROCESS DESIGN


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automatic cleaning devices are provided.

The electromagnetic sensor system is based

on the phenomenon that electromagnetic

fields induce an eddy-current in the conductive

material and this current draws energy from

the EM-field. This induced current in the coils

can be measured and a threshold is defined for

the decision ‘metal’ or ‘non-metal’. Fine tuning

of the system and the use of different

frequencies even allows the detection of

different metal grades or types.

A more exact measurement of the induced

current allows the new SUPPIXX® Image

processing tool to generate eight-time higher

resolution for the EM-picture. This result of this

process is much greater accuracy of the

actuation in the individual valves.

An electromagnetic sensor cannot ‘see’ the

non-conducting items. Therefore it is

impossible, for instance, to remove non-

metallics from a feed that mostly contains

metal containing feed stream. An example

could be the removal of waste or low grade

material from a predominantly high-grade

feed. A combination of optical and EM sensors

covers this and allows the correlation of

optically identified objects and their EM-signal

to identify poor quality material and remove it

from the feed.

Near Infrared (NIR) is the light spectrum

close to the visible red light and covers all

wavelengths between 780 and 3,000 nm (DIN

5031). This technology is used to identify

different materials in another spectrum of

wavelengths. NIR spectroscopy is based on

molecular overtone and combination

vibrations. Such transitions are forbidden by

the selection rules of quantum mechanics. As a

result, the molar absorptivity in the near IR

region is typically quite small. One advantage is

that NIR can typically penetrate much farther

into a sample than mid infrared radiation.

Near-infrared spectroscopy is, therefore, not a


PROCESS DESIGN

The basic scheme of a sorting unit – the ‘chute’ sorter

setup. Material (1) is fed by a vibratory feeder and is

accelerating while sliding down a chute. Scanning

occurs during the free-fall of the particles. After

scanning and evaluation of the data, the compressed

air unit blows the identified objects to one of the

bays of the separation chamber. The air unit consists

of up to 512 valves connected to in-line nozzles,

which are actuated individually to blow only the

clearly identified particles. To reduce the number of

pieces hit by mistake the nozzles are as close to the

material stream as possible, which allows fine

adjustment of the necessary air pressure and with it

reduced operating costs

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particularly sensitive technique, but it can be

very useful in probing bulk material with little

or no sample preparation.

When comparing the curves of two

materials the system samples the materials and

develops scatter clouds, which are derived

from the measured intensities, and where

filters and algorithms have been applied. The

operator selects the channels which show the

best clear difference between these clouds to

create a classifier. Several classifiers can be

applied together for the sorting, so literally the

sorting parameters are vectors inside an n-

dimensional space.

X-ray transmission technology is based on X-

rays which pass through a particle and the

energy of the radiation, which has not been

absorbed, is measured by scintillators. The

influence of the particle’s thickness is

eliminated by applying a dual energy detection

system, where different scintillators measure

different X-ray energy levels. Images of the

two channels are processed and a classified

image is created, indicating the average atomic

number of the particles. This can be used for

Turning to practical examples, the first is the

use of EM pre-concentration of the ore. Nickel

sulphides are disseminated in run-of-mine

material in different concentration grades from

highest grade massive sulphides through rocks

carrying different ore grades with disseminated

sulphides to a pure, nickel-free waste rock. The

challenge is a clear identification of the high-

grade ore and by combination with optical

particle detection the safe physical removal of

the unwanted pieces carrying less than 0.5% Ni.

The results showed the Ni content of the

product is almost double of the feed and

about 40% of the feed material is bypassing

the expensive milling stage. In addition, the

sorter removes the rocks containing most of

the MgO. Since the MgO negatively influences

recovery during subsequent flotation steps, the

efficiency of flotation was increased so much,

that the little extra loss of nickel during the

sorting process is more than balanced.

Additionally most of the lost nickel was not

recoverable during flotation anyway, since it is

attached to the MgO containing particles.

In developing countries handpicking is the

current solution for talc extraction, but in

industrialised countries colour sorting has been

state of the art for many years. The main aim

is to increasingly avoid feeding large amounts

of unwanted material to expensive milling and

flotation processes. Since colour sorting has

reached its limits with the challenge of how to

separate white from white, NIR technology is

one solution, since the sensor’s differentiation

of carbonates from talc is almost 100%.

Sampling for design dataThe recent acquisition of Essa Australia, a

leading international provider of automated

mineral sampling and sample preparation

systems, has given FLSmidth another important

capability in process design. It can now provide

a full sampling solution to the minerals

sector— from sampling to sample preparation

and analysis, including particle sizing,

laboratory applications and metallurgical

testing equipment. These solutions can be an

integral part of other FLSmidth deliveries such

as automated sampling scheduling systems or

automated laboratories. FLSmidth CEO Jørgen

Huno Rasmussen says Essa’s capabilities fit

perfectly into FLSmidth’s existing product

portfolio.

Peter Sandager, GM Global Business

Development, Automation, FLSmidth, adds:

“Acquiring Essa was a natural development for

FLSmidth, as we had begun to make a series

of acquisitions in the mineral sector in the

2000’s. It was logical for the automation

division to look at bringing the value-add that

we bring to cement, in process and quality

control, to the mineral industry.

“Sample size was a challenge for us and so

we had to decide whether to begin the

manufacture of a whole new range of

machinery, or whether to team up with an

established player in this sector. We knew that

PROCESS DESIGN


Available sensor systems

Essa and the importance of sampling

http://www.outotec.com

PROCESS DESIGN


Essa had a good name and good products, so

it was considered a perfect match. The

acquisition gives us the product range and the

immediate market access.

“We see huge potential. Having the

sampling expertise is crucial because an

optimisation system relies on the quality of

information that is fed in — and we now have

both a number of well proven optimisation

systems for process control as well as for stock

yard optimisation together with all the

equipment that will ensure that the basis data

is correct

“It should be mentioned that all our

solutions are designed following the globally

accepted rules expressed as the Theory of

Sampling, thereby ensuring that the sampled

material is representative. When combining

individual sampling solutions with automated

sample preparation and analysis equipment,

FLSmidth can ensure that the relevant mineral

specific ISO standards are met.

“Initially everyone looks to automation as a

labour saver, but really its greatest benefit can

be in operator safety and in the repeatability of

your operations, which can lead to

optimisation of throughput, energy savings

and operational and maintenance costs” he

concludes.

In turn, FLSmidth will be able to provide

Essa with the technological and project

management expertise, underpinned by

financial security, to expand further into the

project automation market for mineral

sampling and analysis systems.

Darryl Stevens, CEO Essa Australia, says the

key requirement for any apparatus associated

with high volume hard minerals is ensuring

that the equipment does not break and

requires minimum maintenance.

“Our sampling knowledge has become as

important as our sample preparation product,”

he says. “Sample preparation equipment is a

catalogue product and the sampling business is

a design and implementation project. The

fusion of the two is in automation. Mining

companies are increasingly operating in remote

locations, where labour is either expensive or

unskilled. Mining companies are looking to

automation to reduce that labour reliance and

increase the quality of their operations.”

“We now have a much stronger knowledge

base to support our mining customers,

particularly those in the iron ore, manganese

and coal industries,” Ernest Bophela,

Technology Specialist – Automation at

FLSmidth in South Africa, says. “With

immediate access to Essa’s offering here in

South Africa, we can provide a total, dedicated

sampling solution that embraces local

equipment supply, technical support and

servicing.”

Innovative processesGeoProMining (GPM) is building a new gold

extraction line at the Ararat gold plant in

Armenia. The Albion gold ore processing

technology is part of a major capital

expenditure program by GPM to upgrade its

Armenian assets, with the aim of improving

efficiency while maintaining high

environmental protection standards. The

Albion process is expected to enable the

company to significantly increase gold

extraction from sulphide-bearing ore from the

Zod mine and increase its gold production to

an estimated 150,000 oz/y. The modernisation

program adheres to strict international

environmental standards. This has been

confirmed by leading experts in environmental

impact assessment including Fraser Alexander

(South Africa), Epoch (South Africa) and Digby

Wells Environment (South Africa). GPM has

also hired Snowden (Australia) to develop an

efficient mining plan for the Zod mine.

The planned investments in the Ararat plant

are expected to enable GPM Gold to process

higher volumes of ore from the Zod mine

without the need to construct any additional

processing facilities at the mine itself. Based

on thorough testing of ore from the Zod mine

GPM decided to implement a solution that will

significantly increase the gold extraction

coefficient. The company is also investing into

minimising its impact on the environment. The

Albion technology, which is capable of

efficiently extracting gold from sulphide-

bearing ore, was successfully implemented in

the Dominican Republic by Envirogold (IM,

May 2011, p72), and the new facility in

Armenia will be the second to adopt this

technology.

Bateman is a company with extensive

experience in process development. Earlier this

year the first copper cathode was produced in

test work for the Udokan copper project in

Russia. It was produced in laboratory test work

in Perth, by Bateman Engineering in Australia

and confirmed in principle, the Bateman

process flowsheet developed for the project,

owned by Baikal Mining (a subsidiary of the

Metalloinvest Group), following Bateman’s

successful completion of the prefeasibility

study. The work has also provided all the

required information for a definitive bankable

feasibility study.

The Udokan copper field, located in the

Kalarski district of the Chita region, is Russia’s

largest known untapped copper resource. Here

Bateman has the role of general designer for

this next stage of the work. The contract

includes co-ordinating a number of Russian

and international subcontractors, on a series of

projects leading up to commencement of a

full-scale feasibility study for a 36 Mt/y copper

processing complex, inclusive of its support

infrastructure.

The sub-projects include a trade-off study of

different types of main technology to be used

in processing the complex copper ore types at

Udokan, and piloting the Udokan ore through

a proposed technology process. Other sub-

projects include determination of a robust

process and reliable flowsheet to take into

account the variability and nuances of the ore

types; preparation of a geo-metallurgical

model for setting a baseline of production, and

operation for the deposit; and preparation of a

piloting facility close to site, according to the

selected processing flowsheet.

It is anticipated that Udokan will be in

production by 2016, producing 474,000 t/y of

copper cathode and also recovering gold and

silver doré. It is a large, complex project in a

remote, environmentally sensitive area. The

development will include road and airport

infrastructure, a rail spur with bulk unloading

The Albion Process, marketed globally by Core

Resources, incorporates ultrafine grinding to increase

the activity of sulphide concentrates to a point where

they can be oxidised readily in conventional open

tanks, without the need for high pressures, expensive

reagents or bacteria

http://www.sulzerpumps.com

and loading facilities, an accommodation

township, a coal fired power station and all

associated support services. Ground conditions

include permafrost, adding an additional level

of complexity.

The process plant will include crushing,

grinding, sulphide and oxide flotation, pressure

leaching of the sulphide concentrates and tank

leaching of oxide concentrates. The plant will

be fully integrated so that the sulphuric acid

produced from the sulphide ore pressure

leaching is consumed and neutralised in

leaching the oxide ores.

The leach solutions will be fed to an SX/EW

circuit, to produce LME grade A copper

cathode for sale on world markets. Gold and

silver will be recovered from copper ore

residues to produce a precious metal doré.

Delkor, owned by Bateman, has received

two major orders for Delkor BQR Flotation

Cells from mining companies in Turkey.

Yildizlar is one of the largest privately owned

mining companies in Turkey, with interests in

zinc, copper, molybdenum and silver mining. It

has ordered roughing, scavenging, cleaning

and recleaning flotation cells to process copper

and zinc for four of its plants, totalling 72

BQR200, 24 BQR100 and 24 BQR50 cells.

The order from Aksu, also a privately owned

Turkish mining company, totals 28 BQR50, nine

BQR30 and 12 BQR15 flotation cells to process

copper oxide. The order also comprises a

combination of roughing, scavenging, cleaning

and recleaning flotation cells.

CML Metals recently ordered three BQR400

flotation cells for its Iron Mountain project

west of Cedar City in southwest Utah, USA.

The Reverse Flotation Circuit process will form

part of a two-stage magnetic separator circuit.

The non-magnetics, silicates and apatite, will

be removed as floated product, and pumped

to a 20 m diameter Delkor tailings thickener.

The magnetics will be pumped to a 16 m

diameter Delkor concentrate thickener.

Essar Projects, located in India, has ordered

BQR700 Flotation Cells for its 4.1 Mt/y

integrated pellet plant at Nashwausk. This is

some 24 km west of Hibbing, Minnesota, USA.

The order includes a design and engineering

portion, with release to fabrication following

the engineering phase.

All three orders will be overseen by the

Flotation Centre of Excellence (CoEx) in South

Africa, which will contribute engineering and

design layout, whilst also providing technical

support for commissioning and site installation.

Tanks will be fabricated close to plant

destinations, with the cell mechanisms being

partially manufactured in South Africa, and

then shipped to site.

Ausenco has continued its strong growth in

South America, winning three new Innovate

and Create phase projects totalling $21

million. Ausenco’s Minerals & Metals business

line has been awarded a Create phase contract

to engineer and manage the delivery of Anglo

American’s $68 million ROM Mercedes heap

leach expansion at its Chilean Mantos Blancos

copper project. The project involves processing

low grade copper waste that is currently

stockpiled at the Mercedes dump. It is

expected to start operations in 2012.

Ausenco’s Process Infrastructure business

line has won an Innovate and Create phase

contract to provide detailed engineering,

procurement and construction support for the

Cerro Negro Norte iron ore project owned by

CAP Mineria in Chile. The project involves

concentrate, water recovery and tailings

pipelines. This new work builds on Ausenco’s

earlier completion of the basic engineering

phase for the project. That business line has

also won an Innovate phase contract to deliver

the detailed engineering and design review for

a 400 km iron ore concentrate pipeline for

Ferrous Resources do Brasil. The pipeline will

transport iron ore concentrate from the Viga

mine region in Minas Gerais state of Brazil to

the port at Presidente Kennedy, in Espírito

Santo state.

Hatch worked on Copper Mountain Mining

Corp’s revival of the Copper Mountain mine in

the southern interior of British Columbia,

Canada. The mine, originally built in 1927, has

been mothballed three times: during the Great

Depression; in 1957, due to low metal prices;

and again in 1996 as a result of low copper

prices. In 2006, Copper Mountain Mining

purchased the property and initiated a

program to bring the mine back to life by

developing a new 'super pit' that would be

bigger, wider and deeper to access additional

mineralization at depth. Copper Mountain also

decided to build a new concentrator, mine

truck shop, primary crusher and associated

conveyor systems.

When the restart project is complete, the

mine will process untapped reserves for an

annual production of 105 Mlb of copper. Since

its original construction, the mine has

produced 1,700 Mlb of copper through both

underground and open-pit mining.

In June Copper Mountain Mining achieved

the first filtered copper concentrate produced

and deposited in the mine concentrate shed.

Mill throughput then was at about 70% of

design capacity due to the limits in moving ore

through the SAG mill. The company reported:

“The grates supplied with the mill are limiting

the tonnage throughput due to undersizing of

the grate openings. New grates with much

larger openings are on order for mid August

delivery and installation to eliminate this

tonnage restriction. Presently the processing

plant is operating with one of the two ball

PROCESS DESIGN


Other flotation news comes from Maelgwyn Mineral

Services (MMS) which has sold an additional two 1.8

m Imhoflot G-Cells to Dorfner in Germany for its

kaolinite flotation circuit. For feldspar-rich kaolinite

mineral it is necessary to clean the concentrate in a

second stage. The two new cells will be installed in

series to treat the concentrate of three existing cells.

The total throughput is about 90m³/h. MMS installed

the three original 1.8 m G-Cells at Dorfner in 2005

treating 120m³/h. The G-Cells were ideal as in

addition to the prime motivation of recovery benefits

over conventional flotation, the cells high throughput

and small footprint facilitated the installation

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mills and minor use of the pebble crusher

which indicates the plant will easily treat the

designed 35,000 t/d target once the new

grates are installed. Mill feed grade is being

intentionally kept low with higher grade ore

being stockpiled for treatment after the tune

up phase is completed.”

Rare earthsAustralian rare earths company Arafura

Resources will process mineral concentrate

from the Nolans Bore mine at its Rare Earths

Complex on the northern outskirts of Whyalla,

about 400 km northwest of Adelaide, on the

western shores of Spencer Gulf. The Whyalla

Rare Earths Complex will comprise a series of

chemical plants and a processing plant where

chemicals such as hydrochloric acid and

sulphuric acid will leach out the rare earths,

phosphate and uranium, for ultimate recovery

and sale.

The mineral concentrate will be separated

into two main processing streams – one for

rare earths, and one for phosphate, through a

patented pre-leach process based on

hydrochloric acid. Further treatment of each

processing stream will recover rare earths,

phosphate, gypsum and uranium as:

■ Rare earth oxides - 20,000 t a year of REO

■ A solid phosphate product - 80,000 t/y

■ Gypsum - 500,000 t/y

■ Uranium oxide - 150 t/y of UO4. Uranium

and other impurities, such as iron, thorium

and aluminium, must be removed from the

rare earths stream in order to produce

saleable rare earth products.

Arafura has successfully completed the

hydrochloric acid regeneration program, a key

part of its wider, previously reported

technology program. The process involves

taking calcium chloride residues from the

phosphate circuit and re-acting them with

sulphuric acid to produce re-useable

hydrochloric acid, a key raw material in

Arafura’s pre-leach circuit, and calcium

sulphate (gypsum), a potential saleable product

PROCESS DESIGN


Hatch delivered engineering, procurement and

logistics management services for the new Copper

Mountain concentrator and its infrastructure. It also

prepared the project's feasibility study. "The success

of this project is gratifying. The very capable owner's

team articulated a clear vision. Equipment was

procured from all over the world—China, Brazil,

Paraguay, South Africa, Australia, Belgium, Mexico,

USA and Canada—and its delivery was accomplished

smoothly," said Bruce Rustad, Project Manager

Putzmeister Solid Pumps GmbH Tel +49 (71 27) 599-0 www.putzmeister-solid-pumps.com

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into various end applications. This reduces

Arafura’s dependence on external hydrochloric

acid sources. AMMTEC successfully operated

the demonstration plant on a continuous basis

at its facility in Perth, Western Australia, with

involvement from experts from McGill

University, Canada, and Arafura’s Technology

team.

The demonstration facility has successfully

achieved:

■ Production of 32% hydrochloric acid from a

simulated recycle stream similar to the

phosphate circuit waste liquors, with a

recycle efficiency of at least 97.5%

■ Production of crystalline gypsum with

filtration characteristics suitable for

processing via commercially available filters

■ Production of Dihydrate gypsum. Feedback

from one major gypsum user indicates that

this material has potential for future

commercial use

■ Provision of detailed design and operating

data for the Bankable Feasibility Study.

Arafura’s Managing Director and CEO, Dr

Steve Ward: “The successful completion of this

demonstration program highlights Arafura’s

commitment to the Nolans project and our

efforts to de-risk key technological aspects.

The logistical and economic benefits of

hydrochloric acid regeneration and gypsum

production will now be incorporated into the

BFS. Engineering design is now underway for

the overall flowsheet.”

The Nolans project comprises operations at

two sites within Australia: the Nolans Bore

mine in the Northern Territory; and the

Whyalla Rare Earths complex in South

Australia. The project is underpinned by a rare

earths deposit at Nolans Bore which has

sufficient resources to support mining and

chemical processing operations for at least 20

years. Arafura is planning to produce 20,000

t/y of rare earth oxides from Whyalla, will be

equivalent to about 10% of the world’s supply.

Rare Earth Industries (RND) has invested in

developing environmentally-sensitive methods

of solvent extraction to process rare earths.

Also, the company has Dr Shyama (Sam) P.

Sinha, on its Advisory Board to further its goal

of becoming a low-cost processor of rare

earths and rare metals. Sinha’s research uses

environmentally-friendly methods to process

and separate rare earth elements from one

another. This approach is different from the

global industry standard use of hydrochloric

acid or nitric acid. His formula is expected to

be substantially more biodegradable than the

industry standard rare earth reagents, as well

as more efficient than the industry standard

process.

Former US rare earth commodity specialist

for the US Geological Survey, and RND

Advisory Board member, James Hedrick, noted,

“Dr Sinha is probably one of the most

important solvent extraction experts today. His

research and technology breakthroughs in the

use of organic solvents could have a major

impact on the rare earths processing industry,

in terms of efficiency, costs and sustainability.”

RND president Alastair Neill, who has more

than 15 years of rare earth industry experience

both inside and outside of China suggests, “As

a company, we remain committed to more

cost-effective means to process materials.

Based on our understanding of Dr Sinha’s

process, the number of steps necessary for

separation should be reduced. This process

may allow us to simplify, and reduce

environmental impact of, processing and

separations of rare earths.”

Sinha has a Masters in Chemistry from

Bucknell University, Pa, and a PhD in Chemistry

from the University of Leeds, England. His PhD

thesis is a study of the solvent extraction of

rare earths. He has written two books on the

rare earths and some 90 original research

papers. He directed a NATO Advanced Studies

Institute on the

Systematics and the

Properties of the

Lanthanides.

RND has entered into

an exclusive due

diligence period, during

which time the

company will

investigate the

potential of applying

Sinha’s patentable

technology in a

commercial setting.

Upon successful due

diligence, RND has an

agreement to purchase

Sinha’s development,

and to make an

investment into the

commercialisation of a

unique process for the

environmentally-friendly

separations of rare

earths on an industrial

scale.

Great Western

Minerals Group

(GWMG) has

contracted DRA Mineral

Projects for the detailed

design of the

Steenkampskraal rare

earths processing plant in South Africa. DRA is

a multi-disciplinary, multi-national organisation

that specialises in the mining, infrastructure

and mineral processing industries. As one of

the largest project management enterprises in

Africa, the South African-founded group of

companies has constructed plants on five

continents. It is highly regarded for managing

projects with a “zero harm” focus, as

evidenced by its excellent safety record. All of

DRA’s world class quality standards, systems

and procedures are based on ISO standards,

GWMG says.

The processing plant, the first step in

converting the ore into rare earth chlorides,

will be located at the Steenkampskraal mine

site. The plant detailed design project is

expected to be completed by December 2011.

It will ‘crack’ the monazite ore through a

caustic leaching process, removing copper and

gold by flotation. Tri-sodium phosphate will

also be produced as a byproduct with the

potential for onward sales. The thorium

contained in the ore will be removed at the

processing stage, and be readied for licensed

storage, leaving a clean rare earth chloride

ready for the solvent extraction separation


PROCESS DESIGN

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phase as at the recently announced rare earth

materials facility.

GWMG President and Chief Executive

Officer Jim Engdahl said, “Awarding the

contract for the detailed design of the

processing plant at our Steenkampskraal

operation is yet another significant step

forward in the execution of our plan to

become a fully integrated Rare Earth producer

by early 2013. Contracting DRA, with its

strong track record of superior performance,

ensures we can achieve worldclass design and

construction standards within the processing

plant, combined with cutting edge

technology.”

GWMG is an integrated rare earths

processor. Its specialty alloys are used in the

battery, magnet and aerospace industries.

Produced at the company's wholly owned

subsidiaries Less Common Metals (LCM) in

Birkenhead, UK and Great Western

Technologies in Troy, Michigan, these alloys

contain aluminium,

nickel, cobalt and

REEs. GWMG also

holds 100% equity

ownership in Rare

Earth Extraction Co,

which owns a 74%

equity interest in

Steenkampskraal.

GWMG has also

negotiated a Heads of

Terms with Ganzhou

Qiandong Rare Earth

Group (GQD) of China

to build a rare earth

separation plant,

located in proximity to

the Steenkampskraal

operation. The

agreement between

the two companies will

form the basis of the

project. A new joint

venture company,

Great Western GQD

Rare Earth Materials,

will be created in

which GWMG will

hold 75% ownership

while GQD will hold

the remaining 25%. It will be responsible for

the design, manufacture, construction,

commissioning and operation of the planned

separation facility. It is anticipated that the

separation plant will be fed with rare earth

chloride that GWMG produces at its

Steenkampskraal monazite mine and/or with

feedstock from sources in the region.

GQD is a highly respected Chinese processor

of rare earth oxides and metals with over 20

years of operational experience. GQD has been

a supplier of metals and oxides to LCM for

over 15 years. Engdahl: "Our agreement with

GQD marks one of the most significant

developments so far in the delivery of our fully

integrated rare earth business model. GQD's

experience in the rare earth industry will

ensure our new facility will be at the cutting

edge of solvent extraction processing.

GWMG's team of metallurgists will be working

closely with those from GQD to finalise process

and plant design in order to commence

construction of this plant early in 2012. This

agreement is a major step in our plans to

deliver separated rare earth oxides and metals

to the world market by the beginning of

2013.”

Gong Bin, Chairman of the Board and

President of GQD stated, "The world of rare

earths has gone through significant changes in

the past two years. We at GQD welcome this

opportunity to work with GWMG and our old

friends at LCM in establishing a new

integrated rare earths producer that is able to

supply ever increasing world demand."

…and vanadiumAn International Patent Application has been

filed for the new hydrometallurgical process

developed for TNG’s 100%-owned Mount

Peake iron-vanadium project in the Northern

Territory, Australia. The newly-named TIVAN™

Process was jointly developed last year in

conjunction with TNG’s metallurgical

consultants. For the first time using

hydrometallurgy, the TIVAN process has

successfully extracted commercial grades of

vanadium, titanium and iron from the Mount

Peake deposit, which is hosted by a similar

rock type (magnetite-gabbro) to that which

hosts most known vanadium deposits

worldwide.

A joint patent application for the process

was lodged by TNG and METS in May 2010,

and an International Patent Application

(PCT/AU2011/000519) has now been filed. In

addition, TNG and METS have now named it

The TIVAN Process and submitted a Trade Mark

PROCESS DESIGN


Artist’s impression of the Arafura rare earths complex

R o c k M o r eI n t e r n a t i o n a l

Rockmore InternationalWilsonville, Oregon USATel (503) [email protected], AustriaTel +43 [email protected]

Rock Drilling Tools

For more than 60 years, Rockmore International has provided innovative drilling solutions, with manufacturing centers in two hemispheres and a global distribution network. Rockmore high performance drilling tools exceed the toughest demands in mining, construction, and water-well percussive drilling applications.

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For over a century, the mining industry has relied on FLSmidth

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application. The process uses a combination of

acid leaching, SX and chemical stripping to

selectively recover the valuable metals.

Successful test work was undertaken last

year using the new process on Mount Peake

drill core, and TNG is currently undertaking

further diamond drilling to extract a

representative sample of approximately 1 t of

core samples for use in larger scale

metallurgical test work and pilot plant studies,

planned for the second half of this year. The

upcoming pilot plant metallurgical test work

program will provide a definitive test of the

commercial potential of the process and form

part of the prefeasibility study on the Mount

Peake project.

TNG’s Managing Director, Paul Burton: “Test

work conducted on this new process to date

indicates its significant potential to contribute

to the low-cost development of one of

Australia’s largest vanadium projects at Mount

Peake. With this application, we are now

moving to the next stage of global patent

protection for a technology with the potential

to support the development of a fully vertically

integrated ferrous metals business for the

company.”

PhosEnergy for uraniumCameco recently made a third tranche

investment of $5 million for further

development of Uranium Equities’ (UEQ)

PhosEnergy process. A demonstration plant

construction has been built to recover uranium

as a byproduct of phosphate fertiliser

production. Cameco’s total investment in the

PhosEnergy process is now $12.5 million and

represents a further strong endorsement of the

potential of the process. Cameco can elect to

invest up to $16.5 million in the continued

development and commercialisation of the

PhosEnergy process. If it does invest the final

$4 million, the ownership of the technology

related to the PhosEnergy Process will be

Cameco 63%, UEQ 27% and the original

developers10%.

PhosEnergy is a patented ‘bolt-on’ process

to recover U3O8 as a by-product at existing

phosphate production facilities. UEQ, through

PROCESS DESIGN


Constructed to international standards this

demonstration plant is easily transported to, and

integrated into, phosphate fertiliser facilities around

the world. It encompasses all of the key aspects of

the PhosEnergy process within two 40′ shipping

containers

http://www.wh-hw.com

PROCESS DESIGN


USA registered Urtek LLC, has undertaken the

development of the technology in conjunction

with the Australian Nuclear Science and

Technology Organisation (ANSTO) and a major

US-based phosphate producer.

PhosEnergy applies conventional

technologies in an innovative manner to

achieve low operating costs for uranium

production (estimated at $20-25/lb) and high

uranium recoveries (estimated at 92%) with

improved environmental outcomes and

reduced waste.

The demonstration plant is planned to

operate for five to six months at a site in the

US over the second half of this year and will

provide cost and design data to enable the

construction of a full-scale commercial facility.

A prefeasibility study is also planned to be

completed in parallel.

Diamond designsDRA which is designing the Steenkampskraal

processing plant (above) is better known for its

diamond processing expertise. In Russia it, is

constructing two new 150 t/h automated DMS

plants at Alrosa’s Mirnyi Ore and Processing

Complex, Plant No. 3 Main Building in the

northeast of Siberia. The new plants are being

retro fitted into the existing plant to treat the -

5+1.2mm size fraction.

The plant consists essentially of two

modules in one structure which were

fabricated and pre-assembled in Johannesburg,

South Africa. This included the installation of

mechanical equipment, platework and piping.

Once completed, the plants were

disassembled, packed into containers and

shipped off to Saint Petersburg. At least this

was the intention in early 2008 when the

plants were held back from shipment and

placed in storage when the bottom of the

diamond market fell out.

It was only towards the end of 2010 that

the plants were finally shipped. The plants

were then railed from St. Petersburg to Ust-Kat

near Lake Baikal. From there the containers

were trucked to Mirnyi.

The plants will treat kimberlites from the

mine’s underground operations. The plant is

fed with a compact Thermo Fisher weigh

feeder complete with a variable frequency

drive for control. Material is fed onto a de-

sliming screen, through the parallel cyclones

and the cyclone overflow (waste) material is

split on a double desk screen where the

material is divided into +3mm and -3mm

fractions for reprocessing.

DRA has established a track record for the

supply of its DMS modules to mines operating

in extreme conditions including not only Russia

but also the Snap Lake Diamond Project in

Northern Canada where the environment is

quite similar.

Most recently, Shear Diamonds has engaged

the services of DRA Americas to evaluate the

existing diamond recovery plant at the Jericho

diamond project, Nunavut. “DRA’s extensive

diamond industry experience gives us

confidence that we can properly assess the

existing diamond recovery plant at Jericho and

take the appropriate next steps,” said Julie

Lassonde, Executive Chairman of Shear.

DRA prepared an initial assessment based on

a site visit. Recommendations from this

assessment have been incorporated into

Shear’s 12 to 18 month business plan. IM

References1.Larson, Michael; Anderson, Greg; Morrison Rob and

Young, Michael, Regrind Mills: Challenges of Scaleup,

SME Annual Meeting 2011, Denver.

2.Bergmann, J.-M. Sensor-based sorting - experience

and opportunities at CommodasUltrasort, Physical

Separation’11, Falmouth, England, June 2011.

http://www.ishigaki.co.jp

Crucial in the mining sector for

everything from flotation to

crushing/grinding, pumping and

conveying – drives and motors are supplied by

a range of specialist companies, some of which

specialise in mining, and others that supply a

range of different industries.

Finland-headquartered Moventas

Santasalo took a decision in late 2010 to

expand its Chinese operations into

manufacturing due to the growing market for

industrial gears in the region. The Suzhou unit,

formerly a service centre, is now

manufacturing components and industrial

gears and, when needed, customer-specific

volume products, all fulfilling Western quality

requirements. Maria Lauren, Marketing

Manager told IM: “Currently, our unit in China

manufactures components and industrial gears

for the pulp and paper industry but we have

plans to expand manufacturing to cover

mining and minerals too. The exact timetable

for realising this is still open. The Suzhou unit

is a full-scope gear service centre. Its service

scope covers everything from engineering and

installation to start-up, through condition

monitoring, maintenance and audits to

modernisation projects offers service, either in-

house or on-site. Service and technical support

is given to all our customer industries,

including mining and minerals. The centre

serves customers locally in China and other

parts of the Asia-Pacific region.”

Moventas references in mining include a

complete drive delivery for a grinding mill drive

train (ball and SAG) with two main unit helical

type D2PSF95 drives rated at 1,050kW at

1,485 rpm; inching unit; HS and LS couplings;

and a 198 tooth ring gear and pinion stand for

a mine in Australia. The company has also

supplied a grinding mill drive train with

running power of 7,500 kW at 995 rpm to

South Africa, as well as a flotation drive set-up

for a customer in Finland and pyro-

processing/bulk handling related drive

installations for customers in Russia.

ABB recently expanded its influence in early

2011 with the acquisition of Baldor Electric Co,

the North American leader in industrial motors.

ABB stated: “The acquisition of Baldor

advances ABB’s strategy to become a leader in

the North American industrial motors business

and a global leader for movement and control

in industrial applications. The combination

provides an even stronger growth platform

from which ABB can increase its penetration of

North American markets by building on

Baldor’s strong presence while at the same

time facilitating the sale of Baldor’s products

globally through ABB’s worldwide distribution

network.” Baldor’s leadership in high-efficiency

industrial electric motors positions ABB to

benefit from a projected 10-15% growth in

this business in the US in 2011 as a result of

new energy regulations that were

implemented in December 2010. Similar

regulations mandating higher electric motor

efficiency are being implemented in numerous

countries around the world in 2011 that also

will benefit sales of Baldor products.

ABB has itself just launched a

new motor based on an

innovative rotor design, offering

high efficiency and high power

output. Using synchronous

reluctance technology, the new

motor is robust and has practically no losses.

The motor is offered as a complete package

together with a frequency converter and

dedicated software. The motor and drive

package is offered in two configurations, one

that maximises efficiency, the other maximising

output. Because the rotor runs cooler than

other technologies, the bearings also run much

cooler, making the motor much more reliable.

With bearing failure accounting for around

70% of unplanned motor outages, customers

will appreciate the longer greasing intervals

and higher reliability offered by the new motor

and drive packages.

In large grinding mills, ABB has announced a

series of large installations at key mines.

Commissioning and start-up of the $20 million

gearless mill drive (GMD) system at Osisko’s

Malarctic project in Quebec was completed in

May. The 10 MW GMD powers a 38 ft SAG

mill. The contract for the system, consisting of

ring motor, transformers and E-house including

the new powerful ABB cycloconverter

controller AC 800PEC, was awarded in June

2007. Also completed in May this year was the

commissioning of three GMD systems for the

Esperanza copper mine of Antofagasta

Minerals in Chile. The systems power a 40 ft

22.4 MW SAG mill and two 27 ft 18.6 MW

ball mills. ABB was also contracted to install

the 800xA control system, harmonic filters,

variable frequency converters for the crusher

conveyer belt, gear-driven pumps, an electric

SCADA system and a substation for the port.

Also an Integrated Operations Center (COI),

which ensures complete visualization of the

mine’s operations, was implemented.

In March 2011, ABB announced a contract

with Kinross Gold for the delivery of three

GMD systems for the Tasiast gold mine in

north-western Mauritania. The three ABB

GMDs are part of an expansion project that is

scheduled to go into commercial operation in

early 2014. ABB’s scope of supply consists of

three complete GMD systems including

transformers, ring motors and E-house. One 26

MW GMD system will be installed for a 40 ft

diameter SAG mill,

while two

20.5

MW

GMD

Industry drivers

Powering almost all fixed capital equipment in mining andmineral processing, electromechanical and hydraulic drivesalong with electric motors are at the heart of site efficiency,reports Paul Moore

DRIVES AND CONTROLS


Mining kiln drive installed by Moventas Santasalo

LV synchronous reluctance drives and

motors from ABB

systems will be installed to drive two 27 ft diameter ball mills. In

addition, Kinross ordered the new ABB GAP-Watch™ for each system.

GAP-Watch is a unique rotating air gap monitoring system for ring

motors.

Most recently, Newmont selected ABB for fabrication, delivery and

installation of three gearless mill drive systems for the new Conga

copper/gold project in Peru. The contract includes the complete

engineering and delivery of a 28 MW GMD system for a 42 ft SAG mill.

In addition, the contract includes the complete engineering and delivery

of 15.6 MW foot mounted GMD systems for the two 26 ft ball mills. The

Conga project is located in Peru, approximately 900 km north of Lima, at

an altitude of 4,100 m above sea level. The project is situated near

Newmont’s existing Yanacocha gold mining operations where an ABB

GMD has been operating since early 2008.

Also just announced is the completed commissioning of a low speed

dual pinion mill drive and control systems at the newly reopened Copper

Mountain super pit mine in British Columbia, Canada. The initial order

was awarded in 2008. Engineering, delivery and commissioning of the

complete drive systems are worth over $26 million.

Indian engineering group Crompton Greaves, based in Mumbai, has

entered into an agreement with Polaris Private Equity to acquire the

Swedish drives company Emotron AB. The statement said; “As part of

one of the world’s leading engineering corporations, Emotron will extend

its offer for complete drive solutions, strengthen its R&D resources and

have access to new geographic markets.”

“This is good news for Emotron and our customers,” said Philip

Schwarz, president and CEO at Emotron. “This will be a long-term

ownership with a strategy to invest in our company and our technology.

Stronger resources in research and development will increase speed in

product development. We will be able to offer optimised drive systems

and also expand into new markets such as the high-growth Indian

market. Customers will also gain from a wider global presence for service

and support.” Emotron AC drives offer high accuracy in dynamic

applications such as crushers and conveyors. They ensure the right

feeding rate by adapting motor speed to load variations, minimising

energy consumption and wear. Direct torque control handles abrupt load

changes and overcomes initial peak loads, reducing mechanical stress

and preventing interruptions and false trips. The range covers motor

powers up to 3,000 kW for up to 690 v mains voltage. Units with liquid

cooling are available as an option.

US company Rexnord Industries is known worldwide for its Falk

drives brand. The Falk V-Class was launched in March of this year, and is

said to set a new standard in gear drives, being engineered to handle

demanding production needs in coal, hard rock and aggregate

operations. A three-year warranty is offered with V-Class, which the

group states has a longer seal life, improved thermal performance and

increased operating life. Shorter lead times, convenient serviceability, and

faster, easy-access support, durability and reliability are listed among the

Falk V-Class drive’s other benefits. The drive has a torque range up to

341,000 Nm and a power range of 11-7,457 kW.

Other features of the V-Class include gear sets up to AGMA Class 12

quality standards to ensure high standards of durability; no-leak design

Magnum seals, incorporating a purgeable grease chamber, and a contact

seal which eliminates oil leaks while keeping dirt out; a quiet drive train

for reduced noise levels in sensitive areas; and cooling technology for

longer operating life. One of the most distinguishable features of the

Falk V-Class is the housing itself. The heavy-duty, horizontally split

housing design incorporates advanced gearing, optimised through the

latest materials and technologies, to provide maximum performance

under load. The housing shape and features were designed using

DRIVES AND CONTROLS


http://www.mineradio.com

Computational Fluid Dynamics (CFD), enhancing

the drive’s thermal dissipation qualities.

As of January 2011 the world’s leading

supplier of heavy duty hydraulic variable speed

drives, Hägglunds Drives, has been fully

integrated into hydraulics and motors giant,

Bosch Rexroth AG. Hydraulic drives offer a

combination of benefits that are hard to

reproduce with electromechanical systems,

including high starting torque for an unlimited

period, with full torque from zero speed;

infinitely variable speed, through a gearless

design that allows optimisation of production

capacity; insensitivity to shock loads, thanks to

a low moment of inertia and the ability to

quickly and easily limit torque; and space

savings, due to a compact design and a direct

drive concept that eliminates gearboxes and

heavy foundations. The Hägglunds brand is still

used on the tough and reliable large hydraulic

Hägglunds system solutions that now are a

part of the Bosch Rexroth portfolio. Hägglunds

drives are known worldwide in mining in

applications such as apron feeders, ore car

tippers, crushers, conveyors, bucketwheels,

feeder breakers and ball mills. The Marathon

range is engineered for tough high torque

applications and includes by far the largest

hydraulic motor in the world, the MB 4000,

rated at 1,600 kW and weighing 10.75 t with

a torque of 1,400,000 Nm. Bosch Rexroth

continues to produce the Hägglunds solutions

in Mellansel, Sweden.

Nord Drivesystems is to demonstrate a

unicase for geared motors that integrates all

bearing seats in a single-piece casting during

AIMEX – Asia-Pacific’s International Mining

Exhibition 2011, which is being held in Sydney

from September 6-9. The company, which

describes its design as unique, says the unicase

eliminates all sealing surfaces that could

deflect under the effect of torque or radial

forces. “There are no dividing seams between

the drive and the gear unit housing which are

subjected to transverse forces or torque,” Nord

Drivesystems’ representative, Mark Alexander,

states. “The unicase principle allows the shaft

axes to be staggered, resulting in a more

compact design which, in turn, allows the user

of larger roller bearings to guarantee a long

operating life.” Finished with a unique jig on

state-of-the-art CNC machines, the unicase

incorporates the highest levels of precision,

rigidity and strength, according to Nord. The

Nord Drivesystems’ unicases are available in six

configurations, make mirror-image installation

possible, and have the same housing size or

installation dimensions for all ratios.

WEG believes that its MVW01 range sets a

new standard for medium voltage variable

speed drives (VSDs), achieving an efficiency of

99%. According to WEG this is as a result of a

design that employs 6.5 kv IGTBs to minimise

component levels, and a multi-level topology

to reduce harmonic currents to extremely low

levels. Great Basin Gold’s Burnstone gold mine

recently saw the first local installation of the

new MVW01 VSD on the African continent

and several other mining projects have since

followed suit, specifying the WEG MVM01,

including Sasol in South Africa (1 x 6,000 kW

compressor); Konkola in Zambia (1 x 4,400 kW

mill), Boteti kimberlite mine in Botswana; (1 x

4,000 kW mill) and the Bibiani gold mine in

Ghana (2 x 750 kW pumps). Burnstone is

located about 80 km southeast of

Johannesburg. The major capital projects

included the vertical shaft, ventilation shaft,

decline shaft and metallurgical plant. The

design and roll-out of the metallurgical plant

was performed and administered by consulting

group TWP. For the metallurgical plant, WEG

dealer Zest was responsible for all LV VSDs and

panels; all LV electric motors; medium voltage

equipment consisting of 2 x 3 MW 3.3kV

motors and 2 x MVW01 VSDs and 2 x 3 MVA

18 Pulse phase-shift transformers. Each 3 MW

motor drives a SAG mill and a ball mill

respectively. During the lifespan of the mine, it

is envisaged that speed variation may be a

requirement to change output in the process.

This was the reason for using VSD control as

the VSDs provide the additional advantages of

low mechanical strain on the mechanical

components during starting, low power draw

during mill starting, and frozen charge protection.

Synergy Engineering is a leader in the

development of technologically advanced

engineered drive systems since its inception in

the 1980s. The group’s drive solutions have

brought new cost-efficiencies to some of the

world’s biggest mining operations, including

Freeport Grasberg in Indonesia, Chile’s Minera

Escondida, Peru’s Antamina and Canada’s

Syncrude and Highland Valley Copper. Synergy

DRIVES AND CONTROLS


The renowned range of hydraulic drives from

Hagglunds are now part of Bosch Rexroth but the

brand has been retained

http://www.synergy-eng.com

takes on full responsibility for the project and

takes the risk away from reliable alternatives

for larger horsepower wound rotor motors.

The solution involves inserting resistance in the

rotor circuit to change the characteristics of

the wound rotor motor to match an

application’s load/speed requirements. Synergy

provides these systems for controlled

acceleration of many applications including

overland conveyor systems and large crushers.

From SEW-EURODRIVE, the robust helical

and bevel-helical gear units that are part of the

X Series of industrial gear units cover a torque

range of 6.8 to 475 kNm. Recently, the

Bruchsal-based drive automation specialist

rounded off the lower power range of this

series and is now also offering the proven gear

units for the torque range of 6.8 to 45 kNm.

When it comes to helical and bevel-helical gear

units, nearly any mounting position or shaft

arrangement can be implemented. The X

Series’ finely graduated size and high power

density results in savings in terms of both

weight and cost, according to SEW. The large

amount of pre-defined accessory equipment

creates flexibility in terms of adjusting the unit

to each respective application. This includes a

wide range of modular options such as motor

adapters and mounting flanges, backstops and

cooling systems as well as sealing systems for

the most varied environmental conditions.

One main area of application for SEW industrial

gear units is conveyor systems in a wide variety

of industries. In this context, the gear units

perform reliable service in driving conveyor

belts and bucket elevators for the horizontal

and vertical transport of bulk materials.

At the Forrestania nickel mine in Western

Australia, a central concentrate plant was

developed at Cosmic Boy. The 250,000 t/y

plant was officially opened in March 2009,

since when the plant has been upgraded to

550,000 t/y – processing nickel ore from Flying

Fox and Spotted Quoll. Owner Western Areas

appointed a Perth-based engineering services

team for the engineering, design,

procurement, construction and commissioning

of the Cosmic Boy nickel concentrate plant.

The plant was designed for a process

throughput of 250,000 t/y, at a milling

nominal treatment rate of 30 t/h, with

provision for an expansion in processing

capacity to a throughput of 550,000 t/y.

Processing includes primary crushing,

conveying, coarse ore storage and milling

incorporating flash flotation to produce a

nickel concentrate. Concentrate is dewatered

via thickening and filtration to produce a

concentrate suitable for dispatch via trucking

and shipping. Process plant tails are thickened

prior to being pumped to the tailings storage

facility. Vacon supplied a total of 44 Vacon

NXS range of variable speed AC drives in the

power range from 0.25 kW to 160 kW. The

Vacon variable speed AC drives control various

pumps at the Cosmic Boy concentrator plant.

Pump control with the help of a variable speed

AC drive brings considerable energy savings. It

also improves process control, which is

essential in the concentrating process to

ensure consistent quality for the process ore.

In March, Siemens’ Industry Solutions

Division received an order from ThyssenKrupp

Robins to supply a gearless drive system for an

overland conveyor at Xstrata Copper’s

Antapaccay copper mine in Peru. The overland

conveyor is being supplied by ThyssenKrupp

and will transport ore over a distance of some

6.5 km from the mine to the processing plant.

The belt will be 1,372 mm wide, travel at 6.2 m/sec,

and is designed to transport approximately

5,260 t of material per hour. This will be the

first installation of a gearless-drive conveyor

system outside Germany, said Siemens, which

expects the system to be commissioned in

2012. The drive system for the overland

conveyor comprises two low-speed synchronous

motors, each with a total power of 3,800 kW,

and Sinamics SL150 cycloconverters.

Siemens claims the gearless drive solution has

a number of advantages over the high-speed

motors and gearboxes usually used on conveyor

systems. The size of the motor is not limited by

the size of gearbox available, thus eliminating

the necessity to install multi-motor drives. The

power required to drive a belt can be provided

by just one drive per belt pulley. This enables the

size of the electrical room to be reduced, thus

saving space and weight. Elimination of a whole

series of mechanical and electrical components

increases the reliability and efficiency of the

overall system by 3-4%, and maintenance

requirements are also substantially lower

according to Siemens, gearbox maintenance

work alone can amount to as much as 5%

annually of the original investment. Lubrication

and gearbox cooling systems, and their

maintenance, are also eliminated. IM


DRIVES AND CONTROLS

X Series industrial gear unit from SEW Eurodrive in factory

http://www.fourleafsolutions.com

Lourens says there is “increasing pressure

to progress more rapidly towards

achieving ‘Zero Harm’,” and a

concomitant “industry-wide desire to eliminate

collision-related fatalities in the mining industry

and imminent legislation that will enforce the

installation of some form of proximity

detection system on moving equipment and

vehicles in underground mines.”

While this discussion relates specifically to

South Africa, the problem is of course global

and is being aggressively tackled in a number

of countries.

“Safety of underground mine transport and

machinery is one of the four focus areas of a

dedicated Mining Industry Occupational Safety

and Health (MOSH) team instituted by the

Chamber of Mines of South Africa to drive the

adoption of leading safety practices

throughout the industry,” Lourens explains.

“Under this banner, a Transport and Machinery

Adoption Team is working on developing

processes which will speed up the widespread

adoption of safe practices in this particular

arena.”

He says that his company, electronic

safety equipment specialist Booyco

Electronics, is the leading supplier of

collision warning systems to the

South African industry.

“However, industry uptake

of proximity detection

technology has been

relatively slow. Although

Booyco Electronics has

equipped South African

mines with more than

25,000 collision warning

systems since 2006, this

represents less than 10%

of the market that will

soon be required by law

to install this type of

technology.”

Lourens says both

collision warning

systems and collision avoidance systems are

required, depending on the nature of the

application. A collision warning system consists

of a sensor that detects the presence of an

object, an interface that provides an audible

and/or visual alarm to the equipment operator

and wiring between the two. These systems

warn both vehicle operators and pedestrians of

potential danger. Sensor technologies include

ultrasonic echo detection, infrared reflection,

radar (radio detection and ranging), video

cameras and radio frequency identification

(RFID) systems.

A collision avoidance system is a system of

sensors that is placed within a vehicle to detect

potential collisions with objects or personnel.

This technology is able to interact with the

mobile equipment or vehicle’s brakes and bring

it rapidly to a complete stop.

“The coal industry is starting to install

collision avoidance systems,” Lourens says,

“but collision warning systems are more

appropriate for hard rock mines, with their

steeply angled stopes. Within this technology,

experts agree that very low frequency (VLF)

systems are best for warning pedestrians who

work near moving machinery, while ultra-high

frequency (UHF) signalling is more suitable for

high speed and track-bound equipment.”

Lourens believes, therefore, that mining

companies that are about to install this kind of

technology underground for the first time

should do extensive research before deciding

which system to purchase. This is particularly

advisable at the moment, since he

predicts it is likely that new non-

specialist companies will emerge

in the current climate to market

collision-related technology to

the mining industry, in a

technology maturing market.

“Protecting personnel and

equipment is a

critical focus

area in the

industry,” he

comments.

“Proximity

detection

technology is

also capital

intensive, so

when

investigating

which system

Collision avoidance

HIGH PROFILE

The uptake of man-machine interfacetechnology in the mining industry is poised to increase exponentially,according to Booyco Electronics ManagingDirector, Anton Lourens

The CWS800 Plus incorporates both UHF RFID and

VLF capabilities

Anton Lourens, Managing Director of Booyco Electronics


would be most suitable for a given application, mining companies should

look for a system that has a proven track record and which is well

supported by the supplier in terms of technical support, spares,

stockholding, operator training and change management. Suppliers

should also be seen to be reinvesting into continuous product

development and enhancement.

“Price is always a factor, but we advise companies to evaluate the

total cost of ownership, rather than the initial capital outlay.”

Asked about the proliferation of suppliers in this field, Lourens told IM:

“There are currently a lot of suppliers in the industry that are offering

different technology as different solutions for various applications. The

problem is that the environment dictates the solution where certain

surface solutions will not suffice underground. Going forward we do

expect more suppliers to enter the market and offer solutions. We

believe competition is good and healthy, and have patented our solutions

to create some form of a barrier to entry in the market place. Also, what

we have experienced internally over the last few years, even when you

consider our own long term mining background and expertise in VLF

technology, the original offered solution and the final mature product of

today are miles apart. I’m of the opinion that will be the biggest

challenge for new suppliers, and customers, and will force us, and our

competitors to eventually interface and integrate with other systems as

we’ve already seen with some of the OEMs and their safety

equipment/systems which all needs to be intertwined.”

He concludes that “South African mining companies are definitely

global leaders in this field and should be used for feedback, actual

problems etc. rather than re-inventing the wheel and going through the

growing pains again. I also believe that the applied technology in South

Africa over the last few years have lead to this being mature technology

and solutions.”

Booyco Electronics markets a range of CWS (Collision Warning

System) products, custom adapted for use in both the surface and

underground mining environment. The company is focusing on supplying

reliable safety systems to warn of the possibility of collisions between

vehicles and pedestrians, and vehicles with vehicles. Research in this

arena has led to strategic alliances with the innovative companies, VAK

Technical Solutions (of South Africa) and Selectronic Funk-und

Sicherheitstechnik 9of Germany), which ensure that Booyco Electronics is

able to continuously develop solutions to meet customer-specific

requirements in the mining industry.

One of the company’s early successes was with the CWS500U collision

warning system, out of which its CWS800 and CWS800 PLUS have been

developed. These innovative systems include vehicle-to-vehicle detection

as part of a single underground and surface solution for both close

proximity (pedestrians) and longer range (vehicle) warning. The added

benefits of the system could include, among others, interlocking with

third party equipment, such as ventilation doors and robot systems.

The Driver State Sensor (DSS) System is a fully automatic driver

awareness and fatigue warning system that uses a miniature sensor

mounted on the dashboard of a vehicle. The system provides feedback

on fatigue and other factors to increase operational safety. In addition to

in-cab feedback, the DSS can be integrated into fleet management.

Booyco’s Trapped Miner Locator system has been met with positive

feedback from deep mines. Cap lamps are fitted with a VLF transmitter

(tag) that has pronounced through-rock penetration capabilities. Search

teams are equipped with a battery operated VLF receiver used to screen

the rockfalls ahead of them. The VLF technology enables the device to

read through rock up to 30 m ahead and give a fairly accurate indication

(in metres) of how far away the miner’s tag is located — or if there is no

tag in the vicinity. IM


HIGH PROFILE

http://www.booyco-electronics.co.za

SX/EW growth

The technology is increasinglybeing used by the mineralsindustry to separate, purify andconcentrate metals such asnickel, cobalt, copper, zinc,uranium and rare earths. John Chadwick looks at some of the latest developments

SX/EW


Gustavo Diaz and colleagues1 at

Tecnicas Reunidas point out that “in

recent years there has been considerable

development of hydrometallurgical processes

for copper extraction applying SX combined

with electrowinning for the production of

high-grade electrolytic copper. As a result,

above 20% of world copper production is

currently achieved from heap leaching–SX

operations of oxide copper ores.

Solvent extraction of zinc has been successfully

applied on several industrial plants using the

ZINCEX™ technology. Besides, this technology

is gaining more popularity with the latest ”

“The low capital and operating costs of SX

plants together with the easy operation and

the production of top quality electrolytic

metals close to the mine site make the

economics of the SX processes very attractive,

being suitable and feasible in the range of

small to medium capacities, where

conventional smelting process is not applicable.

“The mining and metallurgical industries are

now in the best position to afford projects with

mixed or polymetallic copper and zinc bearing

materials.

“There are a number of key aspects to be

considered in the hydrometallurgical processing

of mixed copper and zinc primary and

secondary materials:

■ Very frequently, those are complex materials

and the main metals are distributed as

compounds of diverse nature and consequently

are very difficult to separate by physical

treatment. This characteristic has driven the

need to use whole leaching for maximum

copper and zinc metals extraction into solution

■ Whole leaching releases valuable copper

and zinc to the pregnant solution but also

large quantities of other undesirable

components like iron, arsenic, cadmium, etc

■ Application of SX techniques for copper and

zinc recovery from pregnant leaching

solutions containing high levels of impurities

will require tailored solutions to get the

optimum yields applying the best process

conditions and design parameters

■ Other relevant factors like geographical

location and available infrastructures, raw

materials grade and reserves/availability, acid

consumption, power supply and cost, local

environmental regulations for disposal, etc,

have to be carefully analysed.”

Tecnicas Reunidas designed an integrated

flowsheet for the best process performance at

minimum cost. The work was done for an ore

containing 0.4% Cu, 1.6% Zn, 15% Fe, 21%

Ca, 0.5% Mg, 2.5% Al and 50% SiO2.

Nominal production was to be 12,000 t/y

electrolytic copper Grade A and 50,000 t/y

SHG zinc cathodes.

Comminution achieves a size of 100%

minus 20 mm. The ore passes to

agglomeration and then is sent to heap

leaching. Sulphuric acid is added to keep the

pH optimum. The pregnant solution from heap

leaching is subjected first to copper SX and EW

to recover the copper and second to zinc SX

and EW to recover the zinc after removal of

some impurities such as iron, silica, etc. The

acidic raffinate solution leaving SX is recycled

to the leaching operations.

A series of process flowsheet were designed

and developed, and a comparative analysis was

performed to choose the best process

configuration. In the first case, after

comminution the Cu/Zn ore is placed on the

heap and irrigated with fresh acid and recycled

acid raffinate to extract copper and zinc, which

are released to the pregnant solution together

with some impurities. Then, the impurities

(mainly iron) are rejected and the solution goes

first to Zn SX/EW and second zinc acid

raffinate passes to Cu SX/EW. In the second,

Picture courtesy of CSIRO

the Cu/Zn ore is leached in the heaps and the

copper and zinc are extracted into the

pregnant solution. In this case, the Zn SX/EW

circuit and the

Cu SX/EW circuit are set in parallel. In the

third case copper and zinc are extracted into

the pregnant solution. Then, the copper is first

recovered in the Cu Zn-SX circuit and the

raffinate goes to iron removal stage and next

to the Zn SX/EW circuit for zinc recovery.

“Aiming to choose the best process option,

every alternative was developed at a

conceptual level including:

■ Design of block diagrams and integration of

the main process stages closing the global

circuit in a coherent manner

■ Gross mass balance to quantify the main

streams and the principal components, e.g.

copper, zinc, iron, acidity, etc, and also

temperature

■ Definition and calculation of some unit

parameters in order to analyse and compare

the three process flowsheet. The selected

unit parameters were: consumables, energy,

and generation of wastes and effluents.”

In cases 1 and 2, a certain amount of

copper may be co-precipitated together with

iron leading to some copper losses. Copper

extraction in 1 has to be done under acidic

conditions, which can affect the selectivity of

the organic extractant. Losses in liquid retained

in heap leaching may be increased in 2 when

dealing with more concentrated solutions.

The authors conclude that Case 3 offers

“smoother and simpler operating conditions

and higher efficiency, as well as, minimum

reagents and utilities consumption.”

Reagent advancesCytec Industries has developed a simulation

software package to assist operators and

engineering companies who wish to optimise

and design solvent extraction circuits for

CYANEX 272. These new modelling capabilities

are expected to significantly reduce the

amount of laboratory work required by the

designer while increasing confidence in the

ability to achieve the desired metal separations.

This new in-house capability allows evaluation

of the expected impact of various changes to

the PLS metal composition, reagent

concentration, O/A ratios, pH profile, and

overall circuit configuration/layout.

Cytec’s modelling and predictive capabilities

associated with CYANEX 272 have substantially

advanced. The company says “the tool and

skills that have been developed will continue

to advance as Cytec continues to invest in

expanding modelling capabilities.” The

program has been used successfully to

evaluate operational parameters at existing

operations and is being used to assist in

multiple design scenarios.

The software can aid in the design of plants

by modelling the performance under multiple

staging scenarios to find the optimal

configuration and potentially minimising the

overall staging requirements. It also can be

used to optimise existing operations by

providing quick guidance to reach the optimal

O/A ratio, pH profile, or reagent concentration

thus maximising metal transfer while

minimising impurity transfer. Cytec believes

there is substantial opportunity to improve the

economic performance of both existing and

future operations. “The modelling capabilities

should allow optimisation of CYANEX 272

circuits while allowing easy economic

assessment of the benefits of cobalt SX.”

Cytec has developed a new range of

formulations with enhanced stability to

oxidation. The company says “the ACORGA

OR series of extractants provide excellent

chemical stability under high oxidation-

reduction potential (ORP) while maintaining

the desired physical and metallurgical

characteristics. Prior to the development of

ACORGA OR there has been no copper SX

formulations designed to protect against

oxidative degradation.”

SX/EW


http://www.srk.com

Extensive test work and pilot plant trials

were run under oxidising conditions to

evaluate the performance of one of the

formulations, ACORGA OR25, to oxidative

degradation.

To prevent oxidation of the organic phase

due to high ORP values, the Fe2+/Mn ratio in

the electrolyte and ORP should be monitored

and controlled. During plant upset conditions,

steps should be taken to quickly bring the

electrolyte ORP back under control.

The use of Cytec’s oxidation resistant

formulations can provide an extra level of

security to address temporary permanganate

issues or other conditions resulting in oxidation

(short term or ongoing).

It has developed a new series of reagents

(The ACORGA NR Series) for operations with

concerns over nitration. These new reagents

can be formulated at varying strengths to

maximise copper transfer (based on the PLS

copper and acid) while maintaining chemical

stability under nitrating conditions. Historically

plants with high nitrate in their PLS solutions

(20 – 40 g/litre) or concerns over nitration risk,

have elected to use ketoxime (due to its high

hydrolytic stability). The use of ketoxime has

the disadvantages of reduced copper transfer,

copper: iron selectivity, and low copper

recovery when the PLS copper grade is high or

the pH is low. Often the ketoxime is too weak

of a formulation for efficient SX operation.

Cytec has also identified a number of

copper SX operations have been identified

which contain significant molybdenum values

within the leach liquor. At some of these

operations the molybdenum is present due to

the continuous leaching of molybdenum

oxides within the ore; while at others, the Mo

is present from other sources such as scrub

liquors from smelting operations. Due to large

solution inventories, the molybdenum value

within the solutions can be substantial. The

actual Mo concentration within the leach

solution can vary greatly dependent on the

acidity of the leach liquor (i.e. Mo can

precipitate out within the heaps/dumps

dependant on the acidity used).

So, the company has developed a new

modified phosphinic acid reagent formulation

(CYANEX® 600) for extracting and purifying

molybdenum from these leach liquors. A

common problem for recovering molybdenum

from these streams in the past has been

finding a formulation which would have the

right selectivity and kinetic properties to allow

the low Mo concentration to be efficiently

extracted without altering the standard copper

SX/EW process.

The formulation’s unique properties make it

possible to selectively remove molybdenum

while leaving the majority of the impurity

elements behind in the leach liquor. Ideally the

recovery process would take place downstream

of the standard copper SX plant, removing the

molybdenum from the acidified copper

raffinate stream prior to further leaching.

Last year Cognis, now part of BASF Mining

Chemicals, was granted the US patent for its

Split Circuit technology that is particularly

applicable to agitation leach-SX of copper ores.

The Split Circuit configuration effectively splits

the leached solution into high and low grade

streams, which in turn are treated separately in

the SX process.

The raffinate produced from the high grade

solution is returned to the leaching step to

SX/EW


CST Mining Group is an international copper mining

company listed on the Hong Kong Stock Exchange

that operates its wholly owned Lady Annie copper

mine (SX/EW) in Queensland, Australia

Project Client Commodity Equipment type Year

Voisey Bay Vale-Inco Ni/Co/Cu Bateman Settler On-going

Tres Valles Vale Cu (20,000t/y) Bateman Settler 2010

Nippon N-Chlo NMM Cu, Ag Bateman Settler 2009

(demo plant)

Goro Vale Inco Ni (55,000t/y), Bateman Settler 2009

Co (4,500 t/y) and 21 BPCs

Niihama Refinery Sumitomo Bateman Settler 2008

Expansion

Honeymoon UraniumOne U (450t/y Bateman Settler 2008

U3O8 equivalent) and 2 BPC

Gaby Codelco Cu (150,000t/y) Bateman Settler 2008

Dominion Reefs UraniumOne U Bateman Settler 2007

and 2 BPCs

Piedras Verdes Frontera Cu (30,000t/y) Bateman Settler 2007

Demo plant in Japan Confidential Confidential BPC 2007

Timna (demo plant) AHMSA Cu Bateman Settler 2006

Mantos de la Luna MDLL Cu (30,000t/y) Bateman Settler 2004

Weng Fu PPA Weng Fu Phosphoric Acid Bateman Settler 2004

and 2 BPCs

Olympic Dam BHPB Uranium 2 BPCs 2003

Penoles (Demo plant) Cu Bateman Settler 2001

Bulong Nickel Preston Ni/Co/Zn Bateman Settler 1999

Olympic Dam BHPB Uranium 10 BPCs 1999

Mt Gordon Western Metals Cu Bateman Settler 1998

Bateman Settler and BPC installation track record 1998-2010

fully re-use the acid that has been generated.

Raffinate produced from the low grade leach

solution, lower in concentration of both metal

species and acid than would conventionally be

the case, is used in the washing activity, and a

portion is ultimately bled from the circuit as

the soluble loss fraction.

In this way, the configuration minimises

soluble losses. Other operating improvements

are realised with lower neutralisation costs

prior to tailings disposal.

Cognis says “the economic benefits of the

split circuit are clearly apparent once a detailed

mass balance of both the metal species and

acid is performed. The relative simplicity of the

concept means that incorporation into an

existing flowsheet can be done easily and with

a minimum of capital outlay.

“The split circuit provides operational

flexibility and, in areas of the world where the

cost of acid and neutralizing agent are high,

the operating cost benefits of the concept can

be substantial.”

Bateman Litwin’s Advanced Technologies

Division provides state-of-the-art SX know-how

and technologies. It says the Bateman Settler™

“with its advanced design and enhanced

efficiency provides many advantages compared

to conventional settlers used in SX circuits.”

These include high process efficiency with low

organic losses, compact layout and short

construction time, low capital cost and ease of

operation and maintenance:

■ Metals processed include copper, cobalt,

nickel, zinc and uranium

■ PLS flow rate of up to 1,750 m3/h per train

■ PLS grades from less than 1 g/litre up to 30

g/litre

■ Organic strengths up to 30% v/v extractant

■ Organic losses as low as 20 ppm

■ Fully automated interface control system.

The Bateman Pulsed Column (BPC) is an

efficient cost-effective contactor which

enhances SX during extraction, stripping and

scrubbing or washing processes. It is a

continuous and multi-stage extraction process

that can handle liquids with suspended solids.

The company says these columns can “enhance

most industrial SX processes, particularly those

with a fast rate of mass transfer.”

Electrolyte filtersOutotec is a leading SX/EW technology

supplier with an extensive track record in

building complete plants. Larox which was

recently acquired by Outotec is well known for

efficient and reliable filtration process

equipment. The combined companies now

offer Outotec Larox DM electrolyte filters

which are specially designed for excellent

removal of entrained organic and suspended

solids from electrolyte, using the well proven

dual media concept. The Outotec Larox DM

electrolyte filter package can be delivered as an

integral part of Outotec’s SX/EW technology

delivery or as a standalone solution to

engineering companies and end users.

Adsorption filtration using the well proven

dual media concept reduces entrained organic

and particulate concentrations to a level of a

few ppm. Production capacities increase, as

does the quality of cathode products.

The filters use two separate layers of media

for coalescing and for filtration. The upper

media layer provides for organic removal while

the second layer filters particulates in the

electrolyte.

Outotec says “low electrical energy

consumption is a cost-saving benefit, as the

adsorption filtration technique uses low


SX/EW

The Bateman Settler

On-belt Real TimeAnalysis for Process Control

• Iron ore

• Base metals

• Bauxite / Alumina

• Coal, cement

• and others

• Continuous analysis

• Minute by minute results

Contact us:Tel: +61 7 3710 8400Fax: +61 7 3710 8499 [email protected]

THROUGH BELTELEMENTALANALYSER

PATENTED NON-CONTACT DESIGN

TBM 200 SERIES

MICROWAVEMOISTUREMONITOR

NATURAL GAMMAMINERALSMONITOR

Model 1500

http://www.scantech.com.au

pumping pressures compared to alternate

solutions utilising flotation.

“Automatic (PLC) control of the electrolyte

filtration and media cleaning steps at the end

of each filtration cycle ensures maximum

filtration time in subsequent cycles. Outotec

Larox DM electrolyte filters are delivered as an

automated operational filtration system which

can be fully integrated to any SX/EW solution

package.” The package will contain filter

vessels, air and liquid internal distributors, filter

media, piping and valve skid, blower skid, and

automation & instrumentation. A maintenance

platform is optional.

“With no moving parts, the media cleaning

system ensures maximum media lifetimes.

Typically the anthracite media is replaced every

24 months when combined with Outotec’s

proven SX process technology.”

Using lean electrolyte for backwashing and

returning it to the After Settler after holding in

a backwash collection tank (see flow

schematic) means these filters do not reduce

the capacity of SX production. Filter flow rates

as high as 275 m3/h can be consistently

handled by a single unit (5.2 m diameter),

greatly simplifying the process.

Typically, multiple units are installed in

parallel for flexibility and expandability to

economically accommodate growing plant

capacity requirements.

Research and developmentCSIROs’ SX team working within Australia’s

Parker Centre for Integrated Hydrometallurgical

Solutions has developed and demonstrated

novel SX processes for metal separation and

tools to enable enhanced diagnosis and

remediation of phase separation problems.

Using customised combinations of commercially

available organic reagents to improve the metal

selectivity of an SX system is an alternative to

the expensive option of developing new

extractants. The SX team has developed a

number of synergistic SX (SSX) techniques.

The CSIRO SX team has developed SSX

systems which are currently of great interest to

industry. One of these enables the recovery of

cobalt from leach solutions whilst rejecting

impurities such as manganese, magnesium and

calcium without the need for complicated

intermediate precipitation and re-leach steps.

This patented direct SX (DSX) system uses a

combination of LIX63 and Versatic 10. In

another SSX system, TBP is added to enhance

the stripping and extraction kinetics of nickel

so that both nickel and cobalt can be

separated from manganese, magnesium and

calcium without intermediate precipitation and

re-leach steps.

Understanding how operating conditions

affect the stability of expensive organic reagents

and controlling conditions to minimise reagent

degradation is an important aspect of running

SX/EW


Diagram showing the use of Outotec Larox DM

electrolyte filters

High surface potentials (in excess of 10 kV)

measured on HDPE pipelines (Top) and

isolated metal valves by loaded organic

pumps in an SX plant (Left)

successful SX processes. Similarly, phase separation issues in SX circuits

can be problematic and originate from many different factors. The team

offers significant expertise in the techniques and tools available to solve

such issues – from organic stability studies, organic and cruds analysis to

the assessment of physical issues such as in-situ droplet size

measurement, phase disengagement time, interfacial tension and

entrainment analysis.

In addition to desirable metal separation properties, SSX systems also

need to exhibit sufficient chemical robustness under expected operating

conditions. Full SX circuit continuous studies over several months are

routinely performed under proposed operating conditions to optimise

operating conditions, assess reagent stability and to gauge the effect of

any degradation products on the chemical and physical properties of the

resulting organic solution.

Dr Dave Robinson, Research Program Leader: Base Metal

Hydrometallurgy told IM of a multi-sponsor SX project currently

underway (SXT2) that has developed and applied the following tools:

■ Velocity probes for determination of fluid velocities within both the

aqueous and organic phases in laboratory or operational settlers which

has been used to determine flow patterns in real settlers, evaluate

alternative fence designs for improved residence time distributions,

increased coalescence, reduced pressure drop all leading to

implementation of changes that have led to as much as an 85%

reduction in entrainment losses in sponsors settlers

■ Droplet size probe for use in model and real mixers to evaluate the

droplet size distribution generated under differing operating

conditions (e.g. phase ratio, flow rates, organic or aqueous

composition) with varying impellors and various at differing rpm

■ A CSIRO Lewis Cell for independent evaluation of relative kinetics of

mass transfer and direct comparison of alternate reagents, alternate

operating conditions, effect of modifiers or competing elements

■ Tools for on-line entrainment determination of both aqueous in

organic and organic in aqueous which are being tested for potential

operational use and commercialisation

■ Computational and physical modelling capabilities able to evaluate

and establish principles of design for improved mixing ad settling in

new or modified contactors.

CSIRO believes the Parker Centre pilot plant Murdoch University is a

unique facility. It is the largest pilot plant in the Southern Hemisphere

and certainly the largest facility located in a public sector

research/academic institution. The team is highlighting its availability and

the EW scientific expertise and capability within the Parker Centre to

assist industry in addressing EW technology issues.

The pilot plant was originally constructed by the BHP Billiton Base

Metals Technology Group. The EW cell is based on the cross sectional

dimensions of the Escondida mine (Chile) sulphide tankhouse. It is an

800 litre cell that can accommodate five full-scale electrodes at

‘standard’ separation distance. This is what makes this facility unique it

can replicate full scale industrial process conditions.

Safety auditCSIRO notes “the ubiquitous problem of acid mist is associated with

health, safety, environmental, efficiency and operating cost issues.” It is

involved in a project “to establish the important features of acids mist

generation, quantify the contribution of critical operational factors and

pave the way to safer, more efficient and lower cost operation of EW

facilities.”

Graham Hearn, Technical Director of Wolfson Electrostatics says:

“After the catastrophic SX fires of a decade ago, static electricity - the

insidious by-product of the SX process is now well understood and can


SX/EW

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be designed out of new plants and controlled

in existing ones.

“As in most industrial fires, the ignition

source cannot be identified entirely beyond

doubt. However from subsequent detailed

investigations of the incidents in SX it is likely

that the ignition source was due to

electrostatic discharges igniting the organic

solvent under normal operating conditions.

Consequently, the ignition of solvent below its

flashpoint generated huge concerns within the

industry particularly with regard to static

electricity.

“In the SX process the solvent is used in

large quantities and is conveyed between

storage tanks, settler tanks and other process

vessels by a network of pipes. This creates an

electrostatic charge separation between the

liquid and the pipe wall. The pipes may vary in

material of construction; often being a mixture

of metal and plastic within the same plant.

Materials such as high-density polyethylene

(HDPE) and fibreglass (GRP, FRP) are electrical

insulators allowing static charge to

accumulate.”

It must be assumed that pipes and tanks in

SX plants containing organic solvent and air

may produce a flammable atmosphere capable

of ignition by electrostatic discharge at normal

operating temperatures. Good plant design,

however, can greatly reduce this risk by

minimising both the production of flammable

atmospheres and static charge generation. In

summary, SX plants which have a high risk of

electrostatic ignition and fire are those which

operate under the following conditions:

■ Low conductivity organic solvent (below 200

pS/m)

■ Relatively low-flashpoint solvent (more

volatile solvents are easier to ignite even in

mist or froth form)

■ High temperatures within pipelines

■ Gravity flow (allowing air to be present

within the pipe)

■ High solvent flow velocity (well in excess of

2 m/s)

■ Turbulent flow and splashing due to pipeline

constrictions etc.

■ Electrically insulating pipework such as

HDPE and GRP/FRP

■ Ungrounded metal components in or on the

plastic pipeline.

Hearn recommends electrostatic safety

audits of plants to establish the degree of

static hazard present. During the audit the

following actions should be performed:

1. Familiarisation with the plant and process

and identification of risk areas. The principle

risk areas are envisaged as being plastic

pipelines carrying organic solvents but the

audit should also encompass mixer-settlers,

holding/storage tanks and other areas

identified as potentially hazardous

2. Measurements on process fluids and

pipework; such measurements include

quantifying electrostatic potentials, electrical

conductivity of organic solvents starting with

virgin diluent and then at points throughout

the process, electrical properties of

pipework, build up of deposits (Jarosite), etc

3. Inspection of grounding of metal plant and

other conductors

4. Electrostatic hazards from personnel (plant

operators, maintenance workers etc)

5. Identification of electrostatic hazards from

sources other than those above (as

appropriate).

“If a combination of low solvent

conductivity and high potentials are observed,

it must be concluded that an electrostatic

ignition hazard may exist,” he concludes. IM

ReferencesFrias, C. et al, Solvent Extraction Applied to Mixed

Copper and Zinc Bearing Materials, Proceedings of Cu

2010

SX/EW


http://www.infomine.com

Orofino Gold Corp (ORFG) is a

Colombia-based gold company

focusing on discovery, acquisition, and

exploration of mineral-rich resource deposits

primarily in the Americas. It currently holds

concessions in the Senderos de Oro area of

Colombia, making it a neighbour of nearby

Ventana Gold Corp’s proven La Bodega asset

and Greystar Resources’ Angostura project. In

addition, Orofino has rights to other lands in

the gold-producing region totalling over 3,000

ha as well as an option on a strong portfolio

of other small producers and

development/exploration assets in the region.

The primary assets are four gold mining

concessions collectively containing 4,145 ha

(10,241 acres) located in Sur de Bolivar, Colombia.

La Azul is a registered contract, while the San

Carlos, Culoalzao and Rio Viejo contracts have

been signed, with registration pending.

Orofino is exploring the acquisition of eight

additional concessions, also located in the Sur

de Bolivar region, containing 13,620 ha

(33,651 acres), with contracts signed on all eight.

In the 1980s and 1990s, Orofino’s claims

were held by other mining companies who

sought to explore and value these concessions.

The immediate predecessor to Orofino was

what is now AngloGold Ashanti, the world’s

second largest gold producer. AngloGold was

forced to abandon its concessions due, in part,

to the civil unrest that caused many foreign

companies to leave Colombia in the late 1990s.

With AngloGold no longer working in the

region, the company let its concessions lapse,

and they were ultimately ceded back to the

original owner. Although AngloGold clearly

believed its concessions had substantial value

(enough to purchase them from other

companies), when AngloGold left the region, gold

was only worth a fraction of its current value.

Before the concessions were abandoned,

AngloGold invested substantial funds in early

stage geologic exploration of Orofino’s

concessions (this exploration was summarised

in preliminary reports prepared in 1995).

In addition to finding “gold in soils” more

than eight times richer than that reported by

Ventana, these reports (now in Orofino’s possession)

indicate the following, according to these excerpts

from a preliminary technical report prepared by

Robert P. Shaw, M.Sc., in August 1995.

■ “Gold mineralisation is widespread, with

virtually every rock type and every structural

orientation hosting veining returning

anomalous gold values

■ “The region is virtually unexplored from a

modern metallogenic standpoint, but it

demonstrates very good potential for the

economic occurrence of large-scale high

level, volcanic-hosted epithermal gold

deposits, porphyry-style copper±gold

systems and high-grade, mesothermal,

‘Segovia’-style gold vein systems

■ “Ground reconnaissance to date, implies

the potential presence of an as yet poorly

recognised metallogenic domain spanning

1,000s km2, which is only recently surfacing,

in the form of rather spectacular artisanal

gold production.”

Within Orofino’s claims are three currently

producing mines: La Azul, Culoalzado, and the

San Carlos mine near Buena Sena. These mines

are producing artisanal gold using ‘pick and

shovel’ methods employed by local mineros.

Artisanal miners are successfully producing

thousands of ounces of gold using outdated

equipment and methods.

Orofino says “bringing state-of-the-art

equipment and modern metallurgical methods

to the region will result in a higher short term

yield while Orofino explores and develops

these and other targets.

Geology and mineralisationSenderos de Oro; a mixed sequence of

predominantly volcanic rocks of intermediate

to felsic composition, including lithic and

crystal agglomerates and tuffs, and cherty

‘sinters’ and phreatic-style breccias are observed.

These rocks overlie gneissic basement, and

are intruded by plutons of

granodioritic composition.

Structural considerations

indicate the Senderos de Oro

is contained within an east-

west striking normal fault

bound corridor. Three types

of mineralisation are

observed in the Senderos de

Oro concession area:

■ La Azul; silicification and

extensive finely fracture

dispersed Au

mineralisation

■ San Carlos; volcanic-hosted

Au-Ag±Zn vein systems of

broad epithermal affinity

■ Culo Alzado; Cu-Au veinlets and fractures

hosted within plutonic/basement complex

rocks.

Historically one of the wealthiest gold

producing regions in the world, Colombia’s

wealth of gold reserves is virtually unexplored

by modern mining methods. With a stronger

government backed by the wealth and

resources of the United States and strong

foreign direct investment, Colombia is taking

control of the country and providing its

citizens with better organisation,

infrastructure, and security. The result has

been a resurgence of interest in Colombia,

with a particular interest in Colombia’s

abundant mineral resources.

■ Billionaire mogul activity: Carlos Slim, the

world’s wealthiest individual, has expressed

strong interest in investing in Colombia due

to its richness in mineral assets and growing

middle class

■ Foreign Direct Investment (FDI):

Colombian FDI has quadrupled in the past

decade, with 2010’s totals exceeding $10

billion

■ Industry focus: Paralleling the resurgence

of Colombia has been the fall of South

Africa. In the second half of the 20th

century, South Africa went from producing

78% of the world’s gold to now producing

only 10%, Orofino explains. New production

has shifted to areas like Colombia and other

parts of South America. Some experts are

now projecting that Colombia will produce

as much as 3 Moz of gold in 2012, thus

doubling its 2009 production level

■ Current activity: More than 40

international companies are exploring for

gold in Colombia, including major players

such as AngloGold Ashanti

■ Future expectations: Gold mining alone is

expected to attract $5 billion in foreign

investment over the next 10 years. IM

Orofino Gold CorpInsights on the gold boom in Colombia


HIGH PROFILE

Material from La Azul mined byartisanal miners is processed in

these ball mills

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September 201118-21: Mine Closure 2011, Fairmont Chateau,Lake Louise, Lake Louise, Alberta, Canada,www.mineclosure2011.com

21-23: In-pit Crushing & Conveying 2011, BeloHorizonte, Brazil. http://corporate.im-mining.com/imevents.asp

26-29: Exposibram 2011 Belo Horizonte, Brazil,www.ibram.org.br

October 20112-5: COM2011 - Conference of Metallurgists(held in conjunction with World Gold 2011),Hilton Montreal, Québec, [email protected]

3-7: ISEC 2011 - XIX International SolventExtraction Conference, Santiago, Chile,www.isec2011.com

26-29: ExpoMineria 2011 Acapulco, Mexico.VIII National Meeting on Mining Law and IXLatinoamerican and Caribbean Meeting onMining Legislation, Buenos Aires, Argentina.www.derechominerolatin.com.ar

November 20111-3: 8th Fennoscandian Exploration and Miningconference (FEM 2011), Levi, Finland.http://fem.lappi.fi

9-11: Fourth International Seminar on Strategicversus Tactical Approaches in Mining, NovotelLangley, Perth, Australia. www.strategic2011.com

14-17: Flotation 2011, Cape Town, South Africa.www.min-eng.com/conferences

December 2011November 28-December 2: NWMA 2011Annual Meeting and Exposition, John Ascuaga’sNugget Casino Resort, Sparks, NV, USA.www.nwma.org

February 20126-9: Investing in African Mining Indaba, CapeTown, South Africa. www.miningindaba.com

19-22: SME Annual Meeting & Exhibit,Washington State Convention And Trade CenterSeattle, Washington, USA. www.smenet.org

March 20124-7: PDAC 2012, Toronto, Canada. www.pdac.ca

7-9: Mining Vietnam 2012 exhibition, Hanoi.www.allworldexhibitions.com

April 201216-19: 15th International Seminar on Paste andThickening Tailings, Sun City, South Africa.www.saimm.co.za/saimm-events/upcoming-events

16-21: Intermat, Paris, France. www.intermat.fr

24-26: Third International Conference on ShaftDesign and Construction 2012, London, England,United Kingdom. www.iom3.org/events/sdt

September 18-21: Mine Closure 2011Lake Louise, AlbertaCanada.www.mineclosure2011.com

November 14-17:Flotation 2011, CapeTown, South Africa.www.min-eng.com/flotation11

November 1-3: 8th FennoscandianExploration and Mining Conference(FEM 2011), Levi, Finland. http://fem.lappi.fi

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Beyond that, we look at projects indevelopment, publishing regular updatesas they get closer to production. We also detail expansion projects atexisting mines.

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1

ALL dollars are US unless otherwise stated, and all units are metric. The subscription to IM Project News is personal and the

content is copyright. IM Project News should not be passed on to others, either as forwarded emails, as photocopies, or copies in any

other form. Intranet subscription details are available from [email protected]

Contact [email protected] NEWS

Project News (21) June 10, 2007

News from those projects making progress towards production – more every two weeks

A collection of recent starts and progress reports from around the world - updates on

projects around the globe likely to be in the market for equipment and services.

A collection of recent starts and progress reports from around the world - updates on projects around the globe

likely to be in the market for equipment and services. ..................................................................................................1

PREFEASIBILITY.........................................................................................................................................................2

MEXICO - Tyler Resources - COPPER/GOLD....................................................................................................2

PAPUA NEW GUINEA - Harmony Gold - COPPER/GOLD ...............................................................................3

PERU - Strike Resources - IRON ORE.................................................................................................................3

SLOVAKIA - Tournigan Gold - GOLD.................................................................................................................4

ZAMBIA - African Eagle Resources - COPPER ....................................................................................................4

COLUMBIA - Greystar Resources - GOLD/SILVER...........................................................................................4

USA - Galway Resources - MOLYBDENUM/TUNGSTEN.................................................................................5

CANADA - Geodex Minerals - TUNGSTEN/MOLYBDENUM/COPPER .........................................................5

AUSTRALIA - Heron Resources - NICKEL .........................................................................................................6

ARGENTINA - Minera Andes - COPPER..............................................................................................................6

AUSTRALIA - Independence Group - GOLD .......................................................................................................6

RUSSIA – Polymetal - GOLD ................................................................................................................................6

FEASIBILITY STAGE ..................................................................................................................................................7

BURKINA FASO - Goldbelt Resources - GOLD .................................................................................................7

USA - Great Basin Gold - GOLD/SILVER.............................................................................................................7

AUSTRALIA - Moly Mines - MOLYBDENUM....................................................................................................8

CHINA - Golden China Resources - GOLD...........................................................................................................8

AUSTRALIA - Goldstar Resources - GOLD.........................................................................................................8

CANADA - Western Copper Corp’s - GOLD/SILVER .........................................................................................9

AUSTRALIA - Minotaur Exploration/ Helix Resources - GOLD/SILVER ............................................................9

SOUTH AFRICA - Eastern Platinum - PGMs .......................................................................................................9

USA - American Lignite Energy/ Headwaters Energy Services/ Great River Energy/ The North American Coal

Corp – LIGNITE…………………………………………………………………………………………….10

CHILE - Freeport-McMoRan Copper & Gold / Codelco - COPPER.......................................................................10

USA - FutureGen Alliance - COAL.......................................................................................................................10

CANADA - Atlantic Gold - GOLD .......................................................................................................................10

MEXICO - Baja Mining - COPPER/COBALT/ZINC/MANGANESE..............................................................11

GREENLAND - True North Gems - RUBY .........................................................................................................12

CANADA - North American Tungsten Corp - TUNGSTEN ................................................................................12

MONGOLIA - Western Prospector Group - URANIUM.....................................................................................12

ALGERIA - Terramin Australia - ZINC/LEAD....................................................................................................13

INDONESIA - Finders Resources - GOLD/COPPER........................................................................................13

COTE D’IVOIRE - Etruscan Resources - GOLD ...............................................................................................13

SAUDI ARABIA - ADV Group/ Bariq Mining - GOLD/COPPER........................................................................13

BRAZIL - Mirabela Nickel - NICKEL...................................................................................................................14

PERU - Monterrico Metals - COPPER/MOLYBDENUM ...................................................................................14

AUSTRALIA - Gindalbie Metals/ Anshan Iron & Steel Group - IRON ORE........................................................15

CANADA - Canadian Royalties - NICKEL/COPPER/PGM ..............................................................................16

INVEST IN PROJECT NEWS1

ALL dollars are US unless otherwise stated, and all units are metric. The subscription to IM Project News is personal and the

content is copyright. IM Project News should not be passed on to others, either as forwarded emails, as photocopies, or copies in any

other form. Intranet subscription details are available from [email protected]

Contact [email protected] NEWS

Project News (21) June 10, 2007

News from those projects making progress towards production – more every two weeks

A collection of recent starts and progress reports from around the world - updates on

projects around the globe likely to be in the market for equipment and services.

A collection of recent starts and progress reports from around the world - updates on projects around the globe

likely to be in the market for equipment and services. ..................................................................................................1

PREFEASIBILITY.........................................................................................................................................................2

MEXICO - Tyler Resources - COPPER/GOLD....................................................................................................2

PAPUA NEW GUINEA - Harmony Gold - COPPER/GOLD ...............................................................................3

PERU - Strike Resources - IRON ORE.................................................................................................................3

SLOVAKIA - Tournigan Gold - GOLD.................................................................................................................4

ZAMBIA - African Eagle Resources - COPPER ....................................................................................................4

COLUMBIA - Greystar Resources - GOLD/SILVER...........................................................................................4

USA - Galway Resources - MOLYBDENUM/TUNGSTEN.................................................................................5

CANADA - Geodex Minerals - TUNGSTEN/MOLYBDENUM/COPPER .........................................................5

AUSTRALIA - Heron Resources - NICKEL .........................................................................................................6

ARGENTINA - Minera Andes - COPPER..............................................................................................................6

AUSTRALIA - Independence Group - GOLD .......................................................................................................6

RUSSIA – Polymetal - GOLD ................................................................................................................................6

FEASIBILITY STAGE ..................................................................................................................................................7

BURKINA FASO - Goldbelt Resources - GOLD .................................................................................................7

USA - Great Basin Gold - GOLD/SILVER.............................................................................................................7

AUSTRALIA - Moly Mines - MOLYBDENUM....................................................................................................8

CHINA - Golden China Resources - GOLD...........................................................................................................8

AUSTRALIA - Goldstar Resources - GOLD.........................................................................................................8

CANADA - Western Copper Corp’s - GOLD/SILVER .........................................................................................9

AUSTRALIA - Minotaur Exploration/ Helix Resources - GOLD/SILVER ............................................................9

SOUTH AFRICA - Eastern Platinum - PGMs .......................................................................................................9

USA - American Lignite Energy/ Headwaters Energy Services/ Great River Energy/ The North American Coal

Corp – LIGNITE…………………………………………………………………………………………….10

CHILE - Freeport-McMoRan Copper & Gold / Codelco - COPPER.......................................................................10

USA - FutureGen Alliance - COAL.......................................................................................................................10

CANADA - Atlantic Gold - GOLD .......................................................................................................................10

MEXICO - Baja Mining - COPPER/COBALT/ZINC/MANGANESE..............................................................11

GREENLAND - True North Gems - RUBY .........................................................................................................12

CANADA - North American Tungsten Corp - TUNGSTEN ................................................................................12

MONGOLIA - Western Prospector Group - URANIUM.....................................................................................12

ALGERIA - Terramin Australia - ZINC/LEAD....................................................................................................13

INDONESIA - Finders Resources - GOLD/COPPER........................................................................................13

COTE D’IVOIRE - Etruscan Resources - GOLD ...............................................................................................13

SAUDI ARABIA - ADV Group/ Bariq Mining - GOLD/COPPER........................................................................13

BRAZIL - Mirabela Nickel - NICKEL...................................................................................................................14

PERU - Monterrico Metals - COPPER/MOLYBDENUM ...................................................................................14

AUSTRALIA - Gindalbie Metals/ Anshan Iron & Steel Group - IRON ORE........................................................15

CANADA - Canadian Royalties - NICKEL/COPPER/PGM ..............................................................................16

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