Scavenging Flotation Tailings using a Continuous Centrifugal Gravity

Concentrator

by

Hassan Ghaffari

B.A.Sc. & M.A.Sc. Department of Mining Engineering, Technical Faculty

Tehran University, Iran, 1990

A THESIS SUBMITTED IN PARTIAL FULFILMENT OF

T H E REQUIREMENTS FOR T H E D E G R E E OF

Master of Applied Science

in

T H E F A C U L T Y OF GRADUATE STUDIES

DEPARTMENT OF MINING ENGINEERIG

T H E UNIVERSITY OF BRITISH COLUMBIA

We accepted this thesis as conforming

to the required standard

T H E UNIVERSITY OF BRITISH COLUMBIA

August 2004

© Hassan Ghaffari, 2004

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 11

Summary

A study was conducted to evaluate the Knelson Continuous Variable Discharge ( C V D )

concentrator as a scavenger for coarse middling particles from flotation tailings. The

goal was to recover a product of suitable grade for recycling to the grinding circuit to

improve liberation and aid subsequent recovery in flotation. Such a hybrid flotation-

gravity circuit would result in improved metal recoveries, product grades and potentially

lead to lower grinding costs.

Froth flotation, a physico-chemical process, is the most commonly used process

for treating base metal sulphides. Since separation is achieved on the basis of the surface

hydrophobicity, mixed-phased particles or middlings are not efficiently treated by froth

flotation. The coarser fractions in flotation feeds contain heavy and valuable liberated

and non liberated minerals that cannot be floated efficiently. There is a top limit for

particle size floatability which varies for different ores. The specific gravity of these

particles plays an important role which causes decreasing the flotation performance.

This study is based on the premise that the middling particles in tailings can be

recovered efficiently by size enhanced density separation. The ability of gravity

separators to treat fine particles has been limited by the lack of particle inertia relative to

the surface drag forces. Particle inertia can be enhanced by the application of a

centrifugal field. The Knelson C V D is a relatively new technology as a continuous

centrifugal concentrator that recovers particles based primarily on density but also on

size.

Tailing samples from two mines were subjected to characterization, batch gravity

and pilot scale C V D testing. Table 1 shows the specifications of the analyzed samples.
 Ill

Table 1. Specification of the Analyzed Samples

Grade
Mine Sample
Au (ppm) S% Ni%
Low Grade Tails (LGT) l.l 1.0 N/A
Eskay Creek (Barrick)
High Grade Tails (HGT) 1.9 1.2 N/A
Rougher-Scavenger Tails (AS-4) <1 3.0 0.2
Birchtree (INCO Thompson)
Cleaner-Scavenger Tails (SC-4) <1 4.2 0.5

The sample characterization of the both Eskay Creek and INCO Thompson
samples indicated that there is potential to upgrade gold and nickel in the coarsest
fractions. A preliminary assessment of gold and nickel recovery was obtained using a
batch Knelson concentrator and the results were similar to those predicted from the
characterization results.

Based on the characterization and batch gravity tests, there appeared to be a

greater opportunity to recover a recyclable product from the L G T and the SC-4, samples
than the HGT and AS-4 samples. They were therefore selected for pilot scale tests using
the C V D 6 separator. The objective was to produce a concentrate with a low mass yield
and high gold and nickel upgrade ratios. Products from these tests were subjected to
size/assay analysis.

The results for Eskay Creek sample show that the gold distributions are
significantly higher than sulphur and arsenic distributions, which indicates that free gold
or gold associated with poorly floated minerals is being recovered. The best result was
obtained from Test 3 in which 28% of the gold was recovered in a concentrate grading
12.5 ppm A u representing 3.3% of the feed mass. This represents a gold upgrade ratio of
8.7.

The results for INCO Thompson show that the gold distributions are significantly
higher than nickel and sulphur distributions, which indicates that free gold is being
recovered. The best result was obtained from Test 3 in which 12.9% of the nickel was
recovered in a concentrate grading 0.85% N i representing 6.7% of the feed mass. It is
 iv

worth noting that the Mg grade is decreased dramatically in the concentrate products. The
Mg distribution in concentrate was just 1.7%. This is a good indication that the
centrifugal concentrator can also remove the magnesium bearing minerals such as talc.
In the case of gold, remarkable results were produced and the metallurgical balances
showed gold recoveries ranging from 12.6 to 67.3% and gold grades from 1.4 to 10.0
ppm.

Size partition curves were obtained for all tests, which demonstrated that the CVD
operates as a size classifier as well as a density separator (size enhanced density
separation). For the Eskay sample (Tests 3 and 6) and the INCO sample (Test 7), the cut
size was about 300 microns.

In conclusion, the pilot scale testing indicated that the CVD was effective at
recovering gold, gold bearing sulfides and nickel bearing sulfides from the coarse
particles of the flotation tailings and also at de-sliming. The nickel and gold recovered
were primarily in the coarse size fractions, which would likely contain middling particles
(sulfides + silicates). The results showed that the CVD is capable of rejecting the Mg
bearing minerals as well. These results support the application of continuous centrifugal
concentrators into hybrid flotation-gravity circuits that could lead to improved
metallurgical performance.

Plant trials testing are recommended to confirm the results and potential benefits.
 V

TABLE OF CONTENTS

Summary ii

Table of Contents v

List of Figures vii

List of Tables x

Acknowledgements xiii

CHAPTER 1 Introduction 1

1.1. Background 1
1.2. Methodology 2

CHAPTER 2 Literature Review 4

2.1. Introduction 4
2.2. Relationship between Mineral Recovery and Particle Size 4
2.3. Enhanced Gravity Separation Process Technologies 7
2.4. Continuous Centrifugal Gravity Concentrators 8
2.4.1. Types 8
2.4.2. Applications 14
2.5. Conclusion 22

CHAPTER 3 Experimental Program 23

3.1. Analyzed Samples 23

3.1.1 Eskay Creek 23
3.1.2. INCO Thompson 24
3.2. Sample Characterization 25
3.2.1. Sample Preparation 25
3.2.2. Size/Assay Analysis 26
3.2.3. Mineralogical characterization 26
3.2.4. Density Fractionation 26
3.3. Batch Tests 28
3.4. Pilot Scale Tests 29
3.4.1. Products Characterization 30
3.4.2. Concentrate Density Fractionation Tests 31
3.4.3. Flotation Test and Proposed Flowsheet 31

CHAPTER 4 Results and Discussion 32

4.1. Eskay Creek Samples 32

4.1.1. Introduction 32
 vi

4.1.2. Results and Discussion 33

4.1.3. Conclusion and Recommendation 47
4.2. I N C O Thompson sample 49
4.2.1. Introduction 49
4.2.2. Results and Discussion 50
4.2.3. Conclusion and Recommendation 70

CHAPTER 5 Conclusions and Recommendations 73

5.1. Conclusions 73

5.2. Recommendations 75

REFERENCES 76

APPENDICES 81
Appendix I - Eskay Creek 81
Appendix I A Sample Characterization 82
Appendix IB Batch Tests 86
Appendix IC Pilot Scale Test Conditions and Results 87
Appendix ID Mineralogical Analysis 101
Appendix IE Flotation Test 104

Appendix II - I N C O Thompson 105

Appendix IIA Sample Characterization 106
Appendix IIB Batch Tests 117
Appendix IIC Pilot Scale Test Conditions and Results 118
Appendix IID Density Fractionation Test Results 132
Appendix H E Flotation Test 141
 List of Figures

Figure2.1 Dependence of flotation efficiency on particle

size for several ores 6

Figure2.2 Typical grinding throughput, product size and flotation

Recovery relationship for a base metal concentrator 7

Figure2.3 Continuous Centrifugal Gravity Concentrators 9

Figure 3.1 Eskay Creek Flotation Circuit Sample Point 23

Figure 3.2 Birchtree Flotation Circuit Sample Points 24

Figure 3.3 Sampling procedure of wet tailing samples 25

Figure 3.4 Batch Knelson test procedure 28

Figure 4.1 A u Grade Distributions, L G T & H G T 34

Figure 4.2 S Grade Distributions, L G T & H G T 34

Figure 4.3 A u Grade Distributions in Concentrate and

Tailing of Test 3, L G T 38

Figure 4.4 S Grade Distributions in Concentrate and

Tailing of Test 3, L G T 39

Figure 4.5 Mass Y i e l d and A u Recovery versus Pinch

Valve Closed Time, L G T 40

Figure 4.6 A u Grade/Recovery versus Mass Y i e l d , L G T 41

Figure 4.7 A u Upgrade Ratio/Recovery versus Mass Y i e l d , L G T 41

Figure 4.8 Size Separation Partition Curves, L G T 42

Figure 4.9 A u Recovery versus Size, L G T 43

Figure 4.10 S Recovery versus Size, L G T 44

Figure 4.11 A u Recovery versus S Recovery, L G T 44

Figure 4.12 Proposed Flowsheet, Eskay Creek 46

Figure 4.13 N i Grade for each Size Fraction, SC-4 & A S - 4 51

 Vlll

Figure 4.14 M g Grade for each Size Fraction, S C - 4 & A S - 4 52

Figure 4.15 S Grade for each Size Fraction, S C - 4 & A S - 4 52

Figure 4.16 N i Grade for each Size Fraction of Concentrate

& Tailing of Test 3, S C - 4 56

Figure 4.17 M g Grade for each Size Fraction of Concentrate

& Tailing of Test 3, S C - 4 57

Figure 4.18 S Grade for each Size Fraction of Concentrate

& Tailing of Test 3, S C - 4 57

Figure 4.19 A u Grade for each Size Fraction of Concentrate

& Tailing o f Test 3, S C - 4 58

Figure 4.20 Mass Pull, N i Grade/Recovery versus

Pinch Valve Closed Time, S C - 4 59

Figure 4.21 N i Upgrade and M g Downgrade Ratios versus

Mass Pull, S C - 4 60

Figure 4.22 N i Grade/Recovery versus Cone. Mass Pull 60

Figure 4.23 Size Separation Partition Curves, S C - 4 62

Figure 4.24 Partition Coefficient Curve for +50# Size Fraction 63

Figure 4.25 Partition Coefficient Curve for -50+100# Size Fraction 64

Figure 4.26 N i Recovery for +50# Size Fraction 64

Figure 4.27 N i Recovery for -50+100# Size Fraction 65

Figure 4.28 M g Recovery for -100+140# Size Fraction 65

Figure 4.29 M g Recovery for-140+200# Size Fraction 66

Figure 4.30 S Recovery for +50# Size Fraction 67

Figure 4.31 Fe Recovery for +50# Size Fraction 67

Figure 4.32 Proposed Flowsheet, Inco Thompson 69

Figure A . 1.1 Particle Size Distribution, L G T 82

Figure A . 1.2 Particle Size Distribution, H G T 83

Figure C.6.1 Size Separation Partition Curves, L G T 101

Figure C.6.2 A u Recovery versus Size, L G T 101

Figure C.6.3 S Recovery versus Size, L G T 102

Figure C.6.4 A u Recovery versus S Recovery, L G T 102

Figure C.6.5 Size Separation Partition Curves, SC-4 138

Figure C.6.6 Partition Coefficient Curves for each Size Fraction

(Mass Y i e l d versus Density) 138

Figure C.6.7 N i Recovery for each Size Fraction

(Ni Recovery versus Density) 139

Figure C.6.8 M g Recovery for each Size Fraction

( M g Recovery versus Density) 139

Figure C.6.9 S Recovery for each Size Fraction

(S Recovery versus Density) 140

Figure C.6.10 Fe Recovery for each Size Fraction

(Fe Recovery versus Density) 140
 List of Tables

Table 1 Specification of the Analyzed Samples iii

Table 2.1 Continuous Centrifugal Gravity Concentrators

Technologies and Applications 14

Table 2.2 Falcon Model C Operating Applications 15

Table 2.3 The Kelsey Jig Operating Applications 17

Table 2.4 Tested applications for the Altair Centrifugal Jig 19

Table 2.5 The Knelson C V D Tested and Operating Applications 21

Table 3.1 Tests Operating Conditions, L G T 29

Table 3.2 Tests Operating Conditions, S C - 4 30

Table 4.1 Ore Zones Assays (1998), Eskay Creek 32

Table 4.2 Tailing Samples and Ore Types Specifications

(Eskay Creek Plant, 2003) 33

Table 4.3 Samples Characterization Results, L G T & H G T 35

Table 4.4 Degree of Liberation Results, L G T 36

Table 4.5 Batch Test Results, L G T & H G T 36

Table 4.6 Pilot Scale Test Results, L G T 37

Table 4.7 Flotation Test Results, L G T 45

Table 4.8 Birchtree Ore Mineralogy 49

Table 4.9 Birchtree Ore, Concentrate and Tailing Grades 49

Table 4.10 Samples Characterization Results, S C - 4 & A S - 4 53

Table 4.11 Batch Test Results, S C - 4 & A S - 4 54

Table 4.12 Pilot Scale Test Results, S C - 4 55

Table 4.13 Flotation Test Results, S C - 4 68

 XI

Table A . 1.1 L G T Size Analysis 82

Table A . 1.2 H G T Size Analysis 83

Table A . 1.3 Specification of L o w Grade Tails ( L G T ) and

M i l l Performance (Eskay Creek Plant Results, 2003) 84

Table A . 1.4 Specification of High Grade Tails ( H G T ) and

M i l l Performance (Eskay Creek Plant Results, 2003) 84

Table A.2.1 Size/assay Analysis, L G T 85

Table A.2.2 Size/assay Analysis, H G T 85

Tables C.3.1 to C.3.6 C V D Test Products, Size Analysis and P N , L G T 89

Tables C.4.1 to C.4.6 C V D Test Products, Concentrate Size/

Assay Analysis, L G T 92
Tables C.5.1 to C.5.6 C V D Test Products, Tailings Size/
Assay Analysis, L G T . 9 5

Tables C.6.1 to C.6.6 C V D Test Products, Size/ Assay

Analysis and Mass Y i e l d , L G T 98

Table A.3.1 Magnetic Particles Distribution, S C - 4 109

Table A.3.2 Magnetic Particles Distribution, A S - 4 110

Table A.3.3 Magnetic Separation Products Size/Assay Results, S C - 4 111

Table A.3.3 Magnetic Separation Products Size/Assay Results, A S - 4 112

Table A.4.1 Magstream Products, S C - 4 Head Sample 113

Table A.4.2 Magstream Products, A S - 4 Head Sample 115

Table B . l Knelson Batch Test Results S C - 4 117

Table B.2 Knelson Batch Test Results A S - 4 117

Table C. 1 C V D Test Conditions S C - 4 118

Table C.2 Metallurgical Balances S C - 4 119

Tables C.3.1 to C.3.8 C V D Test Products, Size Analysis and P N , S C - 4 120

Tables C.4.1 to C.4.7 C V D Test Products, Concentrate Size/
Assay Analysis, S C - 4

Tables C.5.1 to C.5.7 C V D Test Products, Tailings Size/

Assay Analysis, S C - 4

Table D . l Magstream Products, C V D Test 7 Concentrate, S C - 4

Tables D.2.1 to D.2.8 Partition Coefficient Numbers and

Metal Recoveries, S C - 4
 xiii

Acknowledgements

The work presented here was funded by:

- Natural Sciences and Engineering Research Council of Canada (IPS
Program)
- Knelson Concentrators
The sampling and shipment was done by:
- INCO Manitoba Division, Birchtree Mine
- Barrick Gold Corp., Eskay Creek Mine
The work was directed and supervised by:
Dr. Bern Klein
The advice and support of all is greatly acknowledged.
CHAPTER 1 Introduction

1.1. Background

Froth flotation is the main industrial process that is used to recover metal minerals from

deposits. Metal recoveries from froth flotation range typically from 7 0 % to 95%. Metal

losses are primarily in either the coarsest or finest particles. The coarsest fractions

contain middling particles that have insufficient metal minerals content to float or are too

coarse to be recovered efficiently by flotation.

Continuous centrifugal concentrators are a relatively new technology that evolved

from batch centrifugal concentrators that are used primarily for recovering gold particles.

The main continuous centrifugal gravity concentrators that are commercially available

include Knelson Continuous Variable Discharge ( C V D ) , Falcon M o d e l C , Kelsey Jig,

Altair Centrifugal Jig and M o z l e y Multi-Gravity Separator ( M G S ) .

The C V D has been shown to recover particles by density, particularly at coarse

sizes. Therefore, a study was conducted to assess its ability to recover coarse middlings

into a product suitable for recycling to grinding. It is proposed that this hybrid flotation-

gravity concentration circuit could lead to improved metal recoveries, higher concentrate

grades and lower grinding requirements.

The specific objectives of this study are as follows:

• T o evaluate the C V D concentrator as a scavenger for coarse middling

particles from flotation tailings

• T o identify operating conditions with respect to the objective of achieving

high metal recoveries in a small mass yield.

• T o assess size/density classification in C V D

 2

To achieve these objectives, samples of flotation tailings from the Barrick Eskay

Creek and the I N C O Thompson beneficiation plants were subjected to batch and pilot

scale tests.

1.2. Methodology

The Eskay Creek samples are referred to as H i g h Grade Tails ( H G T , 1.9 ppm A u ) and

L o w Grade Tails ( L G T , 1.1 ppm A u ) . The Thompson samples are Scavenger-Cleaner

Tails (SC-4, 0.5% Ni) and Rougher-Scavenger Tails ( A S - 4 , 0.2% N i ) from processing

Birchtree ore. The test program for each sample was directed into three stages:

1. Sample characterization

2. Batch gravity testing

3. Continuous pilot scale testing

In the first stage, the samples were characterized to identify metal losses from

flotation and to assess potential recoveries associated with coarse middling particles. For

stage two, testing was performed using a batch Knelson concentrator to obtain a

preliminary assessment of metal recovery.

Based on the characterization and batch testing, continuous pilot testing was

performed to assess metallurgical performance.

The thesis outline is as follows:

• Chapter 1 is an introduction to research, objectives and methodology

• Chapter 2 reviews the literature and describes continuous centrifugal

gravity concentrator technologies.

• Chapter 3 describes the experimental program including the

characterization procedures and test conditions.

• Chapter 4 presents and discusses the test results

Chapter 5 comprises of conclusions and recommendations
 4

CHAPTER 2 Literature Review

2.1. Introduction

Froth flotation is a physico-chemical process and is the main industrial process that is

used to recover base metal minerals from ore. It has been shown that froth flotation is not

effective at recovering coarse particles that are either middling particles that have

insufficient metal mineral content or can not be carried to the froth due to shear forces

between the bubbles and particles. Since separation is achieved on the basis of surface

hydrophobocity, mixed phase particles or middlings are not efficiently treated by froth

flotation (Honaker et al., 1995).

M i d d l i n g particles contain grains o f the desired mineral and grains o f other

minerals. If many middling particles report to the concentrate, the metal grade w i l l

decrease and, if these particles report to the tailing, the metal recovery w i l l decrease. In

order to achieve a reasonable mineral recovery, the grinding and flotation circuits should

be examined simultaneously which requires detailed process mineralogy to characterize

the ore and products.

2.2. Relationship between mineral recovery and particle size

The efficiency of froth flotation in mineral processing depends on the size of the mineral,

gangue and middling particles. The dependence of flotation on particle size for several

ores is shown in Figure 2.1 (Reinson data are from Goodman et al., 1977 and Broken H i l l

South data are from Cameron et al., 1965). The plots indicate that the mineral recovery

has a maximum value over a range o f particle size with a decline at the coarse and fine

ends. According to Figure 2.1, recoveries begin to decrease for particles coarser than

about 100 u m which varies depending on the specification of the operation.

Improvements within the flotation circuit itself have the potential to shift the

entire recovery curve (Figure 2.1) to higher values and extend the recovery over a wider
 5

size range. The other opportunity is to seek to optimize the grinding circuit to place more

of the product in the size range of maximum recovery. This is not an easy task (Napier-

M u n n et al., 1999).

A p p l y i n g lower grinding throughput or a finer hydrocyclone cut-size can reduce

the coarse material fractions in the grinding circuit but on the other hand it increases the

undesirable fine material fractions. Multi-stage cycloning has been tested as one

approach to improving the overall distribution of flotation feed.

 6

Figure 2.1. Dependence of flotation efficiency on particle size for several ores
(after L y n c h et al., 1981)

Generally, the coarser the material in flotation feed the lower is mineral recovery

in the concentrate. Mineral recovery is related to the proportion of the coarse material in

the feed. Figure 2.2 shows the relationship between grinding throughput, product size,

and flotation recovery. The grinding circuit regimes determine the flotation feed size;

with increasing the grinding circuit throughput, the percentage of coarse fraction

increases. A s Figures 2.1 and 2.2 represent, with increasing the coarse fraction in
 7

flotation feed, the metal recovery decreases significantly. T o determine the best

condition for throughput, grind and recovery is not simple.

% coarse fraction
Grinding throughput (tph)
In Dotation feed

Figure 2.2. Typical grinding throughput, product size and flotation recovery relationship
for a base metal concentrator (Napier-Munn, 1999)

According to Figure 2.1, recoveries also begin to decrease for particles finer than

about 20 urn. In order to reduce the generation of these ultrafine particles and metal

losses, coarse grinding and flotation followed by size enhanced gravity separation may be

an alternative to common processes. Scavenging flotation tailings using a continuous

centrifugal gravity separator may recover the heavy coarser particles. The goal is to

recover a product of suitable grade for recycling to the grinding-flotation circuit to

improve liberation and aid subsequent recovery i n flotation. If good recoveries can be

achieved using the C V D as a scavenger, there is opportunity to use a coarser grind to

reduce the power requirements and associated costs. This w i l l also reduce the amount of

fine (-20 um) material that floats poorly.

2.3. Enhanced Gravity Separation Process Technologies

During the past decade, several enhanced gravity concentrators have evolved to

commercial scale as a result of the need to achieve efficient separation of finer particles.

The initial interest in enhanced gravity separators was for the recovery of fine gold,

which represents a low product flow rate application whereby the concentrated gold

stream represents 1 % or less o f the total feed. A s a result, semi-batch units are the most
 8

common enhanced gravity separator used in gold applications, in which, the feed and

overflow streams are continuous while the gold particles are collected against the wall of

a spinning bowl and periodically flushed to a concentrate launder. However, due to the

need to treat materials having high-density particle contents greater than 1%, fully

continuous units have been developed (Mohanty et al., 1999).

Extending the particle size limits of devices such as spirals, improved

metallurgical performance over non-sulphide mineral flotation and pre-concentration are

incentives to develop the centrifugal gravity concentrators further. Several enhanced

centrifugal gravity separators including the batch semi-continuous and continuous

concentrators have been designed and commercialized during the past decade for treating

the fine particles. The ability to remove concentrate continuously extends the application

of centrifugal concentrators requiring larger mass pulls, such as for the recovery of gold

bearing and metal sulphide minerals.

The main reasons for selecting continuous technology are as follows:

• When target metal or mineral is present in percentage rather than ppm

concentrations, the fluidized rings become loaded with heavy mineral or metal

very quickly.

• Batch technologies must shut down to remove concentrate

• They are ideal for a wide range of mass yield application

(Simpson, 2003)

2.4. Continuous Centrifugal Gravity Concentrators

2.4.1. Types

The main enhanced gravity concentrators that operate continuously and are commercially

available include the Falcon M o d e l C , the M o z l e y Multi-Gravity Concentrator ( M G S ) ,

the Kelsey J i g , the Altair Centrifugal J i g , and the Knelson Continuous Variable

Discharge (Knelson C V D ) . Figure 2.3 shows photos of Falcon C and Knelson C V D .

 9

Falcon Model C Knelson CVD

Figure 2.3. Continuous Centrifugal Gravity Concentrators

2.4.1.1. Falcon M o d e l C

The Falcon M o d e l C is a continuous centrifugal separator. The operation is similar to

that of the M o d e l S B (Batch concentrator), except the bowl shape is tapered facilitating

upward flow along the wall. N o feed interruptions are required and the high density

product is de-slimed and partially de-watered.

In this machine, feed enters through the top and travels down to the bottom of a

rotational bowl where centrifugal acceleration forces particles to the wall. The particles

travel up the bowl section where heavy particles displace light particles along the bowl

wall. A t the top of the bowl is a concentrate collection ring with valves positioned

radially at the back of the ring. The valve aperture size is controllable and remains open.

The tailing material forms the innermost layer on the bowl wall and overflows the bowl

to a tailings launder (Falcon, 1999; Silva et al., 1999).

The maximum feed solid content is 4 5 % ; however unlike the other continuous

concentrators that are described, no fluidization/hutch water is required. This machine

has only two operating variables; bowl speed and valve aperture size. Advantages of the
 10

Falcon M o d e l C compared to other continuous centrifugal concentrators are its high

capacity, its relative mechanical simplicity and its ability to process particles up to 1 mm.

2.4.1.2. Kelsey Jig

The Kelsey Centrifugal Jig is an enhanced gravity separation device, which has the

ability to increase the apparent gravitational field acting on fine feed particles across a

bed of ragging material. Utilizing the same basic parameters as a conventional jig, as

well as the enhancement of the gravitational field (achieved by spinning the jigging

mechanism), enables very efficient separation of both fine minerals and minerals with a

relatively small specific gravity differential (Richards et al., 2004).

The Kelsey Jig is fed down a fixed central pipe and feed is distributed upward

over the surface of a bed of ragging material, which is supported by a cylindrical shaped

screen. The screen is spun with the rotor and pressurized water is introduced into a series

of hutches behind the screen. This water is pulsed through the ragging particles

facilitating stratification. The denser particles pass through the internal screen to

concentrate hutch and then through spigots to a concentrate launder, while the lighter

mineral particles are discharged over a ragging retention ring into a tailing launder. The

three controllable variables in the Kelsey Jig are bowl speed, ragging size/density and

pulsation stroke length (Geologies, 1999; Silva et al., 1998; W y s l o u z i l , 1990)

The Kelsey Jig combines centrifugal acceleration (up to 50 G ) with jigging action.

Changes in the design have improved its mechanical reliability. The development of the

J1800, with a capacity to 65 tph, has extended the potential applications. Feed must be

screened to remove oversize (+50 mesh). Feed slurry solid contents of up to 6 5 % can be

processed; however pulse water dilutes the slurry to less than 50% solids.

The models available include:

• J200 K C J - laboratory test unit, with nominal capacity of 15-100 kg/h solids
 11

• J1300 M k l l K C J - smallest commercial unit, with nominal capacity of 2-30 t/h

solids

• J1800 K C J - largest commercial unit, with nominal capacity of 5-60 t/h solids

(Roche M i n i n g , 2004)

2.4.1.3. Altair Centrifugal Jig

The Altair Centrifugal Jig is an enhanced gravity separator that provides relatively

efficient separation on +25 u m size fractions (fine coal separation). This Centrifugal Jig

also combines.centrifugal acceleration (35 G ) with jigging. The Altair Jig consists of a

rotating bowl, which is placed inside a static casing having separate launders for

collecting the concentrate and tailing samples. The rotating bowl contains a cylindrical

screen with a lip, whose height can be adjusted to vary the natural depth of the ragging

bed. The ragging material remains in a vertical position on the screen due to the rotation

of the bowl.

In The Altair Jig, feed (slurry) which is introduced from the top at the centre of

the rotating bowl is distributed into the ragging bed on the screen by the diffuser plate

placed under the feed inlet. Pressurized water is injected under the bed periodically

through the four pulse blocks to cause alternating dilation and contraction of the ragging

and feed bed. This action, coupled with the high centrifugal force generated from the

rotation of the bowl, provides the jigging mechanisms and kinetics required to achieve

gravity-based separation for fine and ultrafine particles.

In case of fine coal separation, the tailings, which contain particles having a

relatively high density, settle through the ragging bed and screen into the hutch and

reports to the tailings launder through the discharge ports. O n the other hand, the clean

coal particles, which have a relatively low density do not have sufficient retention time to

settle through the screen, and, thus, report to the concentrate launder. Based on fine coal

separation testwork (Pittsburg N o . 8 seam coal sample), the identified key operating
 12

parameters were the drum speed, pulse water pressure, ragging volume and volumetric
feed flow rate (Mohanty et al, 1999).

2.4.1.4. Mozley Multi Gravity Separator (MGS)

The Mozley Multi Gravity Separator (MGS) was developed by Richard Mozley Ltd. to
improve the economic recovery of very fine heavy minerals and utilizes centrifugal
action to increase the gravitational force acting on mineral particles. The M G S combines
centrifugal acceleration (8 to 22 G) with the motion of a shaking table to achieve
separation. The M G S is effective at recovering particle sizes ranging from 300 Lim to 10
|im and can produce high enrichment ratios even at fine particle sizes.

The principle of the M G S may be visualized as rolling the horizontal surface of a

conventional shaking table into a drum and rotating it. The unit consists of two identical
drums rotating in opposite directions to maintain mechanical equilibrium. Feed to both
drums is gravity fed from a splitter box arrangement. Both the wash water and feed are
directed onto separate accelerator rings located within the drum which reduces the
velocity and prevents disturbance of the particle bed.
Feed enters the drum about half way and wash water is supplied by a perforated
ring near the open end of the drum. The drum motion causes segregation of high density
particles through to the inner wall of the drum. The shaking motion disturbs the bed to
allow high density particles to migrate to the wall. Scrapers moving slightly faster than
the drum transport the concentrate counter to the flow toward the smaller end of the drum
to a launder. The low density particles flow with water towards the larger end o f the
drum to a tailing launder.

Parameters affecting M G S performance are feed pulp density, drum speed,

throughput, wash water flow rate, angle of tilt and shake intensity. The main short term
control variable is the wash water flow rate (Turner et al., 1993).
 13

2.4.1.5. Knelson C V D

The Knelson C V D is a continuous variable discharge concentrator for high mass yield
applications. The machine operates on the same principle as the Knelson batch
concentrators but draws the concentrate through pneumatically actuated pinch valves
located radially in the rings.

In recent gravity separation developments, more difficult sulphide associated gold

ores can be processed using the Knelson C V D . The C V D can capture both the fine free
particles of gold and the gold associated sulphide particles. The C V D can be placed in
various locations of the gold milling circuit. Specific sites may warrant a different
placement as determined by mineralogy and site layout (Knelson, 2003).

In the C V D , feed is introduced to the top of the machine through a feed tube into
the centre of the bowl section. The feed hits a plate at the bottom of the bowl section and
is dispersed radially to the bowl wall. The particles are accelerated to a g-forced defined
by the bowl speed and travel up the wall towards the ring. The upgraded slurry enters the
separation ring where fluidization water, supplied through holes in the ring wall, is added
to fluidize the bed o f packed particles. Concentrate is extracted through pinch valves at
the back of the ring. The pinch valve open and closed time can be adjusted. The light
particles overflow the bowl into a tailings launder (Knelson, 2001).

The C V D has four main operating variables: bowl speed (g-force), fluidization
water flow rate, pinch valve open time and pinch valve closed time. These variables all
interact, meaning, for example that the best bowl speed at one set of pinch valve
open/close times may not be the best at another set of times. Therefore, the appropriate
selection of variable levels is a complicated problem that requires a systematic approach
(Mcleavy et a l , 2001).
 14

2.4.2. A p p l i c a t i o n s

There have been significant innovative advances for all types of gravity concentration

equipment. The best application for these separators needs more study and is affected by

unit capacity, inability to handle coarse particles, water requirements and metallurgical

performance. Despite the present limitations, further development of continuous

centrifugal concentrators has the potential to significantly change mineral processing

plant flowsheet design. Applications and operating parameters of the several continuous

centrifugal concentrators are listed in Table 2.1.

T a b l e 2.1. Continuous Centrifugal Gravity Concentrators Technologies and Applications

Max. Mass G-
Solid Particle Size
Technology Capacity Yield Force Application
(%) (mm)
(t/h) (%) Range
Primary recovery",
Knelson CVD 100 25-55 0.1-40 -1 +0.025 60-120 Pre-concentration*,
Scavenging"
Primary recovery,
Falcon Model C 100 25-45 0.1-50 -1 +0.025 50-300 Pre-concentration*,
Scavenging*
— 1

Primary recovery ,
Altair Centrifugal
18 25-40 1.5-100 -0.3+0.025 35 Secondary treatment,
Jig 30-160 Unit
Scavenging", Pre-
concentration*
Primary recovery*,
Kelsey Jig 65 25-65 Secondary treatment,
10 -0.3+0.010 50
Scavenging, Pre-
concentration*,
Mozley C902 4 Primary recovery,
Multi- MeGaSep 30 1-10 -0.3+0.010 8-22 Pre-concentration,
Gravity 60 Secondary treatment,
(Coal)

* Tested Application
** Potential Application
 15

2.4.2.1. Falcon M o d e l C

The Falcon M o d e l C , with a capacity of up to 100 tph has potential applications for pre-

concentration of heavy minerals and scavenging plant tailings. This machine is suitable

for a wide range of minerals and fine feed applications requiring low to high weight

recoveries (mass yield up to 50%) such as primary recovery of fine gold, fine coal

cleaning, and fine iron ore and tin recovery. Applications of the several Falcon

concentrators are listed in Table 2.2.

Table 2.2. Falcon M o d e l C Operating Applications

Customer Country Model Units Application

EQUIPROM Iron fines
Brazil C-400 1 concentration plant
Gold pre-concentration
Newcrest Mining Australia C-4000 1 trial
Tantalum recovery-
Sons of Gwalia, C-4000 1 rougher
Wodgina Tantalum Australia
Tantalum recovery-
Mine C-1000 1 cleaner
Enviro Gold Canada C-1000 1 Gold recovery
Evis House Inc.,
Canada C-400 1 M i l l clean up
Gold
Metals Research
Canada C-1000 1 Primary gold recovery
Corp.
Tantalum recovery-
C-1000 1 rougher
Tantalum recovery-
Tantalum Mining C-400 1 cleaner
Corp., T A N C O Canada
Spodumene recovery-
Mine C-1000 1 rougher
Spodumene recovery-
C-400 I cleaner
Silver recovery-
Silver Eagle C-1000
rougher
Resources, Silver Chile
tailings treatment C-400 Silver recovery-cleaner
•

E M I N Z A Group
Ecuador C-400 1 Gold Telluride
of Companies
International
Ghana C-400 1 Gold fines - Pilot plant
Tournigan Corp.
DZAMGYR Kyrgyzstan C-400 1 Gold recovery
Hematite recovery
Mikhailovsky Gok Russia C-1000
' from tailings
(Scavenger)
 16

Customer Country Model Units Application

C-400 1
Metso Minerals Russia Gold recovery
C-1000 1
Multotec Process South Africa C-1000 1 Pilot plant
Flotation cone,
Gulf International Tajikistan C-1000 1
cleaning
Sulphide and electrum
Echo Bay Minerals USA C-4000 1
recovery

A M o d e l C-4000 was used to concentrate gold-sulphides at Echo Bays's Kettle

River M i n e , Washington. The feed was overflow from the hydrocyclone (90 tph). The

Falcon concentrate is subjected to high intensity cyanidation and the tailings are leached

in the pre-existing Carbon In Pulp (CIP) circuit. The operators reported an increase in

production of approximately 3,000 ounces per year (increased overall gold recovery of

2.7%) while maintaining cyanide consumption at previous concentration level. Daily

throughput was approximately 2,000 tons (Sprake et al, 2003).

Falcon installed two C-1000 and two C-400 units in the T A N C O tantalite mine in

Manitoba, Canada in 1998. The tantalum ore is ground to -2 m m and concentrated using

a combination of gravity separation methods (spirals, Falcon C , M o z l e y multi-gravity

separators, cross-belt separator and shaking tables). Different circuits recover different

size fractions of the tantalum, for an overall recovery in the 7 0 % range. The tantalum

concentrate typically grades between 3 5 % and 3 8 % Ta2C»5, with smaller percentage of

tin, niobium, and titanium (Hilliard, 2003). A typical installation of two Falcon C

continuous concentrators in series treating up to 100 ton per hour of - 1 m m material

(tailings from the spirals and tables in T A N C O Mine) and the second unit as the primary

concentrate cleaner. The effective use of this circuit yields high recoveries of the target

mineral/metal in a fraction of the feed mass, producing a low tonnage stream for the final

table cleaning unit (Falcon website, 2004).

 17

2.4.2.2. Kelsey Jig

The high efficiency of separation, as well as the introduction of the high-capacity of the

Kelsey Jig, makes it an excellent option for processing existing tailing deposits and

scavenging current plant tailing streams to recover fine valuable minerals, as well as for

removing environmentally unacceptable minerals from plant tailings (Richards et al,

2004).

The Kelsey Jig is used to recover cassiterite, tantalum and chromite. There are

relatively few gold installations, but it:

Has demonstrated the ability to recover fine flaky placer gold;

Is used to scavenge fine gold from shaking table tailings (secondary treatment);

Has been tested for the recovery of gold from the cyclone overflow, where it

recovered gold as fine as 5 um.

Applications of the several Kelsey Jig concentrators are listed in Table 2.3.

Table 2.3. The Kelsey Jig Operating Applications

Customer Country Model Units Application

Bakrychik Gold Kazakhstan J650 1 Gold/sulfides (Scavenger)

Gwalia Consolidated Australia J1300, J650 2 Tantalum recovery-rougher

Lonrho Platinum South Africa Chromite

Beijing Mining Inst. China
Inbras Equpamentos
Paranapanema Brazil Tin recovery
J1300MKII 1
Mineracao
Renison Tin Ltd. Australia J1300, J650 7
BHP Minerals
Cable Sands Australia J1300 1
CRA Ltd. \
Namakwa Mineral sands
South Africa
Richards Bay Minerals
RGC Mineral Sands Australia/USA
TiWestJV Australia J1300 2
Comalco Research Australia Bauxite
Du Pont Corp USA J1800 2 Titanium recovery
 18

Customer Country Model Units Application

Magma Minerals USA PGM's
Regional Research Lab India Iron ore
SINTEF Norway Iron ore/titanium
Comsur Bolivia J1800 1
Placer Dome Asia Australia J1800 3
WMC Australia J1800 1
Minsur Peru J1300 MKII 1

A M o d e l J650 is in production at the Bakrychik gold mine in Kazakhstan. The

unit improves the overall gold recovery by scavenging fine gold-sulfide particles from the

table circuit tails. The concentrate is reground and returned to the head of the circuit. A

major portion of gold recovery (56.7%) is in the fine fraction demonstrating the ability of

the Kelsey J i g to recover finer particles than conventional concentrators such as shaking

tables (Jones, 1999).

A t the G w a l i a Consolidated tantalum mine, Australia, the Kelsey Jig achieved an

upgrade ratio of 80 times at a 6 8 % recovery for ore ground to 5 0 % -75 u m (Clifford,

1999). However; testing to separate ultrafine (45% -12 pm) tantalum minerals (S.G. 6.5-

7.2) from slimes yielded poor results (Burt et al, 1995).

2.4.2.3. Altair Centrifugal Jig

There are no references for commercial operations using the Altair Jig. A 30-16 (screen

diameter - screen height in inches) unit was installed for testing at a plant to separate

zircon from alumina-silicate. Limited testing has been conducted aimed at recovering

gold; however it has demonstrated the ability to recover fine flaky gold and fine coal.

The capacity of the 30-16 unit is 18 tph and for 83-16 unit is 38 tph.

A pilot scale study conducted on -600 + 44 p m coal indicated that the centrifugal

j i g is capable of separating materials at low densities and with small density differentials

over a range of fine particle sizes (Mohanty et al, 1999). The probable error (Ep) ranged

from 0.08 at a separation density of 1.54 to 0.17 at a separation density of 1.43. F o r

particles larger than 300 p m , selectivity was found to decrease, which was explained by

the restricted flow of the particles through the screen. Good separation efficiency was
 19

demonstrated for particles as fine as 44 u m , although the maximum separation efficiency

was achieved for the -150 + 75 urn size range.

The Altair Jig has the potential application to separate efficiently at fine particle

sizes (300 u m to 25 um), at low density differences with product yield from 0 to 100% as

required. Limitations are low capacity and high water requirement. Table 2.4 presents

the tested applications for the Altair Centrifugal Jig.

Table 2.4. Tested applications for the Altair Centrifugal Jig

Heavy/SG Zircon/4.68 Hematite/5.26 Rutile/4.2

Light/SG Kyanite/3.5 Quartz/2.65 Quartz/2.65
Concentration Criterion 1.41 2.56 1.94
%-200 mesh Not specified 29.2 78.8
Weight % 14.6 10.8 28.8
Grade % 37.4 63.6 37.3
Recovery % 80.3 59.4 85.8

For gold processing, tests have been conducted to scavenge gold from secondary

treatment tailings (shaking table and Knelson tails).

2.4.2.4. M o z l e y M u l t i Gravity Separator ( M G S )

The M G S is effective for separation of fine and ultrafine particles. Laplante et al (1998)

conducted tests on samples containing gold from a flash flotation concentrate diluted with

quartz. The M G S was found to be very effective at recovering a full range of gold

particle sizes from 300 u m to 10 u m and out performed a Knelson at the fine sizes.

Laplante stated that the M G S can not compete with the Knelson for the recovery of gold

from grinding circuits due to its low capacity and high water usage. However, he

suggested that its ability to recover very fine gold effectively may be applied to

recovering gold from base metal concentrates with low gold smelter returns such as zinc

concentrates. The high enrichment ratio achieved at fine particle sizes indicates the

potential application for scavenging fine gold from shaking table (secondary treatment)

tailings.
 20

The M G S has been applied at the flotation circuit of the Wheal Jane m i l l ,

Cornwall, U K in 1989. The goal was to improve the tin concentrate grade and plant

metallurgical performance by replacing column flotation with a M G S , as the final stage

of cleaning (Turner et al., 1993). Tests with tantalum slimes (45% -12 pm) indicated far

superior enrichment compared to the Falcon, Knelson and the Kelsey Jig. Open circuit

treatment of chromite slimes from an Albanian deposit grading 2 3 % Cr203 produced a

concentrate grading 5 0 % Cr203 with a recovery o f 72%. It has also demonstrated good

separation of fine pyrite from coal, fine tungsten and base metal flotation concentrates.

The M G S has also been applied to wolframite recovery from plant tailings (as a

scavenger) at mineral Regina, Peru and upgrading graphite flotation concentrates in

South Australia. The low capacity of the M G S limits its potential application (Model

C902 - 4 tph), although a higher capacity unit has been built for coal preparation

(MeGaSep - 60 tph).

In T A N C O M i n e the tantalum ore is ground to -2 m m and concentrated using a

combination of gravity separation methods such as spirals, Falcon C , M G S , cross-belt

separator and shaking tables (Hilliard, 2003).

 21

2.4.2.5. Knelson C V D

Preliminary tests were conducted on synthetic mixtures of magnetite (density 5 similar to

pyrite) and quartz ground to approximately 80% passing 100 mesh at the University of

British Columbia. A single stage of processing increased the magnetite grade from 4% to

18.1% recovering 82.5% of the magnetite in 19.3% of the feed weight (reject 80.7%).

Rougher-scavenger configurations are being evaluated to improve recoveries further

(Lambert et al, 1999).

Most of the C V D applications involved pilot scale testing in the laboratory or on

mine site, using a 2 tph C V D 6 . There are C V D 20 and C V D 3 2 units that were installed

in Russia and A f r i c a , but results are scant and optimization is as yet incomplete

(Simpson, 2003).

Table 2.5. The Knelson C V D Tested and Operating Applications

Country Model Units Application

Mali CVD6 1 Pilot test, gold-sulfides

Ghana CVD6 1 Pilot test, gold-sulfides

Papua New Guinea CVD6 1 Pilot test, gold-sulfides

Ghana (Bogoso) CVD32 1 Gold-sulfides
Russia (Turbokon) CVD32 1 Tin recovery
Russia (Zapadnaya) CVD20 2 Gold-sulfides
Zimbabwe CVD20 1 Alluvial chromite
Canada (Luzenac) CVD32 1 Talc cleaning-reverse separation

There is a C V D 3 2 that has been installed in Luzenac talc mine in Ontario,

Canada. Iron compounds such as magnetite, goethite and hematite are commonly found

as minor contaminants in Luzenac talc mine. Iron compounds are often entrained in froth

flotation concentrate and require removal prior to shipment.

In Luzenac beneficiation plant C V D is typically incorporated into the flotation

circuit treating flotation concentrates. The first cleaner concentrate is fed to the C V D ,

producing light and heavy product streams. The light stream of the C V D has most of the
 22

iron compounds removed, and reports to the second cleaning steps. The rejects stream

from the C V D containing both fine liberated iron particles and coarse talc particles with

locked iron are reground and sent back to primary flotation (Byron et al., 2004).

2.5. Conclusion

Metal values in coarse particle fractions represent a considerable amount of the total

metal loss by most base metal flotation operations. The potential to improve this

recovery by even a small amount w i l l have enormous benefits to the mining industry.

The continuous centrifugal gravity separators represent a relatively new technology that

were developed and manufactured by above mentioned companies.

There is a top limit for particle size floatability which varies for different ores.

The coarser fractions in flotation feeds contain heavy and valuable liberated and non-

liberated minerals (middling) that cannot be floated efficiently. The specific gravity of

these particles plays an important role which causes decreasing flotation performance.

Due to their relative density differences, middling particles can be separated from gangue

using gravity-based processes. For treating fine particles, the ability of gravity separators

has been limited due to lack of particle inertia relative to the surface drag forces.

However, particle inertia can be enhanced by the application of a centrifugal field.

The size enhanced density separator used in this investigation was a Knelson

C V D having a 6 inch diameter bowl. Application of this new technology in scavenging

tailings has the potential to improve metal recovery and reduce grinding power

requirements and associated costs. This research is aimed at assessing the performance

of the C V D for this application.

 23

CHAPTER 3 Experimental Program

3.1. Analyzed Samples

3.1.1. Eskay Creek Samples

T w o samples (600 k g solid of each) referred to as L o w Grade Tailings ( L G T ) and High

Grade Tailings ( H G T ) were obtained from the beneficiation plant of the Eskay Creek

M i n e , Barrick G o l d Corp. Figure 3.1 shows the sample point of the beneficiation plant

circuit.

Tailings
Feed Hydrocyclone Flotation
Bail Mill 1
w
Cyclone
O/F
Cone.

Batch Knelson

Cone.
r
Gemini Table

Cone.
r
Smelter

Figure 3.1. Eskay Creek Flotation Circuit Sample Point

 24

3.1.2. I N C O T h o m p s o n Samples

T w o samples (300 k g solid of each) referred to as Scavenger Tailings (AS-4) and

Scavenger Cleaner Tailings (SC-4) were obtained from the beneficiation plant of the

Thompson M i n e , I N C O Manitoba Division. Figure 3.2 shows the sample points of the

beneficiation plant circuit.

AS-4
Jl££|U Roughers Regrind Scavengers
Rougher-Scavenger Tails
Rougher Con

Rougher-Cleaner Tails SC-4

U Rghr-Clnrs
OH Scav-Clnrs

Scavenger-Cleaner Tails
Xu/Ni Con
Cu/Ni Tails Smelter Ni Con
Cu/Ni Sep.

Cu-Cleaners Tails
J>| Cu-Clnrs

Smelter Cu Con

F i g u r e 3.2. Birchtree Flotation Circuit Sample Points

 25

3.2. Sample Characterization

3.2.1. Sample Preparation

Representative 40 k g sub-samples were obtained from each wet tailing sample. The

sampling facility consisted of an agitated tank and slurry feed pump. Each sample was

fed to the tank and agitated for about two hours. Then the circulation process was begun

in a closed circuit for about six minutes to ensure steady-state conditions prior to

sampling. T o obtain the required sub-samples, the slurry was sampled every two minutes

for ten seconds from the agitated tank discharging pipe. Figure 3.3 shows the sampling

procedure block diagram.

The collected samples were decanted and dried. The dried samples were riffled to

obtain representative portions for:

Size-assay analysis
Density fractionation of sized fractions for elemental characterization

Scoping gravity recovery test using a batch 3 inch Knelson.

Tailing Sample

Pump Box
Split Sample
Feed Tank

Decantation and Drying

Riffling Assay

Screen analysis

LKC T Magstream

IE
Concentrate Assay Assay
Tailings Assay \4

Figure 3.3. Sampling procedure of wet tailing samples

 26

3.2.2. Size/Assay Analysis

The portions were screened using U S Sieve Numbers 50, 70, 100, 140, 200, 270 and 400

and the size fractions were weighed. Each fraction was subjected to multi-element I C P

analysis to obtain grades of N i , C u , Fe, M g , P b , A s , S , A g and A u ( A l l assays were

conducted by A C M E Analytical Laboratories, Vancouver).

3.2.3. Mineralogical Characterization

The representative portion of the Eskay Creek tailing sample ( L G T ) was screened using

U S Sieve Numbers 100, 200 and 400 and the size fractions were weighed. Polished

sections of the each size fraction were examined using optical microscopy. The

mineralogical work was focused on identifying the occurrence, size, association and

degree of liberation o f the gold-sulphide grains. This part of work has been performed by

undergraduate students during their process mineralogy course (Mine 338) under

supervision of Dr. Klein.

3.2.4. Density Fractionation for INCO Samples

Prior to density fractionation, a hand magnet was used to separate the ferromagnetic

particles. A Magstream was then used for separation at densities of 2.7, 3.1, 3.5, 3.9 and

4.3 g cm" . The removed magnetic fractions of each size fraction were then added to the
3

density fraction with density grater than 4.3 to determine mass and metal distribution as

they are mostly pyrrhotite. The density fractions were weighed and assayed. The data

were then used for calculating the partition coefficient numbers.

The Magstream process in general can be described as a combination between

magnetic and gravimetric separation. It is used for non-magnetic or weakly magnetic

particulate materials. Operation is similar to that of a heavy media centrifuge, except that

that the effective density of the liquid is magnetically derived, allowing it to be adjusted
 27

without practical limit by changing the speed of rotation or concentration (magnetic

strenghth) of the process fluid (IGC, 1991). The sample is in slurry with the process

ferrofluid (magnetite in water) and then it enters through a long rotating shaft. The

material that passes through gets separated into a low density and high density stream.

There are several advantages of this process in comparison to conventional heavy-media

sink-float processes. The cost and the toxicity of heavy liquids make the Magstream more

appealing to use, also it is much safer for the operator because no fumes are being

produced. The Magstream process can be used to separate material at much higher

densities to over 8, while most heavy liquids do not go to over density of 5.1 g cm" .
3
 28

3.3. Knelson Batch Tests

For the gravity concentration scoping test, a 2kg portion of each sample was fed to a 3

inch laboratory Knelson Concentrator ( L K C ) . The products were weighed and assayed

for metallurgical balances. Figure 3.4 shows the block diagram of the batch tests.

Head Sample

Pan I
Pan Con. 1
LKC 1 Con.

5
LKC 2
Pan Tail.

Pan 2
Pan Con. 2

Concentrate

LKC 3 Pan Con. 3

Pan 3

Pan Con. 4
LKC 4 Pan 4

Jt±=z
Tailings

Figure 3.4. Batch Knelson test procedure

 29

3.4. K n e l s o n C V D Pilot Scale Tests

Based on the sample characterization and batch scale test results, pilot scale tests (seven

tests for S C - 4 and six for L G T ) were conducted. The pilot scale testing facilities consist

of an agitated feed tank, a C V D 6 concentrator and a Sala pump that pumps the combined

concentrate and tailing products to a storage tank. The glass beads (total weight: 309

gram, bead diameter: 6 m m and density: 2.7 g c m ' ) were used for ragging. The test
3

operating conditions are summarized in Tables 3.1 and 3.2.

To prepare feed for pilot testing, the feed tank agitator was turned on for about

two hours. The pulp density was adjusted by adding water to 25% solid. During the first

6 minutes of the test operation no sampling was performed to ensure steady-state

operating condition. F o r the first 6 tests of S C - 4 and the first five tests of L G T the

concentrates were sampled for 6 minutes (from time six to twelve minutes), and the

tailing product was sampled at 7, 9 and 11 minutes of operation for 10 seconds each. The

sampling times and number of cuts were recorded to calculate the mass yields. After

drying and weighing, the products were riffled to obtain sub-samples for size/assay

analysis. The left over material was returned to the feed tank. For the last pilot test (test

7 for S C - 4 and test 6 for L G T ) , the concentrate sampling was started after 6 minutes and

continued until feed tank was empty. For this test the tailing product was sampled at 7,

11, 15, 19, 23 and 27 minutes of operation for 10 seconds of each sampling time.

Table 3.1. Test Operating Conditions, L G T

Flow Rate Fluidization Pinch open Pinch closed Bowl Speed

Test No.
(lit/min) Water (gpm) Time (s) Time (s) (rpm)

I 43 8 0.03 0.8 830

2 43 8 0.03 0.5 830
3 43 8 0.03 0.2 830
4 43 8 0.03 0.2 650
5 44 8 0.03 0.2 1050
6 42 8 0.03 0.2 830
 30

T a b l e 3.2. Test Operating Conditions, S C - 4

Flow Rate Fluidization Pinch Open Pinch Closed Bowl Speed

Test No.
(lit/min) Water (gpm) Time (s) Time (s) (rpm)

1 42 8 0.03 0.8 .830

2 50 8 0.03 0.8 830
3 42 8 0.03 0.5 830
4 43 8 0.03 1.1 830
5a 42 8 0.03 0.8 500
5b 42 8 0.03 0.8 500
6 42 8 0.03 0.5 500
7 35 8 0.03 0.5 830

3.4.1. Products C h a r a c t e r i z a t i o n

The representative portion of all concentrate and tailing products were screened using U S

Sieve Numbers 50, 70, 100, 140, 200, 270 and 400 and the size fractions were weighed.
Each fraction was subjected to multi-element I C P analysis to obtain grades of N i , C u , Fe,

M g , P b , A s , S , A g and A u ( A l l assays were conducted by A C M E Analytical

Laboratories, Vancouver). The high N i results were re-assayed using an A q u a Regia
Digestion method followed by ICP. The A u and A g results were confirmed using fire

assay.

Metallurgical balance was prepared based on measured mass flow rates and

grades of concentrates and tails. These calculated mass yields were reasonable with

respect to expected changes resulting from changes in operating variables. Average

calculated feed grades were comparable to measured feed grades. Mass yields based on

grades of feed, concentrates and tails were variable due to low mass yield in concentrate

and finer tail grades were similar to feed grades (i.e. mass yield calculations were very

sensitive to small variation in tails grades).

Polished sections of the each size fractions of the obtained products of the pilot

testing (Test 6, Eskay Creek L G T Sample) were used to examine the occurrence, size,

association and degree of liberation of the gold-sulphide grains using optical microscopy.
 31

3.4.2. Concentrate Density Fractionation Tests

Prior to density fractionation test, a hand magnet was used to separate the ferromagnetic

particles from the S C - 4 concentrate of Test 7. This product was screened using the U S

Sieve Numbers: 50, 100, 140, 200 and the size fractions were used for density

fractionation at densities of 2.7, 3.1, 3.5, 3.9 and 4.3 g cm" using a Magstream. The
3

removed magnetic fractions of each size fraction were added to the density fraction with

density grater than 4.3 to determine mass and metal distribution as they are mostly

pyrrhotite. The density fractions were weighed and assayed in order to find the partition

coefficient numbers and cut point.

3.4.3. Flotation Test and Proposed Flowsheet

Flotation tests were conducted on the C V D concentrates of both L G T and S C - 4 samples.

The tests were performed based on the existing plant conditions of grinding and flotation

circuits. The test conditions and metallurgical balances are shown in Appendix E .
 32

CHAPTER 4 Results and Discussions

4.1. Eskay Creek Samples

4.1.1. Introduction

The Eskay Creek M i n e comprises of different ore zones. Table 4.1 shows the typical ore

grades for two main zones.

Table 4.1. Ore Zones Assays (1998)

Ore Zone Au (g/t) Ag (g/t) Cu% Pb% Zn%

109 27.4 76.5 0.02 1.03 1.73
NEX 101.0 2026.0 0.9 3.82 6.02

Based on processing plant results from 1998, the cyclone overflow with a P80 of

74 reports to the flotation feed conditioner. Depending on the ore type, the total gold

recovery by gravity and flotation ranged from 94 to 9 7 % . The G R G (Gravity

Recoverable Gold) depends on the ore type and ranges from 30 to 4 5 % . The flotation

silver recovery ranged from 90 to 95%. For base metals such as copper, lead and zinc the

recoveries are also ore type dependant and all are expected to range from 85 to 9 5 %

(Anand et al, 1998).

The present practice involves mixing of different ore types. The plant was

sampled in M a y , 2003 and showed that the gold recovery has decreased to 92.9%. These

results are based on four different types of ore ( N E X , 2 1 B , 109 and 21C) that were fed to

the processing plant. The specification of beneficiation plant feed and two received

tailing samples are shown in Table 4.2.

 33

Table 4.2. Ore Types Percentages (Plant Feed) and Tailing Sample grades (Data from
Eskay Creek Plant, 2003)

Ore Types % (plant Feed) Au Ag

Tailing
Grind Size Samples
NEX 21 B 109 21 C Total ppm ppm
% -75 pm
36 38 19 7 100 70.3 LGT 1.9 48.3
49 24 12 15 100 72.6 HGT 3.2 39.0

Tables A . 1.3 and A . 1.4 (Appendix A ) present the size/assay results and also the mill

performance for both received samples.

4.1.2. Results and Discussions

4.1.2.1. Sample Characterization

4.1.2.1.1. Size/Assay Analysis

The size/assay analysis of Eskay Creek tailings revealed that the A u grade for L G T and

H G T are 1.1 and 1.9 ppm, respectively. The Pso for L G T sample is 130 p m and for H G T

is 100 pm. The +100 mesh size fraction contains about 9% of mass of L G T and about

5% of H G T . The gold distributions in this size fraction are 8.9% and 3.3%, respectively.

The respective sulphur distributions are 7.0% and 3.4%.

Figures 4.1 and 4.2 show the gold and sulphur grade distributions in each size

fraction of both samples. Based on these data, the following results can be obtained:

1. The gold and sulphur grade distributions shows that gold and sulphur

losses occur at fine (-37 pm) and coarse (+210 pm) fractions.

2. Grinding coarser would reduce losses in the fine fraction.

The objective of the C V D testing is to recover free gold and gold-sulphides from the

coarsest fraction.
 34

2.5

• LGT H HGT
2.0

E
Q. 1.5
Q.
e>
•o
% -
•

2
(3 1.0 •A
a
<
•

"la
0.5

il.
I
•
0.0
-37 -53437 -74+53 -105+74 -149+105 -210+149 -297+210 +297

Size C l a s s (um)

Figure 4.1. A u Grade Distributions, L G T and H G T

2.0

• LGT D HGT
1.5

0>
| 1.0
o

0.5

0.0
-37 -53+37 -74+53 -105+74 -149+105-210+149-297+210 +297

Size Class (um)

Figure 4.2. S Grade Distributions, L G T and H G T

 35

It is believed that the C V D w i l l recover particles based primarily on density but

also based on size. Mass yields, metal recoveries and grade targets are arbitrarily set as

the mass yield in the +149 p m fraction, A u recovery of the +105 p m fraction was taken

as the target and grades were calculated from this fraction. Table 4.3 summarizes the

results.

Table 4.3. Samples Characterization Results, Target Mass Yields and Metal Recoveries

+149 p m Fraction +105 p m Fraction

Sample Pso (pm)
Weight % A u Distribution% S Distribution%
LGT 130 9.3 27.9 20.6
HGT 100 5.3 10.6 10.7

For the L G T sample, the target mass yield is 9.3%, A u recovery is 27.9% and

grade is 3.4 ppm. For the H G T sample, a mass yield of 5.3%, A u recovery of 10.6% and

A u grade of 3.8 ppm are targeted. These numbers indicate that both samples have

potential for middling recovery. In both cases, the gold distribution is greater than the

mass distribution indicating the potential to upgrade the gold bearing minerals.

The results of both the sample characterization and size/assay analysis are shown

in Appendix A .

4.1.2.1.2. Mineralogical Characterization

Optical microscopy revealed that in all size fractions above 37 (im, sulphide minerals

including pyrite and arsenopyrite, are primarily associated with gangue minerals

(silicates) as fine inclusions. The degree of liberation for gold bearing sulphide grains of

each size fraction of the sample were examined applying the point counting method. The

grains were counted and split into five sections. The degree of liberation is calculated

based on the percentage of the free particles divided by the sum of the free and locked

particles. Table 4.4 shows the calculation results for L G T sample. The results indicate

that there are no liberated sulphide grains coarser than 150 |im.
 36

Table 4.4. Degree of Liberation Results, L G T

Size Fraction (|im) Degree of Liberation %

+149 0
-149 + 74 50
-74 + 37 52
-37 82

The mineralogical analysis results of each size fraction of the sample are shown in

Appendix D.

4.1.2.2. Batch Tests Results

The results of the batch Knelson tests are summarized in Table 4.5, which shows the

weight %, A u grade and A u distribution for the concentrates.

Table 4.5. Batch Test Results

Cone. Weight A u Grade

Sample A u Distribution %
Recovery % (ppm)
LGT 5.0 5.1 20.0
HGT 4.0 3.9 8.8

The metallurgical balances are presented in Appendix B. For the H G T , results are

similar to those predicted from the characterization results. For the L G T sample, while

the weight and A u distributions are lower than the target value, the A u grade is higher.

4.1.2.3. Pilot Scale Tests Results

Based on the characterization and batch Knelson tests, there appeared to be a greater

opportunity to recover a recyclable product from the L G T sample than the H G T sample.

It was therefore selected for pilot scale tests using the C V D 6 separator. These tests were

conducted with different operating variables including pinch valve closed time and bowl

speed. These plant testing produced a range of results. The pinch open time was

maintained at 0.03 seconds and fluidization water flow rate maintained at 8 gallon per
 37

minute for all tests. A s shown in Table 4.6, the best result was obtained from Test 3

based on pinch valve closed time of 0.2 seconds and bowl speed of 830 rpm (60G).

The pilot scale test results were used to evaluate the possibility of improving gold

recovery from the L G T sample of the Eskay Creek beneficiation plant. These results

were also used to evaluate the Knelson C V D concentrator as a scavenger for coarse

middling particles from flotation tailing and to identify the target mass yields and set

points for the operating variables.

4.1.2.3.1. Products Characterization

Products from the pilot scale tests were subjected to size/assay and mineralogical

analysis. The metallurgical balances for the all tests are summarized in Table 4.6.

Table 4.6. Pilot Scale Test Results, L G T

Cone. Grade Distribution %

Test Mass
No. Yield Au(ppm) S% Ag(ppm) As(ppm) Au S Ag As
%
1 0.9 6.31 1.29 87.3 202.8 5.5 1.3 1.5 1.4
2 1.7 4.46 1.07 84.8 192.1 6.5 1.7 2.8 2.1
3 3.3 12.51 1.14 76.4 198.5 28.4 3.9 4.9 4.0
4 4.4 3.66 0.71 71.1 129.3 14.7 4.4 5.9 3.4
5 7.7 5.60 1.04 63.1 165.7 35.0 11.5 9.4 9.3
6 9.3 4.36 0.99 68.5 157.6 15.3 12.4 12.3 10.0

The results show that the gold distributions are significantly higher than sulphur

and arsenic distributions, which indicates that free gold or gold associated with poorly

floated minerals is being recovered. The best result was obtained from Test 3 in which

28% of the gold was recovered in a concentrate grading 12.5 ppm A u representing 3.3%

of the feed mass. This represents a gold upgrade ratio of 8.7.

Figures 4.3 and 4.4 show the gold and sulphur grade distributions in each size

fraction of concentrate and tailings of Test 3. Based on these data, the following results

can be obtained:
 38

1. The gold and sulphur grade in the coarse fraction of the concentrate

are higher than that for fine fractions

2. The gold grade in tailing is very low.

3. C V D has successfully upgraded the gold in the coarsest fraction of the

concentrate.

Grinding coarser would reduce losses in finer fractions and resulting in a greater

portion of coarse middlings to report to the flotation tailings. These types of particles can

be recovered using C V D and recycled to the grinding circuit. The overall consequence

w i l l improve overall gold recovery and reduce energy costs.

140 T ,

-37 -53+37 -74+53 -105+74 -149+105 -210+149-297+210 +297

S i z e C l a s s (pm)

Figure 4.3. A u Grade versus Particle Size in Concentrate and Tailing of Test 3
 39

I Concentrate. • Tailing

-53+37 -74+53
Ii n i
-105+74 -149+105 -210+149 -297+210 +297

Size Class (um)

F i g u r e 4.4. S Grade versus Particle Size in Concentrate and Tailing of Test 3

The test results show that the Au grade increased in the concentrate products
significantly. This is a good indication that the centrifugal gravity concentrator can
capture the middlings and the fine free particles of gold as well. The S grade increased in
the finer fractions of the concentrate due to overgrinding soft sulphides. In case of Ag
the results indicate no remarkable improvement. The table of metallurgical balances for
all tests is shown in Appendix C.

Optical microscopy revealed that in all size fractions above 37 (Jm for CVD
concentrate, sulphide minerals including pyrite and arsenopyrite, are primarily associated
with gangue minerals (silicates) as fine inclusions. The mineralogical analysis results of
each size fraction of the products are shown in Appendix D.
 40

4.1.2.3.2. C V D Operating Conditions

Figure 4.5 shows the relationships between the mass yield, A u recovery and pinch valve

closed time. The mass pull and the A u recovery decrease with increasing the pinch valve

closed time. Figure 4.6 shows that the A u grade has a maximum value at the mass yield

3.5% and A u recovery increases with increasing the mass yield. The A u upgrade ratio

has a maximum value at 3.5% concentrate mass yield (Figure 4.7).

Based on the metallurgical balance results o f the conducted pilot scale tests, it is

suggested to apply the operating variables as following: Pinch valve closed time o f 0.2

seconds, pinch valve open time o f 0.03 seconds, bowl speed o f 830 rpm (60G) and water

fluidization flow rate o f 8 U S gallon per minute (1.8 m /h).

3

F i g u r e 4.5. Mass Y i e l d and A u Recovery versus Pinch Valve Closed Time

F i g u r e 4.7. A u Upgrade Ratio/Recovery versus Mass Y i e l d
 42

4.1.2.3.3. Size Partition

The size partition curves were obtained based on the results of all pilot scale tests. The

feed mass flow rate of each test was calculated based on measured mass flow rate of

concentrate and tailing products. These data and the size analysis results were then used

for calculating the weight percentages and the mass flow rates for each size fraction (i) of

concentrate, tailing and feed (Appendix C.3). The partition number (PN) for each size

fraction was determined by using the following formula:

P N i = 100 * (concentrate mass flow rate j/feed mass flow rate;)

Figure 4.8 shows the size separation partition curves, which demonstrated that the

C V D operates as a size classifier as well as a density separator (size enhanced density

separation). For Tests 3 and 6, the cut size was about 300 microns. The gold recovered

was primarily in the coarse size fractions, which based on mineralogical analysis would

likely contain middling particles (sulfides + silicates).

100 1000

Size (um)

F i g u r e 4.8. Size Separation Partition Curves

 43

Figure 4.9 presents the relationship between gold recovery and particle size. It

shows that the gold recovery increases with increasing particle size. The separation

efficiency performance is being affected by the feed characterization. The relationship

between sulphur recovery and particle size is shown in Figure 4.10. The coarser the

particle, the higher the sulphur recovery in concentrates. The increasing rate of sulphur

recovery is lower than that for gold. The results of size/assay analysis for all C V D test

products are presented in Appendix C .

100 1000
Size (Mm)

F i g u r e 4.9. A u Recovery versus Size

 44

80
I ; !
i
70 i l I i
-A- - Test 3 ------- Test 6 ' i
60 ! i I j
0^
50

> 40
8
$
rr 30
(0
20

10

0
10 100 1000
Size (Mm)

Figure 4.10. S Recovery versus Size

Figure 4.11 presents the relationship between gold recovery and sulphur recovery

for C V D pilot tests (Tests 3 and 6). It shows that the gold recovery has a good

correlation with sulphur recovery. Therefore, C V D could recover sulphides containing

gold. The figures of all test results are presented in Appendix C .

S Recovery %
Figure 4.11. A u Recovery versus S Recovery
 45

4.1.2.4. Flotation Test Result and Proposed Flowsheet

The representative portion of C V D concentrate product (Pso = 180 pm) obtained from

Tests 6 of L G T sample was ground to 80% less than 75 p m (based on data from existing

plant). The flotation test was conducted on the ground sample at natural p H and addition

of P A X (100 g/t) and M I B C . The flotation test conditions and results are shown in

Appendix E . The aim of the test was to float the sulphides, which tends to maximize the

recovery of the precious metals. The metallurgical balance is shown in Table 4.7.

T a b l e 4.7. Flotation Test Results, L G T

Weight Grade Distribution %

Material Au Ag Fe S
% Au Ag Fe S
(ppm) (ppm) % %
Concentrate 33.4 9.26 141.0 3.85 2.3 81.0 72.9 37.6 74.3
Tailings 66.6 1.09 26.3 3.2 0.4 19.0 27.1 62.4 25.7
Feed (CVD Con) 100 3.82 64.6 3.42 1.03 100 100 100 100

The gold, silver and sulphur recoveries of the flotation test are high, which can

have an impact on overall recovery of the beneficiation plant. Based on the existing plant

results (93% A u recovery), C V D Test 6 (15.3% gold recovery from tailings) and

followed by flotation (gold recovery of 81%), the overall gold recovery w i l l be increased

by about 1%.

It should be kept in mind that the samples used in this study are lower grade than

the typical plant tailings. Therefore, it is expected overall improvements would be

greater than 1%. Plant trials are recommended to assess this more accurately. The

proposed flowsheet is shown in Figure 4.12.

 Tailings
Feed Hydrocyclone Flotation
Ball Mill
Cyclone
O/F

Cone..

Knelson
Batch Knelson CVD

Cone.
Final Tails
r
Gemini Table

Cone.

Smelter

F i g u r e 4.12. Proposed Flowsheet, Eskay Creek

 47

4.1.3. Conclusion and Recommendation

T w o samples of flotation tailings referred to as H i g h Grade Tails ( H G T ) and low Grade

Tails ( L G T ) from the Eskay Creek beneficiation plant were studied. The test program

was directed into three stages including sample characterization, batch gravity and pilot

scale C V D testing.

The data from sample characterization and batch tests on samples revealed that

both samples have potential for middling recovery. The Pso for L G T sample is 130 p m

and for H G T is 100 p m . A batch 3 inch Knelson was used to obtain a preliminary

assessment o f gold recovery. For L G T sample the test revealed a concentrate grading 5.1

ppm with 5 % weight and 2 0 % gold recovery. F o r H G T sample, results are 3.9 ppm at

4 % mass yield and 8.8% gold recovery.

Six pilot scale tests were performed on the L G T sample using the C V D 6

separator. Products were subjected to size/assay analysis to assess separation. The

results showed the possibility o f producing a concentrate with a l o w mass yield and high

gold upgrade ratio.

Pilot scale testing indicated that the C V D was effective at recovering gold from

flotation tailings. The results indicated that the gold recovered was primarily in the

coarse size fractions, which would likely contain middling particles (sulfide + silicates)

i.e. size enhanced density separation. The best result (Test3) was 3.3 % mass yield with

12.5 ppm A u grade and 2 8 % A u recovery. For this test the A u upgrade ratio was 8.7.

Comparison of sulphur, silver and gold distribution indicates that free gold is

being recovered. According to the results attained, the C V D machine can upgrade the

flotation tailings of the Eskay Creek gold processing plant with a reasonable recovery. It

seems that the C V D recovers not only the coarser grains of gold bearing sulphides but

also captures the ultrafine free gold particles. The separation efficiency performance is

being affected by the feed characterization.

 48

Size partition curves were obtained for all tests, which demonstrated that the C V D

operates as a size classifier as well as a density separator (size enhanced density

separation). For Tests 3 and 6, the cut size was about 300 microns.

Flotation test on ground C V D concentrate of L G T sample showed that, with

recycling the C V D concentrate to the grinding and flotation circuit, the overall gold

recovery will be increased by about 1%.

Modeling of grinding, flotation and CVD circuits to assess potential

improvements in overall gold recovery and assess the potential for increasing grind size

to reduce losses in ultrafine fraction, reduce energy requirements and increase throughput

is recommended.

Based on the tests results and also the low mass stream of tailings at the Eskay

Creek beneficiation plant, onsite installation of a Knelson C V D 6 is recommended to

perform plant-trial test.

 49

4.2. INCO Thompson Samples

4.2.1. Introduction

The Birchtree ore consists of pyrrhotite (both monoclinic which is ferromagnetic and

hexagonal which is paramagnetic), pentlandite and minor chalcopyrite. This ore is

closely associated with significant ultramafic rocks mostly serpentinites (magnesium

bearing materials) as well as talc. Typical ore composition and grades are shown in

Tables 4.8 and 4.9.

Table 4.8. Birchtree Ore Mineralogy (Wyshynski, et al, 1999)

Mineral Percent
Pentlandite, (NiFe) S9 8
7.0
Chalcopyrite, CuFeS 2
0.4
Pyrrhotite, Fe S
8 9
22.0
Graphite 0.5
Other 70.0

Table 4.9. Birchtree Ore, Concentrate and T a i l Grades (Drapac, 2004)

Grade %
Material
Ni MgO Fe
Ore 1.54 20.1 20.6
Final Ni Concentrate 10.8 6.7 36.5
Scavenger-Cleaner Tails (SC-4) 0.57 19.8 22.4
Rougher-Scavenger Tails (AS-4) 0.25 22.8 16.7

The nickel losses in Thompson flotation plant is about 20% of the total nickel of

the beneficiation plant feed. About 50% of this amount reports to the rougher-cleaner

tailing and 50% to the scavenger-cleaner tailing. The complexity of the ore mineralogy

and poor liberation may cause the low recovery. Talc plays an important role in froth

flotation process due to its natural hydrophobicity. Talc rejection from Birchtree ore may

improve the overall plant recovery.

 50

4.2.2. Results a n d Discussions

4.2.2.1. Size/Assay Analysis

The size/assay analysis of Birchtree tailing samples revealed that the N i grade for S C - 4

and A S - 4 are 0.5 and 0.2%, respectively. The Pgo for S C - 4 sample is 94 urn and for A S - 4

is 140 u m . The +100 mesh size fraction contains about 10% of mass of S C - 4 and about

16% of A S - 4 . The nickel distributions in this size fraction are 8.7% and 14%,

respectively. The respective sulphur distributions are 9.7% and 7.4%. The M g grade for

S C - 4 and A S - 4 are 10.4% and 11.8%, respectively.

Figures 4.13, 4.14 and 4.15 show the nickel, magnesium and sulphur distributions

in each size fraction of both samples. Based on these data, the following results can be

obtained:

1. The element distribution shows that metal losses at fine (-37 um) and

coarse (+149 um) fractions.

2. Grinding coarser would reduce losses in fine fraction.

The objective of the C V D testing is to recover nickel sulphides from the coarsest fraction.
7 -53+37 -74+53 -105+74 -149+105 -210+149 -297+210 +297

Size Class (um)

F i g u r e 4.13. N i Grade for each Size Fraction, S C - 4 & A S - 4

 52

-37 -53+37 -74+53 -105+74 -149+105 -210+149 -297+210 +297

Size Class (um)

Figure 4.14. M g Grade for each Size Fraction, S C - 4 & A S - 4

-37 -53+37 -74+53 -105+74 -149+105 -210+149 -297+210 +297

Size Class (Mm)

Figure 4.15. S Grade for each Size Fraction, S C - 4 & A S - 4

The C V D recovers particles based primarily on density but also based on size.

Mass yields, metal recoveries and grade targets are arbitrarily set as the mass yield in the
 53

+149 u m fraction, N i recovery of the +105 u m fraction and grades calculated from these

numbers. Table 4.10 summarizes the results.

T a b l e 4.10. Target Mass Yields and Metal Recoveries

+ 149um Fraction + 105 um Fraction

Sample Pgo (nm)
Weight % Ni Distribution% S Distribution%
SC-4 94 10.2 14.0 16.6
AS-4 140 16.8 28.1 21.0

For the S C - 4 sample, target mass yield is 10.2%, N i recovery is 14.0% and grade

is 0.68%. For the A S - 4 sample, a mass yield of 16.8%, N i recovery of 28.1% and N i

grade of 0.37% are targeted. These numbers indicate that both samples have potential for

middling recovery using C V D . In both cases, the metal distribution is greater than the

mass distribution indicating the potential to upgrade the metal bearing minerals.

Density fractionations for both samples were conducted using the Magstream. It

was necessary to remove the magnetic particles from each size fraction as these particles

w i l l not separate effectively due to the magnetic field in the Magstream. Assays of the

magnetic and non-magnetic components show that the N i grade in the magnetic product

is only slightly higher than in the non-magnetic product. Therefore, magnetic separation

is likely not suitable for scavenging. The density fractionation data of S C - 4 was used for

plotting density partition curves in conjunction with the data of density fractionation tests

on each size fraction of pilot scale test (Test 7) concentrate.

The results of the sample characterization, magnetic particle distribution,

size/assay results of magnetic and non magnetic products and density fractionation for

both S C - 4 and A S - 4 head samples are shown in Appendix A .

4.2.2.2. Batch Tests Results

The results of the batch Knelson test are summarized in Table 4.11, which shows the

weight %, N i / M g grades and distributions in the concentrates.

 54

T a b l e 4.11. Batch Test Results, Concentrates

Cone. Weight Ni Grade Mg Grade Ni Distribution Mg Distribution

Sample % % %
Recovery % . %
SC-4 9.5 0.70 3.4 14.0 3.3
AS-4 9.9 0.38 5.0 18.1 4.1

The tables including the detailed results and metallurgical balances are presented

in Appendix B. For the S C - 4 sample, the results are similar to the target results based on

the size-assay analysis. For the A S - 4 sample, while the N i grade is similar to the target

value, the weight and N i distributions are lower. For S C - 4 , only 3.3% o f M g reported to

the concentrate product, demonstrating the ability of the continuous concentrator to reject

talc.

4.2.2.3. Pilot Scale Tests Results

Based on the characterization and batch Knelson test results and due to lower mass

stream of the scavenger-cleaner tailing of the plant, S C - 4 sample was selected for pilot

scale tests using the C V D 6 separator. These tests were conducted with different

operating variables including pinch valve closed time and bowl speed. These pilot scale

testing produced a range o f results. The pinch open time was maintained at 0.03 seconds

and fluidization water flow rate maintained at 8 gallon per minute for all tests. The best

result was obtained from Test 3 based on pinch closed time of 0.5 seconds and bowl

speed of 830 rpm (60G).

The pilot scale test results were used to evaluate the possibility of improving

nickel and gold recoveries from flotation scavenger-cleaner tailings of the Birchtree ore

processed at the Thompson beneficiation plant. These results were also used to

investigate the possibility of decreasing the magnesium content from the product and

finally to evaluate the C V D concentrator as a scavenger for coarse middling particles

from flotation tailings.

 55

4.2.2.3.1. Products Characterization

Products from the pilot scale tests were subjected to size/assay analysis. The

metallurgical balances for the all tests are summarized in Table 4.12.

T a b l e 4.12. Pilot Scale Test Results, S C - 4

Cone. Grade Distribution %

Test Mass
No. Yield Ni S Cu Mg Fe Au
Ni S Cu Mg Fe Au
%
% % % % % (ppm)
1 4.2 0.99 7.50 0.05 1.30 39.9 2.53 9.0 6.6 5.5 0.6 8.3 24.5
2 3.7 0.96 8.96 0.05 1.67 38.6 2.73 8.2 6.6 5.1 0.7 6.9 23.8
3 6.7 0.85 7.67 0.05 2.27 37.1 1.43 12.9 10.2 8.7 1.7 11.8 67.3
4 3.6 0.99 9.04 0.05 1.73 39.5 2.13 8.3 6.1 5.3 0.7 6.6 12.6
5b 0.3 1.43 6.19 0.07 1.42 41.5 3.95 1.1 0.4 0.6 0.0 0.7 18.2
6 0.5 1.13 7.47 0.06 1.11 45.6 9.99 1.5 0.8 1.4 0.1 1.2 52.4
7 9.4 0.72 5.80 0.04 2.86 33.0 2.34 16.1 13.5 11.8 3.2 16.1 60.1

The results show that the gold distributions are significantly higher than nickel

and sulphur distributions, which indicates that free gold is being recovered. The best

result was obtained from Test 3 in which 12.9% of the nickel was recovered in a

concentrate grading 0.85% N i representing 6.7% of the feed mass. It is worth noting that

the M g grade is decreased dramatically in the concentrate products. The M g distribution

in concentrate was just 1.7%. This is a good indication that the centrifugal concentrator

can also remove the magnesium bearing minerals such as talc. In case of gold

remarkable results were produced and the metallurgical balances showed gold recoveries

ranging from 12.58 to 67.26% and gold grades from 1.4 to 10.0 ppm.

The pilot scale testing indicated that the C V D was effective at recovering gold

and nickel bearing sulfides from the flotation tailings. The nickel and gold recovered

were primarily in the coarse size fractions, which would likely contain middling particles

(sulfides + silicates). The results showed that C V D is able to reject the M g bearing

minerals as well.
 56

Figures 4.16, 4.17, 4.18 and 4.19 show the nickel, magnesium, sulphur and gold
grade distributions in each size fraction of concentrate and tailings of Test 3. Based on
these data, the following results can be obtained:
1. C V D has successfully upgraded the nickel, gold and sulphur in the
coarsest fraction of the concentrate.
2. C V D has reduced the magnesium in the concentrate.
Grinding coarser would reduce losses in finer fractions and result in a greater portion of
coarse middlings to report to the flotation tailings. These types of particles can be
recovered using C V D and recycled to the grinding circuit. The overall consequence will
improve overall nickel and gold recoveries and reduce energy costs.

-37 -53+37 -74+53 -105+74 -149+105 -210+149 -297+210 +297

Size Class (um)

Figure 4.16. N i Grade for each Size Fraction of Concentrate & Tailing, Test 3
 57

l Concentrate • Tailing

-37 -53+37 -74+53 -105+74 -149+105-210+149 -297+210 +297

S i z e C l a s s (um)

Figure 4.17. M g Grade for each Size Fraction of Concentrate & Tailing of Test 3

10

-37 -53+37 -74+53 -105+74 -149+105 -210+149 -297+210 +297

S i z e C l a s s (um)

Figure 4.18. S Grade for each Size Fraction of Concentrate & Tailing, Test 3
 58

E
Q. 5 -
a

a3 3

Size Class (um)

F i g u r e 4.19. A u Grade for each Size Fraction of Concentrate & Tailing, Test 3

The test results showed that the N i , A u and S grades increased and the M g grade

decreased in the concentrate products. The N i and S upgrade ratios for the coarser

fractions (+149 um) are higher than that for fine fractions. In case of the M g , the smaller

the size fraction, the higher the M g reduction. The table of metallurgical balances for all

tests is shown in Appendix C .

4.1.2.3.2. C V D Operating Conditions

Figure 4.20 shows the relationships between the concentrate mass yield, Ni

grade/recovery, M g grade in concentrate and the pinch valve closed time. The mass yield

and the N i recovery decrease with increasing the pinch valve closed time. With

increasing the pinch valve closed time, the N i and M g grades do not have a considerable

change.

Based on the metallurgical balance results of the conducted pilot scale tests, it is

suggested to apply the operating variables as following: Pinch valve closed time of 0.5
 59

seconds, pinch valve open time of 0.03 seconds, bowl speed of 830 rpm (60G) and water

fluidization flow rate of 8 gallon per minute.

0.4 0.5 0.6 0.7 0.8 0.9 1 1.1

Pinch Valve Closed Time (seconds)

Figure 4.20. Mass Yield, Ni Grade/Recovery versus Pinch Valve Closed Time

Figure 4.21 shows that the lower the concentrate mass yield, the higher the N i
upgrade ratio (Ni grade in concentrate/Ni grade in feed) and the higher the M g
downgrade ratio.
 10 10

• Ni upgrade Ratio Mg dow ngrade Ratio 9

+ 8

6
13
5 O)
c
4 5
§ fi
2 3
S
2

+ 1

0
3 4
Mass Yield %

Figure 4.21. N i Upgrade and M g Downgrade Ratios versus Mass Y i e l d

Figure 4.22 shows that the lower the concentrate mass yield, the higher the

grade and the lower the N i recovery.

Figure 4.22. N i Grade/Recovery versus Cone. Mass Y i e l d

 61

The results indicate that the C V D can recover most of the fine particles of free

gold, middlings containing gold grains, N i bearing sulphides and also reject the M g

bearing minerals. For both A u and N i , the grades decrease with increasing the mass pull

but the recoveries increase.

4.2.2.3.3. Size Partition

The size partition curves were obtained based on the results of all pilot scale tests. The

feed mass flow rate of each test was calculated based on measured mass flow rate of

concentrate and tailing products. These data and the size analysis results were then used

for calculating the weight percentages and the mass flow rates for each size fraction (i) of

concentrate, tailing and feed (Appendix C.3). The partition number (PN) for each size

fraction was determined as following:

P N ; = 100 * (concentrate mass flow rate i /feed mass flow rate 0

Figure 4.23 shows the size separation partition curves for tests 3 and 7. For size

enhancing the individual test results showed a good trend that C V D can recover the

coarse middling particles with a cut size of about 250 micron. For test 7, the individual

partition numbers for size fractions of +297, -297+210, and -210+149 p m are 81.1, 49.3

and 27.6, respectively. The results of size/assay analysis for all C V D tests are presented

in Appendix C . The metal recovered was primarily in the coarse size fractions, which

would likely occur as middling particles (sulfides + silicates).

 62

90

80
•A- - - Test 3 - Test 7 m
A
^ 70
i ;
JQ 60
M i l
E
3
Z 50
c
o
S 40 MM
a
°- 30

20
! il
i!
10-1

jI
! !

I! I
10 100 1000
Size (um)

Figure 4.23. Size Separation Partition Curves

4.2.2.3.4. Density Fractionation

The density fractionation tests on each size fraction of feed and concentrate of test 7 at
densities of 2.7, 3.1, 3.5, 3.9 and 4.3 g cm" were performed using a Magstream. The
3

density fractions were weighed and assayed. These data and the size analysis results
were then used for calculating the weight percentages and the mass flow rates for each
size fraction of concentrate (Appendix D.2).
The same as feed mass flow rates, the concentrate mass flow rates for all density
fractions of each size fraction (i) were also calculated based on concentrate mass flow
rates of each size fraction and the weight percentage of each density fraction (Mass flow
rate of each density fraction = Weight % * Mass flow rate of each size fraction). The
 63

partition number for each density fraction was determined by using the following

formula:

PN i = 100 * (concentrate mass flow rate j /feed mass flow rate >)

The tables of results are shown in Appendix D. The partition coefficient curves
for densities were examined and presented in Figures 4.24 (+297 pm size fraction) and
4.25 (-297+149 pm size fraction). Figures 4.26 to 4.31 present the element recoveries for
each density fraction.

20

10 -

0 J , , , ,
2.25 2.75 3.25 3.75 4.25 4.75

Density (g/cm3)

Figure 4.24. Partition Coefficient Curve for +297 pm Size Fraction

 100 -r

90 -

80

$ 70
n
E 60
3
Z 50 •

.2 4 0

1 30 •
a
Q- 20 ••

10

0 •
2.25 2.75 3.25 3.75 4.25 4.75

Density (g/cm3)

Figure 4.25. Partition Coefficient Curve for -297+149 u m Size Fraction

Figure 4.26. N i Recovery versus Density for +297 u m Size Fraction

 Figure 4.27. N i Recovery versus Density for -297+149 pm Fraction

Figure 4.28. M g Recovery versus Density for-149+105 um Size Fraction

 66

2.25 2.75 3.25 3.75 4.25 4.75

Density (g/cm3)

Figure 4.29. M g Recovery versus Density for-105+74 u m Size Fraction

The curves for density of individual size fraction showed that the heavy and

coarser size fractions have sufficiently higher partition numbers than the lighter fine

material. The N i recovery is higher in the coarser and heavier fractions. The achieved

results for M g showed that the finer particle size fractions have the same partition

numbers (less than 10%). The C V D separation performance revealed a good recovery for

middlings (sulphides + silicates) and a good rejection of magnesium bearing minerals.

Figures 4.30 and 4.31 present sulfur and iron recoveries for densities of +297 p m

size fraction. The iron and sulfur recovery in higher density of +297 p m fraction size

have the maximum amount. It means that C V D has recovered the sulfides efficiently.
20 -1

10

0 -I , , , : ,
2.25 2.75 3.25 3.75 4.25 4.75

Density (g/cm3)

F i g u r e 4.30. S Recovery versus Density for +297 u m Size Fraction

100

10 -I
0 J , , , ,
2.25 2.75 3.25 3.75 4.25 4.75

Density (g/crr>3)

F i g u r e 4.31. Fe Recovery versus Density for +297 u m Size Fraction

 68

4.2.2.4. Flotation Test Results and Proposed Flowsheet

The representative portion of C V D concentrate product (Pgn = 160 p m ) obtained from

Tests 7 of S C - 4 sample was ground to 80% less than 100 p m (based on data from

existing plant). The flotation test was conducted on the ground sample at p H 10 and

addition of P A X (125 g/t) and M I B C . Soda ash ( N a C 0 ) was used as a p H regulator.

2 3

The flotation test conditions and results are shown in Appendix E. The aim of the test

was to float the nickel sulphides, which tends to maximize the recovery of the nickel.

The metallurgical balance is shown in Table 4.13.

Table 4.13. Flotation Test Results

weight Grade Distribution %

Material Ni Fe Mg S Au
% Ni Fe Mg S Au
% % % % (g/t)
Concentrate 35.1 1.32 50.4 2.7 29.7 3.97 64.1 37.6 26.1 38.9 98.2
Tailing 64.9 0.40 45.2 4.1 25.2 0.04 35.9 62.4 73.9 61.1 1.8
Feed(CVD Con) 100 0.72 47.0 3.6 26.8 1.42 100 100 100 100 100

The nickel recovery of the flotation test is about 64%, which can have an impact

on overall nickel and gold recoveries of the beneficiation plant. Based on the existing

plant results (80% nickel recovery), C V D Test 7 (16.1% recovery from S C - 4 tailings)

and followed b y flotation (nickel recovery of 64.1%), the overall nickel recovery w i l l be

increased b y about 1%. In case of gold the overall gold recovery w i l l be increased by

6%. The proposed flowsheet is shown in Figure 4.32.

 69

Feed Regrind Scavengers

AS-4
Roughers , r
fc
w
Rougher-Scavenger Tails
Rougher Con

Rougher-Cleaner Tails SC-4

Rghr-Clnrs Scav-Clnrs

Scavenger-Cleaner Tails
Xu/Ni Con

•0
Cu/Ni Tails Smelter Ni Con
Cu/Ni Sep. •

Knelson
Cu-Cleaners Tails CVD
Cu-Clnrs

T
Smelter Cu Con Tailings

Figure 4.32. Proposed Flowsheet, INCO Thompson

 70

4.2.3. C o n c l u s i o n a n d R e c o m m e n d a t i o n

Two samples of flotation tailings referred to as Scavenger-Cleaner (SC-4) and Scavenger

(AS-4) from the Birchtree ore processed at the Thompson beneficiation plant, was
studied. The test program was directed into three stages including sample
characterization, batch gravity and pilot scale C V D testing followed by product
characterization and density fractionation of sized fractions of feed and concentrate.

The data from sample characterization and batch tests on samples revealed that
both samples have potential for middling recovery. The Pso for SC-4 sample is 94 um
and for AS-4 is 140 um. A batch 3 inch Knelson was used to obtain a preliminary
assessment of nickel recovery. For the SC-4 sample, the results were similar to the target
results based on the size-assay analysis. For the AS-4 sample, while the N i grade was
similar to the target value, the weight and N i distributions were lower. The M g grade is
decreased dramatically in the concentrate products. For SC-4, only 3.3% of M g reported
to the concentrate product.

Seven pilot scale tests were performed on the SC-4 sample using the C V D 6
separator. Operating conditions including pinch valve closed time and bowl speed were
varied producing a range of results. The pinch open time was maintained at 0.03 second
and the fluidization water flow rate maintained at 8 gallon per minute for all tests.
Products were subjected to size/assay analysis to assess separation. The results showed
the possibility of producing a concentrate with a reasonable low mass yield, low
magnesium and high nickel upgrade ratio.

Pilot scale testing indicated that the C V D was effective at recovering nickel
sulphides from flotation tailings. The results indicated that the N i recovered was
primarily in the coarse size fractions, which would likely contain middling particles
(sulfide + silicates) i.e. size enhanced density separation. The best result (Test 3) was
6.7% concentrate mass yield with 0.85% N i grade and 13% N i recovery. The M g
distribution in concentrate was just 1.7%. This is a good indication that the centrifugal
 71

concentrator can also remove the magnesium bearing minerals such as talc. In case of

gold remarkable results were produced and the metallurgical balances showed the gold

recovery of 6 7 % for this test.

Comparison of nickel, sulphur, and gold distribution indicates that free gold is

being recovered. According to the results attained, the C V D machine can upgrade the

flotation tailings of the Birchtree ore processed at the Thompson beneficiation plant with

a reasonable recovery. It seems that the C V D recovers not only the coarser grains of

nickel bearing sulphides but also captures the ultrafine free gold particles.

Size partition curves were obtained for all tests, which demonstrated that the C V D

operates as a size classifier as well as a density separator (size enhanced density

separation). For Test 7, the cut size was about 250 microns and the individual partition

numbers for size fractions of +297, -297+210, and -210+149 p m are 81.06, 49.33 and

27.64, respectively. The curve for density of individual size fraction did not show a

systematic trend for test 7, at the same time the partition numbers for the heavier portion

of coarser size classes (+50, -50+100 mesh) are high.

The results showed that the process option to recover the middling particles

containing nickel sulphides and fine gold particles is application of the C V D for the S C - 4

sample. It seems that the C V D recovers not only the coarser grains of N i bearing

sulphides but also captures the ultrafine free gold particles simultaneously.

The results also indicated a product with very low content in M g is achievable.

Recycling the concentrate product of C V D to the grinding m i l l may improve the overall

recovery. The separation efficiency performance is being affected by the feed

characterization.

Flotation test on ground C V D concentrate of S C - 4 sample showed that with

recycling the C V D concentrate to the grinding and flotation circuit, the overall nickel and

gold recoveries w i l l be increased by about 1% and 6%, respectively.

 72

Modeling of grinding, flotation and C V D circuits to assess potential

improvements in overall metal recovery and assess the potential for increasing grind size
to reduce losses in ultrafine fraction, reduce energy requirements and increase throughput
is recommended.

Based on the low mass stream of the scavenger-cleaner tailings at the Thompson
beneficiation plant (for Birchtree ore), installation of a Knelson CVD6 is recommended
to perform plant-trial test. It can be located inside the grinding and flotation circuit to
minimize overgrinding of materials.
 73

CHAPTER 5 Conclusions and Recommendations

5.1. Conclusions

A study was conducted to evaluate the Knelson Continuous Variable Discharge (CVD)
concentrator as a scavenger for coarse middling particles from flotation tailings. The
tailing samples were from Eskay Creek and INCO Thompson beneficiation plants. The
goal was to produce a product suitable for recycling to grinding to improve the degree of
liberation and aid subsequent recovery in flotation.

• Based on the characterization and batch Knelson tests, there appeared to be an

opportunity to recover a recyclable product from the flotation tailings.

• Pilot scale testing indicated that the C V D was effective at recovering gold and
sulphides from flotation tailings. The results indicate that the gold and sulphides
recovered were primarily in the coarse size fractions, which would likely contain
middling particles (sulfide + silicates) i.e. size enhanced density separation.

• For Eskay Creek sample (LGT) the best result (test 3) was 3.3 % mass yield with
12.5 ppm A u grade and 28% A u recovery. For this test the A u upgrade ratio was
8.7.

• For INCO Thompson sample (SC-4) the best result (test 3) was 6.7%
concentrate mass yield with 0.85 % N i grade and 13% N i recovery. The M g
distribution in concentrate was just 1.7%.

• Comparison of sulphur, silver and gold distribution indicates that free gold is
being recovered. According to the results attained, the C V D machine can upgrade
the flotation tailings of the Eskay Creek gold processing plant with a reasonable
recovery. It seems that the C V D recovers not only the coarser grains of gold
associated sulphides but also captures the ultrafine free gold particles.
 74

Size partition curves were obtained for all tests, which demonstrated that the C V D
operates as a size classifier as well as a density separator (size enhanced density
separation). For tests 3 and 6 (Eskay) and test 7 (INCO), the cut size was about
300 and 250 microns, respectively.

Flotation test on ground C V D concentrate of L G T and SC-4 samples showed that

with recycling the C V D concentrate to the grinding and flotation circuit, the
overall nickel and gold recoveries will be improved.
 .75

5.2. Recommendations

• Modeling of grinding, flotation and C V D circuits to assess potential

improvements in overall metal recovery and assess the potential for increasing
grind size to reduce losses in ultrafine fraction, reduce energy requirements and
increase throughput is recommended.

• Based on the low mass stream of tailings at the Eskay Creek beneficiation plant,
installation of Knelson CVD6 is recommended to perform plant-trial test. It can
be located inside the grinding and flotation circuit to minimize overgrinding of
materials. Even at the Eskay Creek the Knelson batch machine has been located
and fed from cyclone underflow discharge, The C V D can upgrade the flotation
tailings at a low mass yield.

• Based on the low mass stream of the scavenger-cleaner tailings (SC-4) at the
Thompson beneficiation plant (for Birchtree ore), installation of a Knelson CVD6
is recommended to perform plant-trial test.
 76

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Proceedings 30 lh
Annual Meeting of the Canadian Mineral Processors, Ottawa,
Ontario, pp. 275-294.

Awmack J., B. Kuljit, R. Buhler, F. Jesse, 2004, "The effectiveness of the Knelson
C V D to process Flotation Tailings from the Eskay Creek M i l l " , Mine 338 Course,
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Burt, R.O., 1984, "Gravity Concentration - from Bench Scale to Plant", Annual
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Burt, R.O., 1999 "The Role of Gravity Concentration in Modern Processing Plants",
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Burt, R.O., 1998,"A Review of Gravity Concentration Techniques for Processing

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Annual Meeting of the Canadian Mineral
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Chan B S . K., R.H. Mozley and G.J.C. Childs, 1991, "Extended trials with the high
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 77

Drapack J . , 2004, "Identification of a Birchtree Ore M i l l Stream for Application of

the Knelson C V D Concentrator for Nickel and Precious Metals Recovery", Internal

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Guerney P. J . , A. R. Laplante S. O'Leary, 2003, "Gravity recoverable G o l d and the

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Annual Meeting of the Canadian

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Hilliard T., 2003, " T A N C O - Endurance through adaptability", C I M Bulletin, V o l .

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th

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 78

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New Era in Gravity Concentration, the Experience of C V R D Research Centre", pp. 1-
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th

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 80

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50 and 100 Laboratory Separators".

 Appendices

Appendix I - Eskay Creek

 82

Appendix IA Sample Characterization

A.l Particle Size Distributions

Table A.1.1. LGT Size Analysis

Size Fraction Weight % cummul.

Mesh um 9 % Passing
+50 +297 2.5 0.1 99.9
-50+70 -297+210 20.4 1.0 98.9
-70+100 -210+149 177.0 8.2 90.7
-100+140 -149+105 432.4 20.1 70.6
-140+200 -105+74 401.8 18.7 51.9
-200+270 -74+53 201.5 9.4 42.5
-270+400 -53+37 90.8 4.2 38.3
-400 -37 821.4 38.3
Tot. 2147.7 100.0

v . - -,
90

80

0> 70

| 60
CO

^ 50

E 40

5
30

20

10

0
10 100 1000
S i z e (um)

Figure A.1.1. Particle Size Distribution, L G T

 83

Table A.1.2. H G T Size Analysis

Size Fraction Weight % cummul.

Mesh um g % Passing
+50 +297 12.0 0.6 99.4
-50+70 -297+210 13.2 . 0.7 98.7
-70+100 -210+149 76.8 4.0 94.7
-100+140 -149+105 235.5 12.3 82.4
-140+200 -105+74 242.9 12.7 69.7
-200+270 -74+53 229.0 12.0 57.7
-270+400 -53+37 152.2 7.9 49.8
-400 -37 953.6 49.8
Tot. 1915.2 100.0

! | 1 1 1
i
'»•---«

' ! i
| ! i!
! 1

! ! i i
! i Mi I !V -I \ 'I ! ; 1
i ii
: j 1 1 1
*
I ! : ! ii
; !
I ! ij ii M
1 l !i
f 1
1
! ;•*
•' i i i i
i !
1

i i i !
i
j 1
I j
i
i j |
! ! i
i i
i
i i i WW
i j
I
i
! I
1 !

I III ! |
!— i
ii
!

10 100 1000
S i z e (pm)

Figure A.1.2. Particle Size Distribution, H G T

 # OX)

91.9
95.9
97.3

95.7
96.8
Tt

97.1
95.1
00 OS

Plant
a

Recov
eu o

93.2
9

92.9
90.8

95.0
90.3

90.4
95.1
Au
DC

r- 4* OS
o SO Tt ro Ov VO o » S

o o

0.12
0.12
0.17

0.26

0.15
0.11

0.11
3 3

Di
0.10
0.10
0.12

0.09
0.19
0.06

0.11
OS
£^
ci
cu 5# *s>
0.02

0.02
0.02

0.01
0.01

0.01
0.01
3

u
<D u
l-l
u
Total

41.4

33.0

80.9

48.3
69.7

32.7

21.7

U 3
>^ >s
o
03
M
w co r- 00 ON oo Tt t-
w
pm)

Tt vo ro CN vo CN Tt
u (D
o O
o.
Assays

+400*
-150"

ac oo oo o
<
Tt
r— CN T? oo T,

o
s
%

cu ro
Tt r- VO
CN Tt
o
ft
OS Os
CO
r- CN Tt
+

T3
Total

oq o ro Tt CS Os CN
CN CN CN o CO
H
H
r-; o
400*

O as Tt Os Tt Os
A u ( »pm)

CN CN
F

c3 r-; CN vq Os CN Os C3
bo
H m O
CN CN CN H CO
<u T +" a>
-o -a
CO CM
*o oo oo o
11 OS VO —
I-I

o + O CO

-a T3 *
Grind

70.3
82.3
64.9
70.0
68.7

71.7

69.5

o .a S ^ a
•r .2
S o
q
c «3 CN c O 8 9
^
o o
'3
21C

o o in o VO
r-
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A u Recovery v e r s u s Size
 102

10 100 1000

Size (um)
Figure C.6.3. S Recovery versus Size, L G T

S Recovery %
Figure C.6.4. A u Recovery versus S Recovery, L G T
Appendix ID Mineralogical Analysis
 fo3-l

Concentrate +100
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 70 7 2.985 208.95 45.73
21-40 0.3 25 7.5 3.655 91.38 20.00
41-60 0.5 10 5 4.325 43.25 9.47
61-80 0.7 0 0 4.995 0.00 0.00
81-100 0.9 20 18 5.665 113.30 24.80
Total 125 37.5 456.88
Total 1000
Grains

Class: Cone.+100
Texture: Complex
Grain Shape: Sub-Rounded
Grain Size: >149 pm
Mineral Associations: Primarily associated with the light colored gangue mineral
Mineral Surface: Because the sulfides exist as fine inclusions, it appears as though there
in insufficient surface area, indicating lowest sulfide recovery.
Impurities or Inclusions: Sulfide exists asfineinclusions within the gangue particles

Cone +100 Class Middlings Distribution

0-20 21-40 41-60 61-80 81-100

Class Middlings

Degree of liberation
 \ol-Z

Concentrate -1 00
Average # Of Sulphides Weight per grain Weight Wt%
Class
0.1 75 7.5 2.985 223.88 24.08
0-20
21^0 0.3 45 13.5 3.655 164.48 17.69
41-60 0.5 35 17.5 4.325 151.38 16.28
0.7 10 7 4.995 49.95 5.37
61-80
81-100 0.9 60 54 5.665 339.90 36.57
225 99.5 929.58
Total
Total 2500
Grains

Class: Cone.-100
Texture: Fairly complex. Some liberated particles
Grain Shape: Sub-Rounded
Grain Size: > 74 pm, < 149 pm
Mineral Associations: Primarily associated with the light colored gangue mineral
Mineral Surface: Because the sulfides exist as fine inclusions, it appears as though there
in insufficient surface area, indicating low sulfide recovery.
Impurities or Inclusions: Sulfide exists as fine inclusions within the gangue particles

Cone -100 Class Middlings Distribution

40.00
35.00
30.00
25.00
20.00
15.00
10.00
5.00
0.00
0-20 21-40 41-60 61-80 81-100

Class Middlings

Degree of Liberation = 49.09

 Concentrate -200
Average # Of Sulphides Weight per grain Weight Wt%
Class
0-20 0.1 100 10 2.985 298.50 15.18
21-40 0.3 60 18 3.655 219.30 11.15
41-60 0.5 50 25 4.325 216.25 10.99
61-80 0.7 20 14 4.995 99.90 5.08
81-100 0.9 200 180 5.665 1133.00 57.60
Total 430 247 1966.95
Total 2000
Grains

Class: Cone.-200
Texture: Primarily simple. Few complex particles, mainly liberated particles.
Grain Shape: Both Sub-Angular and Sub-Rounded
Grain Size: > 37 pm, < 74 pm
Mineral Associations: There are more particles which are fully liberated, hence minimal
association
Mineral Surface: Because most particles are fully liberated, recovery is higher
Impurities or Inclusions: Primarily none

Cone -200 Class Middlings Distribution

70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
0-20 21-40 41-60 61-80 81-100
Class Middlings

Degree of Liberation = 75.90

 Concentrate -400
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 60 6 2.985 179.10 1.95
21-40 0.3 20 6 3.655 73.10 0.80
41-60 0.5 80 40 4.325 346.00 3.77
61-80 0.7 120 84 4.995 599.40 6.53
81-100 0.9 1410 1269 5.665 7987.65 86.96
Total 1690 1405 9185.25
Total
5000
Grains

Class: Cone.-400
Texture: Fully Liberated, primarily simple.
Grain Shape: Both Sub-Angular and Sub-Rounded
Grain Size: < 37 |Jm
Mineral Associations: None
Mineral Surface: Fully liberated, so highest recovery
Impurities or Inclusions: None

Cone -400 Class Middlings Distribution

100.00 — i

80.00

60.00
pm
m i
I
i
m
— .— i—n
M
m
i
i
0-20 21-40 41-60 61-80 81-100

Class Middlings

Degree of Liberation = 90.32

 '03-5"

Feed +100
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 110 11 2.985 328.35 65.29
21-40 0.3 30 9 3.655 109.65 21.80
41-60 0.5 15 7.5 4.325 64.88 12.90
61-80 0.7 0 0 4.995 0.00 0.00
81-100 0.9 0 0 5.665 0.00 0.00
Total 155 27.5 502.88
Total 1000
Grains

Class: Feed+100
Texture: Complex
Grain Shape: Sub-Angular
Grain Size: >149 \im
Mineral Associations: Associated with both light and dark colored gangue minerals
Mineral Surface: Low sulfide content. Because the sulfides exist as fine inclusions, it
appears as though there in insufficient surface area for flotation of the sulfides
Impurities or Inclusions: Sulfide exists as fine inclusions within the gangue particles.

Feed +100 Class Middlings Distribution

70.00
60.00
50.00
gS 40.00
5 30.00
20.00
10.00
0.00
0-20 21-40 41-60 61-80 81-100

I Class Middlings

Degree of Liberation = 0
 Feed -100
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 90 9 2.985 268.65 49.00
21-40 0.3 25 7.5 3.655 91.38 16.67
41-60 0.5 5 2.5 4.325 21.63 3.94
61-80 0.7 5 3.5 4.995 24.98 4.56
81-100 0.9 25 22.5 5.665 141.63 25.83
Total 150 45 548.25
Total
2500
Grains

Class: Feed-100
Texture: Lower degree of complexity.
Grain Shape: Both Sub-Angular and Sub-Rounded
Grain Size: > 74 |jm, < 149 |Jm
Mineral Associations: Associated with both light and dark colored gangue minerals
Mineral Surface: Low sulfide content. Because the sulfides exist as fine inclusions, it
appears as though there in insufficient surface area for flotation of the sulfides
Impurities or Inclusions: Sulfide exists asfineinclusions within the gangue particles

Feed -100 Class Middlings Distribution

21-40 41-60 61-80 81-100

Class Middlings

Degree of Liberation = 50.0

 Feed -200
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 230 23 2.985 686.55 47.72
21-40 0.3 50 15 3.655 182.75 12.70
41-60 0.5 40 20 4.325 173.00 12.02
61-80 0.7 0 0 4.995 0.00 0.00
81-100 0.9 70 63 5.665 396.55 27.56
Total 390 121 1438.85
Total 2000
Grains

Class: Feed-200
Texture: Primarily simple. Some fully liberated particles
Grain Shape: Both Sub-Angular and Sub-Rounded
Grain Size: > 37 pm, < 74 pm
Mineral Associations: Mainly associated with light gangue mineral. There are more
particles which are fully liberated
Mineral Surface: Because more particles are fully liberated, higher sulfide content
Impurities or Inclusions: Sulfide exists as bothfineinclusions within the gangue
particles and as liberated particles

Feed -200 Class Middlings Distribution

60.00

0-20 21-40 41-60 61-80 81-100

Class Middlings

Degree of Liberation = 52.07

 Feed -400
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 140 14 2.985 417.90 13.78
21-40 0.3 40 12 3.655 146.20 4.82
41-60 0.5 40 20 4.325 173.00 5.70
61-80 0.7 40 28 4.995 199.80 6.59
81-100 0.9 370 333 5.665 2096.05 69.11
Total 630 407 3032.95
Total 5000
Grains

Class: Feed-400
Texture: Fully Liberated
Grain Shape: Sub-Rounded
Grain Size: < 37 pm
Mineral Associations: None
Mineral Surface: Fully liberated, indicating highest sulfide content of the feed
Impurities or Inclusions: None

Feed -400 Class Middlings Distribution

80.00

60.00

40.00

20.00

0.00
0-20 21-40 41-60 61-80 81-100
Class Middlings

Degree of Liberation = 81.82

 Tails +10C
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 100 10 2.985 298.50 80.33
21-40 0.3 20 6 3.655 73.10 19.67
41-60 0.5 0 0 4.325 0.00 0.00
61-80 0.7 0 0 4.995 0.00 0.00
81-100 0.9 0 0 5.665 0.00 0.00
Total 120 16 371.60
Total
1500
Grains

Class: Tails+100
Texture: Complex
Grain Shape: Sub-Rounded
Grain Size: >149 pm
Mineral Associations: Associated with both light and dark colored gangue minerals
Mineral Surface: Little to no sulfide content
Impurities or Inclusions: Sulfide exists asfineinclusions within the gangue particles

Tails +100 Class Middlings Distribution

100.00

80.00

3= 60.00

§ 40.00

20.00

0.00
0-20 21-40 41-60 61-80 81-100
Class Middlings

Degree of Liberation = 0
 Tails -100
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 95 9.5 2.985 283.58 44.68
21-40 0.3 20 6 3.655 73.10 11.52
41-60 0.5 25 12.5 4.325 108.13 17.03
61-80 0.7 0 0 4.995 0.00 0.00
81-100 0.9 30 27 5.665 169.95 26.77
Total 170 55 634.75
Total
1000
Grains

C l a s s : Tails-100
Texture: Lower degree of complexity.
Grain Shape: Sub-Rounded
Grain Size: > 74 pm, < 149 pm
Mineral Associations: Associated with both light and dark colored gangue minerals
Mineral Surface: Low sulfide content
Impurities or Inclusions: Sulfide exists as fine inclusions within the gangue particles

Tails -100 Class Middlings Distribution

50.00

40.00

3? 30.00

§ 20.00

10.00
0.00
0-20 21-40 41-60 61-80 81-100
Class Middlings

Degree of Liberation = 54.27

 Tails -200
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 150 15 2.985 447.75 38.26
21-40 0.3 50 15 3.655 182.75 15.62
41-60 0.5 10 5 4.325 43.25 3.70
61-80 0.7 20 14 4.995 99.90 8.54
81-100 0.9 70 63 5.665 396.55 33.89
Total 300 112 1170.20
Total
2000
Grains
I

I
( Class: Tails-200
Texture: Primarily simple. Some fully liberated particles
1
Grain Shape: Both Sub-Angular and Sub-Rounded
i Grain Size: > 37 pm, < 74 pm
Mineral Associations: Mainly associated with light colored gangue mineral. There are
more particles which are fully liberated, indicating the CVD was unable to recover these
sulfide particles.
Mineral Surface: Because more particles are fully liberated, higher sulfide content
Impurities or Inclusions: Primarily none due to simple structure

Tails -200 Class Middlings Distribution

50.00 T-

0-20 21-40 41-60 61-80 81-100

Class Middlings

Degree of Liberation = 72.87

 Tails -400
Class Average # Of Sulphides Weight per grain Weight Wt%
0-20 0.1 80 8 2.985 238.80 8.44
21-40 0.3 50 15 3.655 182.75 6.46
41-60 0.5 80 40 4.325 346.00 12.23
61-80 0.7 50 35 4.995 249.75 8.82
81-100 0.9 320 288 5.665 1812.80 64.05
Total 580 386 2830.10
Total
5000
Grains

Class: Tails-400
Texture: Fully Liberated
Grain Shape: Both Sub-Angular and Sub-Rounded
Grain Size: < 37 pm
Mineral Associations: None
Mineral Surface: Fully liberated. Indicating the CVD was unable to recover these
sulfide particles, and highest sulfide content of the tails.
Impurities or Inclusions: None

Tails -400 Class Middlings Distribution

70.00
60.00
50.00
3? 40.00
S 30.00
20.00
10.00
0.00
0-20 21-40 41-60 61-80 81-100
Class Middlings

Degree of Liberation = 90.32

 104

Appendix I E Flotation Test

Flotation Test on C V D Concentrate

Sample: C V D Concentrate ( C V D Pilot Test 6)

Sample weight: 500 g
Particle Size: P o =
8 180 (im

For flotation test the sample was ground to Pso = 75 pm.

Flotation Procedures and Conditions:

pH: Natural
Conditioning time: 5 minutes
Collector: P A X (100 g/t)
Frother: MIBC
Rougher flotation time: 5 minutes

T a b l e 1. Metallurgical Balance, L G T

Weight Grade Distribution %

Material Au Fe S
% A u (ppm) A g (ppm) Fe% S % Ag
Concentrate 33.4 9.26 141.0 3.85 2.3 81.0 72.9 37.6 74.3
Tailings 66.6 1.09 26.3 3.2 0.4 19.0 27.1 62.4 25.7

Feed ( C V D Con) 100 3.82 64.6 3.42 1.03 100 100 100 100
A p p e n d i x II - I N C O T h o m p s o n
Appendix HA Sample Characterization

A.l Particle Size Distributions

Table A. 1.1. SC-4 Size Analysis

Size Fraction Weight % cummul.

Mesh um 9 % Passing
+50 +297 127.1 3.0 97.0
-50+70 -297+210 113.2 2.7 94.3
-70+100 -210+149 192.3 4.5 89.8
-100+140 -149+105 289.4 6.8 83.0
-140+200 -105+74 460.6 10.8 72.2
-200+270 -74+53 755.9 17.8 54.4
-270+400 -53+37 488.5 11.5 42.9
-400 -37 1824.6 42.9
Tot. 4251.7 100.0

. .4

80

4
/

20

g ^ I I I I I I I I | I I I I I I I I |
10 100 1000
Particle Size(um)

Figure A.1.1. Particle Size Distribution, SC-4

 107

Table A.1.2. AS-4 Size Analysis

Size Fraction Weight % cummul.

Mesh um g % Passing
+50 +297 86.5 1.5 98.5
-50+70 -297+210 233.2 3.9 94.6
-70+100 -210+149 676.0 11.4 83.2
-100+140 -149+105 994.6 16.8 66.4
-140+200 -105+74 1004.6 17.0 49.5
-200+270 -74+53 1117.0 18.9 30.6
-270+400 -53+37 532.1 9.0 21.6
-400 -37 1281.5 21.6
Tot. 5925.4 100.0

100

! I ! ! -:*
I i : I 1
i i ;
.•:

80 i I !i 1 i ! : 1 / ]
!
I ; i I

i i l l !
i ji.il.*.- :
I i
• 1 i
| !!;!•' ! | !
I ; i :

4
/! i!!
11
!
! i
E I

i | i III!
i1
'
!
I !
! MM
• i !! 1 | ! | i

i i
20 I ;

! !
i \ i i i '

!i 1
i
\
i ;
0
10 100 1000
Particle Size (um)

Figure A.1.2. Particle Size Distribution, AS-4

 CO
CO

CO
05

CO

CM

CO
LO LO
CO

CO
CO

3
of

'I
ID
CO
LO LO

H
CO
CM
CN
CM

<
CT>

CU

s
co CM CO
H
CO CO
A.3 Magnetic Particles Distribution

Table A.3.1. Magnetic Particles Distribution, SC-4

Size Non
Magnetics Magnetics
Fraction magnetics
9 %
(um) 9
+297 2.1 76.9 2.6
-297+210 12.6 56.1 18.3
-210+149 32.2 111.0 22.5
-149+105 48.2 184.2 20.7
-105+74 75.8 186.2 28.9
-74+53 50.7 115.5 30.5
-53+37 50.8 101.8 33.3
-37 27.7 177.0 13.5
Tot. 299.9 1008.6 22.9

50

40 ]

I
J Z L
+297 -297+210 -210+149 -149+105 -105 +74 -74 +53 -53 +37 -37

Size Class (um)

Figure A.3.1. Magnetic Particles Distribution for each size fraction of SC-4
 Table A . 3 . 2 . Magnetic Particles Distribution, AS-4

Size Non
Magnetics Magnetics
Fraction magnetics
g %
(pm) g
+297 0.9 35.2 2.5
-297+210 18.2 152.5 10.6
-210+149 47.2 273.5 14.7
-149+105 47.3 137.7 25.6
-105+74 60.3 153.2 28.2
-74+53 79.7 198.3 28.7
-53+37 64.5 113.9 36.1
-37 53.9 122.8 30.5
. Tot. 371.9 1187.1 23.9

10 4

+297 -297+210 -210+149 -149+105 -105+74 -74 +53 -53 +37

Size Class (um)

Figure A.3.2. Magnetic Particles Distribution for each size fraction of A S - 4

 oq m rn

Mag

21.2
Tt CN Tf
d d d CN •n Tf SO p
o
co coap i n CN p r-- O rn oo o
CN CN rn CN 00 CN od

z s
60
Tf r~

Tf oo p Tf
CN
ca d d rn Tf rn SO CN p
00
o
s
o
a oo oo •n CN in rn 00
o ca Tf
r~ od
CN CN SO
s m r-
Tt

Distrib ution% z
oo m rn oo p CN
ca sq SO Tf

rn •n CN i n
s
d d CN CN p
3 o
CJ o
B OO in O o Tf o oq
o ca rn CN TT SO SO t~ Tf
Tf od
Tf
Z S
60 m OO rn OO Os s q CN CN
ca d d d CN •n rn SO CN p
7
C/3
s
c jp rn rn in
o ca so in Tf
o
oq o
rn r-" Os' od
u Z 2
rn CN TT
m
00 CN
»> TT Os s q rn CN s q
ca d d d rn in rn so p
CN
"a
c« z o
sa
c cSP 00 Os s q m Tf os Osoq o
CU
CN CN rn TT d od
Z S Tf
m r~
rt
« 00 O o
oo
Tf CN r- Os i n
CN i n rn CN s q
Tf Tf

.a u.
2
ca od
CN CN
OS in CN
CN CN od m m od
Tt

CN CN
CZ) CN O O OS SO OS m m Os SO
cn o ca t-; t-; Os <N O
O oo SO od
U Z S rn od OS d
Tf i n so SO
S
-B
O 60 os m SO os SD o OS O O
CN SO CN rn
ca in Tf
i n rn T f
so d od Os od
a 00
so
o
cct s o ca o
OS rr Os i n
in
•n m 00 CN oo
o I-; s q m d
Tf

« Z 2 d CN CN
H
d
OS Os d
a •n OS oo m m T f OS m
CU
SP •n in SO in T f m m T f
CD
ide%

o o p o o O o o
cu
CU
3
CJ
s d d d d
d d d d d

So O m so oo CN in
« o ca TT TT
O
Tf m
o
CN CN CN T f
O O o
rn
O
o o o
z s d d d d
d
d d d d

00 oo T f in r- oo Tf Tf
oo O O rn r-; OS
ca Tf Tf
TT m' rn rn rn T f rn Tf Tf

— m so O in r ~ o m oo
O rt SO TT oo o oo m o
3 Z S Tr' CN CN rn TT
Tf
Tf rn T f T f
cct
H OS m CS TJ" m Tf oo
CN o CN SO •n 00 T f so

s sri SO in T f
•n d d in d d s q
d d d
in
d
d
z B 60 imn m •n m oo m in o
OSoo rn r- oo o Tf
o ca m m
m d d CN CN
Tj- SO T f
d d d d d
s
d
d
z
oo OS CN m m CN oo
60 o Tf O Tt Tf OO oq
ca d d —
i< rn in rn in CN

s
-*—»
rf p
Weigl

NonMag%

d
o
m
o o o rn o
OS in TT sq oq
CN CN rn •n CN od
m

o Os iv, Tf
Fraction

Tf O rn
r~
+ + + + + m
Size

CN
6 OS + m o
3. + OS o Os
Tf
o Tf f-
CN
 m

Mag

28.0
CN OO CN Os CN
d d rn TT' od rn O
1> o

-
co ocap p 00 sq Os Os p oq p o
CN m" CN
Z £ CN TT od CN

60 p
00 m 00 p CN
ca od
£ d d Tr" sd TT Tt CN iri
CN p
00
o
£
c op rn sq Os u-i p Os oo O o
CN CN SO CN
Z £ rn oc iri

Distrib ution% 00 m r-- sq Os rn sq oo p

ca od
£ d d rn w~i u-i TT p
CN
3 o
u co ocap ON o 00 r- p oo oo p o
oo TI" OS CN
z £
(--* Tt
CN

00 oo p sq CN Os sq p
ca od
d d CN rn Tf SO rn sd o
£ CN
o
c op p Os p CN rn O o
o * Tf CN
r~* d CN CN
Z £ CN rn CN i/-i OS CN

00 m sq ST) oo CN sq sq rn p
ca 00
d d CN rn l/-i r-" CN «-i CN p
£
o
Z co ocap C-; p SO OO OS CN m O o
sd CN
rn SO od O* Os SO
Z £ CN f~

00 SO m r- oo CN Tt CN r-
C3 OS TT sq r- CN OS iri
•<r i/"i CN* d CN rn rn
£ CN CN CN m CN CN
m
u- OS OS Vl OS oo m CN
o « CN C~; m TT lo CN
d rn d
OO SO V-i r-"
z £
00 CN Tf
OS OS
IT) 1/1 Os Os
ca Tf
oo
Os l/-i iri d d d
6X1
£
t-H
r-^
£
OS SO l/"» m OS m Os
o <2«P
c 1/-S

o Tt p m rn p
CN rn CN rn rn rn
Z £ TT CN m"

r~ SO m in
OO i/-i m m m CN CN
Gr ade%

o o o CN O o CN
ca o o
d d d d o d d o
3 £ d d d

u -3- un m SO SO
m CN
O
CN CN
o o
CN CN
o O O o O
o
d d d d d d d d
d

. gp OS
OS
oo
>/-> m
OS
SO
o oo Tl"

Tf'
£ CN Tf CN CN* CN rn Tf' rn

TJ-
CN TT CN SO Os Os CN «-i
o ca Tf
oo O oo Tf Os rn TT
CN
z £ Tt
d
rn rn rn CN

Vi CN O T1- OS Tf TT in
OS C^ TT m o OS 00
m CN CN CN m m CN CN CN
£ d d d d d d d
d d

z
m oT t oSO
00 CN «-> oo
o ca I/I
CN
SO OS
rn
OS
Z £ d d d d d d d d d

oo CN •>*• SO Tl" so so
00 in OS 00 Os
oo
ca d d CN* Tr" Tt" sd CN vi t-^
CN
£
o
Weigl

d
NonMag%

o
o SO OS T
p
Os Tf
O
TT O Tl-
m
rn TT
p CN TT O
CN CN CN sd CN*
rn oo SO

o OS
Fraction

V,
TT rn
r- TT
o m
Size

S + + + +
3.
Os
OS o
+
Os
O TT
r~
+
"?
1
+ (N
 Grade Distribution %

Of
•e
Density

.2 w
. 0

?
£
Class

0
S3
M

S?
Ni% Stot.% Fe% Cu% Au (ppm) Stot. Fe Cu Au

*> s
S
d<2.7 55.57 0.195 2.71 10.84 7.22 0.042 0.013 37.0 43.0 43.5 46.2 50.0 16.4

OO
od
CC
2.7<d<3.1 20.18 0.312 4.43 9.93 0.041 0.024 21.5 25.5 27.5 23.1 0 17.7 10.9

o\
ov'
3.1<d<3.5 8.23 10.41 -
00

0.306 3.85 17.33 0.044 0.026 10.3

06
Tf
Tf

Tt
Tt
+297 2.99
IN

OV
m
m
rn

3.5<d<3.9 4.07 0.295 4.18 15.49 11.15 0.052 0.037

Tf
Tf
Tf

rs
<N
rs

3.9<d<4.3 1.61 0.263 4.42 14.59 11.9 0.050 0.122

d>4.3 10.34 0.775 5.24 16.76 11.32 0.083 0.263 27.4 15.5 12.5 13.5 18.3 60.3
0001 0 001 0 001
0.293 3.50 13.86 8.69 0.047 0.045 100.0 100.0 100.0 100.0

d<2.7 40.72 0.157 1.45 6.46 7.77 0.031 0.010 18.5 13.1 21.1 28.5 29.7 13.6

2.7<d<3.1 17.44 0.239 2.58 10.85 12.94 0.043 0.025 12.1 10.0 15.2 20.3 17.4 14.5
O

vo
Tt

-
rs
rs
in
rs

06

3.1<d<3.5 9.29 0.261 13.61 0.049 0.017 11.4

vn

10.6
in
in

(N
vq

-297+149 7.18
O;

VO
rn
0^

00
rn

3.5<d<3.9 4.27
00

0.293 2.97 10.96 14.68 0.059 0.027

m'
p

0
0

in
Tf
(N

rs
rs
rs

rn
rn

3.9<d<4.3 2.30 0.300 2.89 10.71 14.4 0.059 0.031

vO
rn

d>4.3 25.99 0.757 11.68 23.87 13.33 0.054 0.069 56.8 49.8 31.2 33.2 60.4
r->"

—
0 001 0 001 0001 0 001 0 001
0.346 4.51 12.46 0.043 0.030 100.0 100.0

Ov
00
d<2.7 ' 40.21 0.201 3.17 10.38 0.035 0.017 27.3 20.8 24.0 35.1 34.9 26.8

V
rn
19.61 0.269 3.98 14.85 11.09 0.045 0.027 17.8 12.7 16.7 21.3 21.9 21.1
m
t>

Tt
r-
NO

00

3.1<d<3.5 5.61 14.74 0.049

00
»n

0.281 4.15 12.63 0.025

<>

Tf

vo
vq

-149+105 6.81
rs
rs

3.5<d<3.9
rn
rn

2.62 3.91 13.04 0.074

00

0.288 14.05 0.056

p
in

vq
m
rs
rs
rs

VO

rn
3.9<d<4.3 1.89 0.251 11.53 13.58 0.055 0.032 ,
wn

d>4.3 30.07 0.445 12.24 29.64 10.43 0.041 0.030 45.3 60.1 51.2 30.8 30.3 36.2
0 001 0 001 0 001 0001 0 001
0.295 6.13 17.41 10.20 0.041 0.025 100.0 100.0
 Grade Distribution %

Oli

.c
S
Size Density

OX)

o
Class(um) Class

? v?
B
C
Ni% Stot.% Fe% Cu% Au (ppm) Stot. Fe Cu Au

SD <*"
a
rn
d<2.7 41.49 0.155 2.42 7.92 9.55 0.022 0.011 27.0 15.3 44.1 35.5 25.7

-
od
2.7<d<3.1 11.56 0.228 4.64 15.18 11.74 0.033 0.022 15.1 14.5 15.0
O
o

O
Tt

vq

rn
rn
rn

3.1<d<3.5 2.79 0.267 4.71 20.46 11.5 0.036 0.030

fN
fS

P
-105+74 10.83
rs
rs
oo

4.67 21.42 0.040

oq
3.5<d<3.9 1.83 0.261 11.85 0.026
p

fN
fN
(N

Tt
Tt

- -
rn

1.84 4.64 15.84 12.32 0.045 0.047

un

3.9<d<4.3 0.305

d>4.3 40.50 0.320 14.43 37.54 7.18 0.026 0.020 54.4 76.0 70.7 32.3 40.2 46.6
0001 0 001 0 001 0 001 0 001
0.238 7.68 21.50 8.99 0.026 0.017 100.0 100.0

d<2.7 41.03 0.165 3.25 10.25 9.93 0.020 0.071 27.5 15.7 17.2 49.2 36.6 73.9
o

r-'
Ov

14.07 4.74 9.94 10.9

oq

2.7<d<3.1 0.217 18.92 0.028 0.025 12.4 16.9 17.4

fN
fN
fN
fN

Tt
m
vq

3.1<d<3.5 2.28 5.28 9.62 0.032

vn

0.273 24.25 0.036

m"

tN
fN
fN

-74+37 29.27
vq

rvi

3.5<d<3.9
oq

1.76 0.292 24.36 9.91 0.036 0.037

oq

d
d
d
d
d

vO

3.9<d<4.3 0.57 0.267 5.22 21.37 10.73 0.046 0.038

un

d>4.3 40.29 0.334 15.58 40.74 5.84 0.022 0.013 54.8 73.7 67.3 28.4 38.9 12.8
0001 0 001 0 001
100.0 0.245 8.52 24.39 8.28 0.023 0.039 100.0 100.0 100.0
66 01

r~
rn
42.91 0.659 4.47 20.55 0.044 0.032 57.2 45.7 45.9 45.5 47.4 60.1
0 001 0 001
Tot.(calc) 100.0 0.434 6.09 20.78 9.86 0.036 0.032 100.0 100.0 100.0 100.0
 Grade Distribution %

U
.c
•s
Density

Mo

§^

u
?
0 -
Class

<* 3
M
Ni% Stot.% Fe% Mg% Au (ppm) Stot. Fe Cu Au

d<2.7 37.1 0.166 1.05 5.57 9.04 0.033 0.023 20.9 17.7 26.0 32.0 33.4 10.3
o-

2.7<d<3.1 25.03 0.160 1.00 5.46 8.92 0.032

rn

0.013 13.6 11.3 17.2 21.3 22.0

o
d

(N
3.1<d<3.5 5.11 0.164 0.97 9.27 rr

OO
9.28 0.030 0.011

CN
rr'

<N
>n

p
+297 1.46

m
rn
rn
rr
(N

CN
rr
rr

3.5<d<3.9 3.02 0.227 2.18 8.95 14.58 0.051

rr'
rM

0.067
<N

p
o

ON
o'

3.9<d<4.3 6.74 0.307 4.09 11.53 13.94

OO
0.054
OO

0.897 12.5
r>

73.7
o
ON

d>4.3 23.01 0.684 5.11 12.99 13.28 0.043 0.032 53.4 53.3 37.6 29.1 26.5
0 001 0 001 0 001 0 001
100.0 0.295 2.206 7.943 10.495 0.037 0.082 100.0 100.0

d<2.7 38.11 0.089 0.55 3.89 8.48 0.016 0.022 23.5 10.7 20.0 25.1 27.3 49.7
1
NO

2.7<d<3.1 21.22 0.147 0.63 6.82 12.41 0.026

oo

0.017 21.7 19.6 20.5 24.5 22.2

NO
vi

3.1<d<3.5 12.27 0.157 0.81 6.83 0.027 0.017 13.3 11.3 15.3 14.8 12.9
p

-297+149 15.35 3.5<d<3.9 5.65 0.178 1.32 6.66 18.09 0.029

rn

0.008
oq
OO
CN

wS

m'
Q\

rn

3.9<d<4.3 3.17 0.192

m
rr

rN

CN

1.69 7.21 18.14 0.027

r-^

rr'
rn
rN

0.011
CN

oo

d>4.3 19.58 0.222 7.09 15.45 17.59 0.026 0.009 30.3 70.8 40.9 26.8 22.3 10.2
0001 0 001 0 001
100.0 0.144 1.96
0 001
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to ©
Ni%
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yield)

2 ^
(ppm)
t
in

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Tr'

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15.00 8.33
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>37 57.08 3.5<d<3.9 2.31 1.23 0.038 19.57 4.46 11.71 0.285 2.61 0.29 3.38 31.50 4.28 3.76 0.674 23.5 37.8 22.5 55.5
od

3.9<d<4.3 1.24 0.71 0.040 15.49 4.19 12.52 0.285 1.43 0.16 3.33 28.99 4.57 4.66 0.754 23.1 43.2 25.2 61.0
d>4.3 35.74 21.69 0.020 37.67 14.7 7.14 0.369 65.22 7.86 0.67 47.56 19.4 1.25 0.592 36.2 45.8 47.8 58.2
w-i

0 001
Tot. 57.75 0.031 21.62 7.61 8.96 0.259 100.0 12.1 1.06 38.82 13.9 2.51 0.554 20.9 37.5 38.3 44.6
CT-
 138

90 -I

-•- - - Test 1
80
• » - • Test 2
70
Test 3
60
Test 4
50 Test 5b

40 J, -•- • - Test 6

•+•-• Test7
30 .4.
20
-<«\
10

10 100 1000

S i z e (pm)

F i g u r e C.6.5. Size Separation P a r t i t i o n C u r v e s , SC-4

2.25 2.75 3.25 3.75 4.25 4.75

Density (g/cm3)

a -297+149 pm -149+105 pm -105+74 pm x -74+37 pm • +37 pm • + 2 9 7 pm

F i g u r e C.6.6. Partition Coefficient Curves for each Size Fraction

Mass Y i e l d versus Density)
 2.25 2.75 3.25 3.75 4.25 4.75

Density (g/cm3)
• 297 (jm • -297+149 pm -149+105 pm -105+74 pm X -74+37 pm • +37 pm

Figure C.6.8. M g Recovery for each Size Fraction

( M g Recovery versus Density)
 140

2.25 2.75 3.25 3.75 4.25 4.75

Density (g/cm3)
4> +297 pm • -297+149 pm -149+105 pm -105+74 pm x -74+37 pm • +37 pm

F i g u r e C.6.9. S Recovery for each Size Fraction

(S Recovery versus Density)

F i g u r e C.6.10. Fe Recovery for each Size Fraction

(Fe Recovery versus Density)
 141

Appendix H E Flotation Test

Flotation Test on C V D Concentrate

Sample: C V D Concentrate ( C V D Pilot Test 7)

Sample weight: 500 g
Sample Particle Size: Pgo = 160 [im

For flotation test the sample was ground to Pso - 100 |im.

Flotation Procedures and Conditions:

Conditioning time: 5 minutes

pH: 10
p H Regulator: Soda A s h
Collector: P A X (125 g/t)
Frother: MIBC
Rougher flotation time: 5 minutes

T a b l e 1. Metallurgical Balance, S C - 4

weight Grade Distribution %

Material
% Ni% Fe% Mg% S% Au(g/t) Ni Fe Mg S Au
Concentrate 35.1 1.32 50.4 2.7 29.7 3.97 64.1 37.6 26.1 38.9 98.2
Tailing 64.9 0.40 45.2 4.1 25.2 0.04 35.9 62.4 73.9 61.1 1.8
Feed 100 100 100
100 0.72 47.0 3.6 26.8 1.42 100 100
( C V D Con)