Integrated Mining and Preconcentration Systems for Nickel Sulfide Ores Trent William Weatherwax
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INTEGRATED MINING AND PRECONCENTRATION SYSTEMS FOR NICKEL SULFIDE ORES by TRENT WILLIAM WEATHERWAX BS Michigan Technological University, 2003 THESIS SUBMITTED IN PARTIAL FULFILMENT OF REQUIREMENTS FOR THE DEGREE OF MASTER OF APPLIED SCIENCE in THE FACULTY OF GRADUATE STUDIES (Mining Engineering) THE UNIVERSITY OF BRITISH COLUMBIA December, 2007 © Trent William Weatherwax, 2007 Abstract As part of a strategic research initiative at UBC to design and evaluate integrated underground mining and mineral processing systems, work has been done to determine how to utilize the coarse rejects of pre-concentration in the underground environment. An amenability study for nine orebodies from four of Xstrata Nickel’s Ontario operations evaluated both processing and waste disposal methods. Metallurgically the orebodies showed amenability to dense media separation and conductivity sorting. The dense media results showed high mass rejections and high metal recoveries for all nine orebodies. Conductivity sorter results were not as consistent, but still showed good results. Dense media rejects were examined to determine the applicability of their use in rockfills and composite minefills. The geotechnical properties indicated that the rejects would provide a competent material for minefills. The mix designs were examined for both strength and rheological properties and showed that fills utilizing rejects were comparable to fills currently used by industry. Composite fills containing rejects had significantly lower void ratios, decreasing cement requirements for a given strength requirement. Conceptual designs for pre-concentration systems based on the metallurgical, reject characterization, and mix design were developed for each of the four mines in the study. The designs took into consideration the current mining plans. ii Table of Contents Abstract .........................................................................................................................ii Table of Contents ...............................................................................................................iii List of Tables......................................................................................................................vi List of Figures ...................................................................................................................vii Chapter 1 Introduction..................................................................................................... 1 1.1 Underground Preconcentration ........................................................................... 1 1.2 Objectives............................................................................................................2 1.3 The Mines and Ores of Xstrata Nickel................................................................ 2 1.4 Methodology .......................................................................................................4 Chapter 2 Experimental Procedure.................................................................................. 6 2.1 Introduction.........................................................................................................6 2.2 Sample Collecting and Classification ................................................................. 6 2.2.1 Sample Collecting....................................................................................... 6 2.2.1 Mineralogical and Physical Characterization..............................................6 2.3 Metallurgical Preconcentration Testing .............................................................. 7 2.3.1 Size Assay...................................................................................................7 2.3.2 Feed Preparation..........................................................................................7 2.3.3 Dense Media Separation.............................................................................. 7 2.3.4 Conductivity Sorting................................................................................... 9 2.4 Geotechnical Classification of Rejects.............................................................. 10 2.4.1 Particle Size Distribution .......................................................................... 10 2.4.2 Particle Shape............................................................................................11 2.4.3 Adsorption and Specific Gravity...............................................................11 2.4.4 Void Space ................................................................................................11 2.4.5 Hardness (Strength)................................................................................... 12 2.4.6 Chemical Composition.............................................................................. 12 2.5 Backfill Mix Evaluation....................................................................................12 2.5.1 Fill Mixing.................................................................................................12 2.5.2 Slump Testing ...........................................................................................13 2.5.3 UCS Cylinders and Testing....................................................................... 14 Chapter 3 Metallurgical Results .................................................................................... 15 3.1 Introduction................................................................................................... 15 3.2 Literature Review..............................................................................................15 3.2.1 Preconcentration Plants............................................................................. 15 3.2.1.1 Dense Media Separation........................................................................ 16 3.2.1.2 Ore Sorting............................................................................................17 3.2.2 Metallurgical Results from Preconcentration............................................19 3.3 Procedures.........................................................................................................21 3.4 Results and Discussion......................................................................................21 3.4.1 Mineralogical and Physical Characterization............................................21 3.4.2 Size Assay.................................................................................................23 3.4.3 Dense Media Separation............................................................................ 28 3.4.3.1 Overall Preconcentration....................................................................... 28 3.4.3.2 Precious Metal Recovery ......................................................................30 iii 3.4.3.3 MgO Rejection...................................................................................... 30 3.4.4 Conductivity Sorting................................................................................. 32 3.4.4.1 Overall Preconcentration....................................................................... 32 3.4.4.2 MgO Rejection...................................................................................... 34 3.5 Conclusions.......................................................................................................34 3.6 Recommendations.............................................................................................35 Chapter 4 Classification of Preconcentration Rejects.................................................... 36 4.1 Introduction.......................................................................................................36 4.2 Literature Review..............................................................................................36 4.2.1 Particle Size Distribution .......................................................................... 37 4.2.2 Particle Shape............................................................................................39 4.2.3 Void Ratio.................................................................................................40 4.2.4 Adsorption and Porosity............................................................................ 40 4.2.5 Specific Gravity.........................................................................................41 4.2.6 Hardness and Durability............................................................................ 41 4.2.7 Particle Strength........................................................................................42 4.2.8 Chemical Composition.............................................................................. 43 4.2.9 How to Compare Minefill Aggregate to Traditional Aggregate...............43 4.3 Procedures.........................................................................................................44 4.4 Results and Discussion......................................................................................44 4.4.1 Geotechnical Properties............................................................................. 44 4.4.1.1 Particle size distribution........................................................................ 47 4.4.1.2 Particle shape.........................................................................................49 4.4.1.3 Void Ratio .............................................................................................51 4.4.1.4 Adsorption and Porosity.......................................................................