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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.
1 2
tk Polysius AG
Graf-Galen-Str. 17 59269 Beckum Germany
Tel.: +49-2525-99-0 Fax: +49-2525-99-2100
polysius@thyssenkrupp.com www.polysius.com
Minerals Report
4/2011
Minerals Report
4/2011
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
m
3
/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 its 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 monitoring
The 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
14 International Mining SEPTEMBER 2011
OPERATION FOCUS United States
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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F E D E R E R P G N I N I F S U O I C E
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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 SMCs mines
include labour (56%), power (5%) and fuel
(4%), mining materials and supplies (27%) and
contracted services (8%).
Stillwater looking ahead
The 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 SMCs 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 Stillwaters 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
16 International Mining SEPTEMBER 2011
OPERATION FOCUS United States
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strategy of consolidating mining activity into
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 Stillwaters 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.
SEPTEMBER 2011 International Mining 17
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The Stillwater mine with the Blitz project area
highlighted in red
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 growth
In 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
18 International Mining SEPTEMBER 2011
OPERATION FOCUS United States
Stillwater
operations map
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Blast fragmentation should be optimised
for material haulage, comminution and
mineral processing. John Chadwick
examines some technologies and the
benefits accruing
FRAGMENTATION
20 International Mining SEPTEMBER 2011
J
ack 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 doesnt mean the
understanding has caught up.
Recent laboratory work by Katsibanis
1
and
computer modelling by Preece
2
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
Mines
3
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
FRAGMENTATION
22 International Mining SEPTEMBER 2011
prevalent than previously thought. Research by
Rodgers and Lee
4
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
The power of
innovative mining
Innovative mining requires innovative thinking. The power of
Atlas Copcos solutions comes from almost 140 years of experience
in developing groundbreaking technology in close cooperation
with our customers. This is what we call sustainable productivity.
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 Africas 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
24 International Mining SEPTEMBER 2011
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 years 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 Mintecs
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, Mintecs
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 can
occur. Well-trained drill operators can
minimise this type of error although
hole deflection errors are more difficult
to eliminate
Hole positioning relative
to damage contour line
caused by sub-drill from
previous hole positions in
blast above
26 International Mining SEPTEMBER 2011
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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 harms 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
28 International Mining SEPTEMBER 2011
Using Carlsons 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 Copcos 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 Confrm
Greater 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
previously closed due to community concerns
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
Complete Reports at www.VariStem.com
The VariStem slows stemming movement, directing blast energy into the ore mass.
- IIy Rock & Noise ControI
- Increased Iragmentation
- Greater Micro-Iractures
- Improved Crusher Output
- Pattern Spread
- Cuttings as Stemming
REDUCE BLASTING & CRUSHING COSTS WITH www.VariStem.com
ROCK ONLY VARI-STEM
h
PLUG
ANIO" VeIocity of Detonation 12,000 ft/sec 12,020 ft/sec
7ime to Stemming Movement 2.3 msec 5.3 msec
Stemming Velocity 1,580 ft/sec 920 ft/sec
*Similar ANFO Velocity of Detonation shows equal ANFO explosive force occured in all tests
PLUS, Upcoming Study on
Less ANFO with Air Decking
Videos and Independent Studies
ANFO
CRUSHED
AGGREGATE
VARI-STEM
PLUG
emmin t S
S o t ime 7
V ANIO"
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FRAGMENTATION
30 International Mining SEPTEMBER 2011
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 Internationals 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
operators 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
Mining More for Less.
The Group
Liebherr Mining Equipment
Newport News Co.
4100 Chestnut Avenue
Newport News, VA 23607
Phone: (757) 245-5251
E-mail: info.lme@liebherr.com
www.liebherr.com
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 dilution
A 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 systems 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 BMTs 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
References
1. 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
32 International Mining SEPTEMBER 2011
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
Contributors consider
regrind mills, physical
separation, new process
development for rare
earths and vanadium,
and much more
PROCESS DESIGN
36 International Mining SEPTEMBER 2011
X
strata Technologys 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 mills
1
.
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 doesnt
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 dont get the tonnes it is easy to
recognise. But for similar design flaws in the
regrind section no one seems to notice.
Whether its a case of you dont know what
you dont 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 70m 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
doesnt 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
Bateman has strong process expertise with similar
complex base metal flowsheets to that of Udokan,
featured in this article, including its successful
operating processes at Kansanshi in Zambia, and,
here, Sepon in Laos. In addition, it has proven
expertise in construction in Central Asia, and is
familiar with design and construction for cold
climates
PROCESS DESIGN
38 International Mining SEPTEMBER 2011
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 doesnt sound
right, it probably isnt 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 recovery
Knelson 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 Knelsons 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 installations
in 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-VGM
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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 separation
Jens-Michael Bergmann of CommodasUltrasort
recently presented a paper
2
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 todays 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
40 International Mining SEPTEMBER 2011
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
SEPTEMBER 2011 International Mining 41
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
wmb-501
Watson-Marlow Bredel Alitea Flexicon MasoSine
info@wmpg.co.uk www.wmpg.co.uk
Tel: +44 (0) 1326 370370
Bredel pumps save
water, chemical and
maintenance costs
Average 71% water savings
*
lowers
chemical costs
Glandless design, no costly valves, seals
or liners to replace
Can easily handle SG4.0 and 80% solids
Metering to
+
-
0.5% accuracy
*
vs centrifugal pump
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 particles 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 sensors differentiation
of carbonates from talc is almost 100%.
Sampling for design data
The 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 Jrgen
Huno Rasmussen says Essas capabilities fit
perfectly into FLSmidths 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
2000s. 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
42 International Mining SEPTEMBER 2011
Available sensor systems
Essa and the importance of sampling
PROCESS DESIGN
44 International Mining SEPTEMBER 2011
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 Essas offering here in
South Africa, we can provide a total, dedicated
sampling solution that embraces local
equipment supply, technical support and
servicing.
Innovative processes
GeoProMining (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 Batemans
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 Russias
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 dor. 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
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 dor.
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. Ausencos Minerals & Metals business
line has been awarded a Create phase contract
to engineer and manage the delivery of Anglo
Americans $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.
Ausencos 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 Ausencos
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 Esprito
Santo state.
Hatch worked on Copper Mountain Mining
Corps 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
46 International Mining SEPTEMBER 2011
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 90m/h. MMS installed
the three original 1.8 m G-Cells at Dorfner in 2005
treating 120m/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
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 earths
Australian 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
Arafuras pre-leach circuit, and calcium
sulphate (gypsum), a potential saleable product
PROCESS DESIGN
48 International Mining SEPTEMBER 2011
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 worldChina, Brazil,
Paraguay, South Africa, Australia, Belgium, Mexico,
USA and Canadaand 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
Arafuras 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 Arafuras 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.
Arafuras Managing Director and CEO, Dr
Steve Ward: The successful completion of this
demonstration program highlights Arafuras
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 worlds 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. Sinhas 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 Sinhas
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
Sinhas patentable
technology in a
commercial setting.
Upon successful due
diligence, RND has an
agreement to purchase
Sinhas 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
DRAs 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
SEPTEMBER 2011 International Mining 49
PROCESS DESIGN
FELUWA Pumpen GmbH | Germany | Phone +49 (0) 6594.10-0 | www.feluwa.com
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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 vanadium
An International Patent Application has been
filed for the new hydrometallurgical process
developed for TNGs 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 TNGs 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
50 International Mining SEPTEMBER 2011
Artists impression of the Arafura rare earths complex
R o c k M o r e
I n t e r n a t i o n a l
Rockmore International
Wilsonville, Oregon USA
Tel (503) 682-1001
info@rockmore-intl.com
Judenburg, Austria
Tel +43 3572-86300
austria@rockmore-intl.com
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.
Drill More
www.rockmore-intl.com
Uniting
technology,
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For over a century, the mining industry has relied on FLSmidth
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es.
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.
TNGs 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
Australias 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 uranium
Cameco 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. Camecos 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
52 International Mining SEPTEMBER 2011
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
PROCESS DESIGN
SEPTEMBER 2011 International Mining 53
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 designs
DRA 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 Alrosas 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
mines 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. DRAs 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
Shears 12 to 18 month business plan. IM
References
1.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
Separation11, Falmouth, England, June 2011.
C
rucial 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 ABBs 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
Baldors strong presence while at the same
time facilitating the sale of Baldors products
globally through ABBs worldwide distribution
network. Baldors 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 Osiskos
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
mines 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. ABBs 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
Powering almost all fixed capital equipment in mining and
mineral processing, electromechanical and hydraulic drives
along with electric motors are at the heart of site efficiency,
reports Paul Moore
DRIVES AND CONTROLS
54 International Mining SEPTEMBER 2011
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
Newmonts 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 worlds 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 drives 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
SEPTEMBER 2011 International Mining 55
Computational Fluid Dynamics (CFD), enhancing
the drives thermal dissipation qualities.
As of January 2011 the worlds leading
supplier of heavy duty hydraulic variable speed
drives, Hgglunds 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 Hgglunds brand is still
used on the tough and reliable large hydraulic
Hgglunds system solutions that now are a
part of the Bosch Rexroth portfolio. Hgglunds
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 Hgglunds 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-Pacifics 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 Golds 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 groups drive solutions have
brought new cost-efficiencies to some of the
worlds biggest mining operations, including
Freeport Grasberg in Indonesia, Chiles Minera
Escondida, Perus Antamina and Canadas
Syncrude and Highland Valley Copper. Synergy
DRIVES AND CONTROLS
56 International Mining SEPTEMBER 2011
The renowned range of hydraulic drives from
Hagglunds are now part of Bosch Rexroth but the
brand has been retained
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
applications 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 Coppers
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
SEPTEMBER 2011 International Mining 57
DRIVES AND CONTROLS
X Series industrial gear unit from SEW Eurodrive in factory
L
ourens 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 vehicles 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 interface
technology in the mining industry
is poised to increase exponentially,
according to Booyco Electronics Managing
Director, Anton Lourens
The CWS800 Plus incorporates both UHF RFID and
VLF capabilities
Anton Lourens, Managing Director of Booyco Electronics
58 International Mining SEPTEMBER 2011
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. Im 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
weve 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 companys 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.
Booycos 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 miners tag is located or if there is no
tag in the vicinity. IM
SEPTEMBER 2011 International Mining 59
HIGH PROFILE
The technology is increasingly
being used by the minerals
industry to separate, purify and
concentrate metals such as
nickel, cobalt, copper, zinc,
uranium and rare earths.
John Chadwick looks at some
of the latest developments
SX/EW
60 International Mining SEPTEMBER 2011
G
ustavo Diaz and colleagues
1
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 leachingSX
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 advances
Cytec 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.
Cytecs 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
SEPTEMBER 2011 International Mining 61
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 Cytecs 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