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GOLD EXTRACTION As the Discovery Rate and Grades Fall, John Chadwick

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GOLD EXTRACTION As the Discovery Rate and Grades Fall, John Chadwick GOLD EXTRACTION Midas mission As the discovery rate and grades fall, John Chadwick looks at ideas and technologies to get the most out of the world’s gold deposits he declining rate of new gold discoveries North America, although with significantly less MDM Engineering Group has signed an EPC contract for the execution of a 2.4 Mt/y gold and grades across the global market new ounces of 290 Moz, and with a much lower plant for African Barrick Gold’s (ABG) Tduring the last decade has accelerated grade of 1.3 g/t. Bulyanhulu Process Plant Expansion project in over the last four years. Data and analysis from Europe had the third most new discoveries Tanzania. ABG is the largest gold producer in Tanzania with a portfolio of four operating IntierraRMG reveals that the two-year period with 240 Moz but with a higher grade than North mines and is the owner and operator of from 2003 to 2004 was the best in the study America of 2.0 g/t. South America recorded 188 Bulyanhulu Gold Mine. MDM successfully range, with over 400 Moz of new gold Moz, whilst Australasia saw 74 Moz of new completed the bankable feasibility study in December 2011 followed by value engineering discovered. This includes Inferred, Indicated and discoveries with an average grade of 1.4 g/t. in March and April 2012. MDM is now executing Measured ounces with an average grade of 1.65 Glen Jones, Western Hemisphere Director for the project which includes construction of a g/t. In contrast, 2005 and 2006 had the lowest IntierraRMG concluded, “With global drilling new 2.4 Mt/y CIL (carbon in leach) facility to process tailings reclaimed from the historical number, with just over 150 Moz of new gold activity waning, IntierraRMG forecasts that the tailings concurrently with current flotation discovered - albeit with a similar grade. next few years will continue the trend with fewer tailings Discoveries then increased significantly during new gold discoveries.” 2007 to 2008 with greater than 390 Moz. The Once a deposit has been discovered, Whittle “New technologies in ore characterisation average grade also increased significantly to Consulting has new software that it claims and extraction processes enable substantial 2.65 g/t; the highest in the 10 year period. “increases mining NPV by 5% to 35%, or economic and energy saving opportunities. Over the next two years, slightly more than substantially more.” It has announced a Developments in these areas, led by our alliance 250 Moz were discovered with a declining grade significant upgrade to its in-house 'Prober' partner JKTech, have clear operational benefits, of 1.25 g/t. This deterioration continued through software. After more than three years of and now we can harness their strategic 2011 and 2012 as the amount of new gold development, prototyping and testing, the latest significance by re-optimising the pits/phases or ounces discovered dipped below 225 Moz with a version 'Prober C' enables intricate modelling of underground mines, mining methods, life-of- reduced grade of 1.17 g/t. multiple steps in the mining value chain, bringing mine schedules, cut-off grade and stockpiling In this ten-year study period, Africa led the technologies such as mine-to-mill, selective strategies, processing policies, product way with new discoveries of 479 Moz of gold blasting, ore sorting, and complex comminution strategies, logistics and capital scaling with an average grade of 2.8 g/t. Next was strategies into the strategic planning process. decisions to apply these technologies in an integrated fashion. This will compound economic performance and capital efficiency to new levels.” explains Whittle Consulting CEO – Gerald Whittle. For the last decade, Whittle Consulting has helped mining companies substantially improve the cash flow profiles of projects and operations through an integrated approach of ‘Enterprise Optimisation’. “Invariably,” it claims, “the result is an increase in NPV of 5% to 35%, and sometimes substantially more. In many cases the net cash flow is doubled in the first three to five years, usually with little or no capital expenditure involved. As the trends continue The world's declining rate of new gold discoveries and grades Source: IntierraRMG towards lower grade and problematic orebodies, 14 International Mining | MAY 2013 GOLD EXTRACTION escalating costs, scarce capital and diminishing margins – the Enterprise Optimisation capability will help progressive mining companies lead the way in terms of competitiveness and sustainability.” Enterprise Optimisation, often nick-named the ‘Money Mining’ approach, is underpinned by Prober software developed by Jeff Whittle, founder of the Whittle business and the Gold ore by QEMSCAN developer of the original Whittle Pit Optimisation software that has become the cycle and how it behaves. Many operations and the reliance on gold concentration by industry standard for mine planning over the perform routine metallurgical audits to monitor gravity methods can be reduced. This leads to last three decades. Jeff, now 83 years old, process behaviour but these rely on chemical greater efficiency in the gold deportment explains “We have been using the previous assays or basic test work and provide little characterisation process and much more reliable version Prober B for over a decade. It allows for fundamental understanding of the mineralogy or determination of gold populations. In addition three steps in the value chain: mining, fundamental associations of gold or gold- to location of gold grains, information about the processing and production, although with some bearing grains. Adding a fundamental ore mineralogy is gathered. This provides much clever but convoluted modelling more could be mineralogical understanding to routine more information about the process behaviour accommodated. The new Prober C supports metallurgical test work can provide great of an ore and means that gold deportment unlimited sequential or parallel procedures, insights into the results and lead to more characterisation studies can become detailed making more detailed yet more intuitive efficient programs that identify and address process diagnostic tools. modelling of complex mining and processing issues more quickly and at reduced overall “MinAssist is a leader in applying the technologies possible. This is then cost.” information generated through gold deportment simultaneously optimised to maximise the value The last decade has seen rapid advancement characterisation for process troubleshooting and of the business.” in Scanning Electron Microscope (SEM) based optimisation. Operations can benefit greatly automated mineralogy systems, such as from using the advanced methodologies for gold Recovery challenges QEMSCAN and the Mineral liberation Analyser deportment characterisation. Detailed The AMIRA P420 series of Gold Processing (MLA). These systems provide a tool for rapid evaluation of distinct ore types or feed blends Technology projects has delivered industry evaluation of mineral composition using can be used to guide process optimisation. focussed research outcomes for 25 years. The standardised sample preparation procedures. Understanding the fundamental gold P420E extension project proposes new Statistically representative populations of populations and mineral associations in feed initiatives in the area of gold processing set particles can be analysed to generate false material can be used to highlight areas of within the context of the complex technical, colour mineral maps and determine important inefficiency within the process. Targeted human resource development and environmental information such as mineral grain size, evaluation of process streams can be used to challenges that face the gold industries of the associations of minerals within particles and troubleshoot specific problems, identifying the second decade of the 21st century. mineral locking/liberation characteristics. When root cause and reducing the need to additional The 420E project attempts to address the applied to analysis of trace phases, such as gold forensic metallurgical testwork. Finally, routine challenges of the gold mining sector “with a and precious metals, automated mineralogy evaluation of tailings streams is used as a dual approach to low grade ores; investigating systems provide the capability to rapidly locate ‘health check’ for the process, identifying physical methods for continuous early gangue and identify grains with size greater than 1 whether gold losses are occurring and what is rejection, with an emphasis on ore micron and allow many more particles to be causing them.” characterisation of the amenability for ores for examined than would be possible by manual Using these tools operations are continuous high mass gravity separation; and methods. progressively moving from a reactive approach novel research into the production of “The use of gold deportment to process troubleshooting to a diagnostic and environmentally benign gold lixiviants at site, characterisation as a tool for routine analysis in manageable approach. This saves time and with an emphasis on organic acids lixiviants gold operations has always been hampered by money, leading to a smoother operation and through bacterial production. Both these difficulties in locating representative reduced gold losses. approaches, one physical and the other populations of gold particles,” Goodall chemical, seek to reduce 1) fine grinding of the continues. “Traditionally, gold deportment Gravity still improving total mined ore; 2) the associated
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