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I-249 processed in a recently commissioned heap leach plant, owned and operated by WMC Resources. BACKGROUND The St. Ives gold deposits are situated in the north-west trending Norseman-Wiluna Greenstone Belt. The deposits are located on secondary structures that splay off the regionally dominant BoulderLefroy Fault. In most of the St. Ives deposits, gold is most commonly native and quite coarse. It is readily liberated from gangue minerals and relatively higher recoveries can be achieved by the application of gravity separation and cyanidation techniques. Plant Description The ore supply to the plant is from a number of open pits and one underground mine. ROM ore from these mines are stockpiled separately on the plant crusher ROM pad. Blending from different stockpiles with respect to grade and hardness, at the point of feeding into the crusher, is practiced for optimum grinding and recovery characteristics. Run of mine ore is crushed to 110 mm by a 375 kW Nordberg gyratory crusher. Primary crushed product is fed to a 7ft, 450 kW Symons crusher after scalping of the 35 mm material. Secondary crusher operates in closed circuit with a 35 mm aperture screen. The crushing circuit has a multi-function design, which allows by passing of secondary crushing circuit or operating secondary crushing circuit in closed or open circuit. Final product from the crushing circuit is stockpiled before feeding into a 7.2 m SAG mill. When the main stockpile is full, secondary crushed product can be diverted to an emergency stockpile. The SAG mill is fixed speed and was supplied by ANI PRODUCTS. A 2,500 kW motor drives it. The ore with high clay content, or from the emergency stockpile, can be fed to the SAG mill via a separate conveyor located after the main stockpile. The target SAG F80 is 25-30 mm for maximum throughput rate. Ball charge in the SAG mill is maintained between 12 % and 15.5 % depending on the feed size and ore hardness. SAG discharge slurry passes over a vibrating screen deck with a 5 x 26 mm aperture. Screen oversize scats are returned to SAG mill without crushing. Downstream of the SAG mill are two 4.2 m diameter ball mills running in parallel. Both ball mills are driven by 2,400 kW motors. Cyclone overflow slurry is fed directly to the leach tanks. Therefore, maintaining slurry densities of around 45 % solids is essential for efficient carbon to solution contact in the adsorption tanks. CIP circuit consists of three leach tanks and seven adsorption tanks. Slurry agitation in the leach tanks is by mechanical impellers. Adsorption tanks are air agitated Pachuca tanks.

SAG
2001
MINING AND MINERAL PROCESS ENGINEERING
UNIVERSITY OF BRITISH COLUMBIA Vancouver, B. C., Canada

PRIMARY VERSUS SECONDARY CRUSHING AT ST. IVES (WMC) SAG MILL CIRCUIT Yavuz Atasoy 1, Walter Valery 2, Andrew Skalski1, 1St. Ives Gold Mine 2 (WMC Resources Ltd), JKMRC, Australia ABSTRACT The St Ives Gold mining operations are 80 km south of Kalgoorlie and 20 km south of Kambalda, near Lake Lefroy in Western Australia. The processing plant was commissioned in 1988 at its nameplate capacity of 1.8 Mtpa. The grinding section of the plant consists of one 7.20 m diameter SAG mill followed by two 4.2 m diameter ball mills running in parallel to treat a free milling gold ore. To aid in optimizing the grinding circuit the mineral processing simulator JKSimMet was used to construct mathematical models of the circuit. Simulations were then run to determine the best operating strategy to achieve maximum throughput and best product specifications. Secondary versus primary crushed ore was evaluated as the feed to the SAG mill along with the introduction of a recycle crusher. Lifter and liner optimization was also part of the study. This paper describes the performance of the St. Ives grinding circuit under different operating conditions and the results of the optimization programme. INTRODUCTION The St. Ives Gold Plant is part of St. Ives Gold Mines, a wholly owned subsidiary of WMC Resources Ltd. The plant currently produces about 430,000 ounces of gold per annum from about 3.2 Mtpa of high grade gold bearing ore. Lower and marginal grade ores are separately

I-250 A detailed description of the crushing and grinding circuit can be seen in Figure 1.

I-251

Sound Level and Power

Sound Level Controller AIC20900

Power Override Controller JC20002

Winding Temperature Controller TC20003

Gyratory Crusher

Low Selector

Charge Weight

Screen Emergency Stockpile

Charge Weight Controller WIC20327

Secondary Crusher Screen To leach

Feed Rate

Charge Weight Rate-of-Change Controller WIC22516

Stockpile Cyclones

CV3 - 4 Split Control

Gravity Conc. Ball Mill

S

CV3 Tonnage Controller WIC22312

CV4 Tonnage Controller WIC22412

SAG Mill Screen

Feeder Split

Feeder Split Control

Feeder Split Control

New Feed
Feeder 1 Speed Auto/Manual WY22107 Feeder 2 Speed Auto/Manual WY22108 Feeder 3 Speed Auto/Manual WY22109 Feeder 1 Speed Auto/Manual WY22110 Feeder 2 Speed Auto/Manual WY22108 WY22111 Feeder 3 Speed Auto/Manual WY22112

Emergency Feeder

Water Additi on

Knelson Concentrators
S

Ball Mill

Feed Water Flow

Discharge % solids setpoint feed rate

Pump

Feed water flow Ratio Controller FFC20901

Feed water flow Controller FIC20901

valve

Sampling points

Pump

Figure 2. SAG mill grinding circuit control system block diagram

Figure 1. Crushing and grinding circuit flowsheet

I-252 SAG Grinding Process Control Process control in the plant is achieved by using ABB MOD-300 distributed control system. The main control objectives in the grinding circuit are summarized as follows: Stabilize charge weight and ball-on shell impact sound level through automatic feed rate control Maintain SAG mill power draw just below maximum allowable power to prevent a mill motor trip. This is achieved by charge weight control Allow the SAG operator to adjust the feed size distribution by changing the ore split among feeders on any of the stockpile reclaim conveyors and between the stockpile reclaim conveyors. A schematic of the control block diagram is in Figure 2 page I-251. PLANT OPTIMIZATION WORK The grinding circuit was originally designed to treat only primary crushed ore. A 150 kW Jacques Gyracone No.50 crusher was included in the original design for crushing scats return. After commissioning, attempts to increase the actual plant throughput capacity beyond the design capacity of 2 Mtpa were not successful with coarse feed. Further production improvement to 3.2 Mtpa was achieved with the addition of a secondary crushing circuit and the removal of the scats crusher. Operating the St.Ives SAG mill at the current feed size F80 of 28 mm has brought with itself a number of issues. These are summarized as follows: High SAG liner maintenance cost Low SAG utilization due to frequent shutdowns for mill re-lines High ball consumption rates Maintaining and operating a high cost secondary crushing circuit.

I-253 The objectives of this the SAG mill optimization program were set as follows: Improve mill utilization by increasing SAG mill liner life Reduce total crushing and grinding circuit operating costs by optimizing feed size into the SAG mill. Ensure current throughput rates are maintained

Investigating the effect of feed size to the SAG mill is a longer-term project. Therefore, the two phases of this optimization programme have been progressed simultaneously. Liner Optimization Whilst operating the SAG mill with fine feed resulted in higher throughput rates, operating and maintenance costs have been unacceptably high. Consequently the crushing and grinding circuit have to be shut down more frequently for relines. The St. Ives SAG mill has been operating under these conditions for the last 10 years. There has been no significant change to liner/lifter profile or operating conditions since commissioning. Original lifter bars had a 7 degree face angle. They also had extra metal put around boltholes for extra strength. As a result, the original lifter bars have dog bone shape, which did not help improve the throw of balls against the toe of charge. New lifters were designed with 25- degree face angle and smooth profile across the lifting face to help improve the throw of balls. As part of the liner optimization programme lifter heights on the Feed Head and Discharge Head of the SAG mill were increased from 80 mm to 150 mm. The seating arrangement between the shell plates and lifter bars was also re-designed with the objective to reduce bolt breakages and improve sealing for leakage prevention. All of these changes have been in effect since May 2001. Investigation of the Effect of Feed Size This part of the optimization programme was conducted in an iterative manner in conjunction with JKTech and JKMRC. The main programme steps can be summarized as follows: Conduct two surveys of the grinding circuit prior to any changes (ie. with fine feed) Conduct JK Breakage and Bond ball mill work index tests on fine ore samples for ore characterization Produce a baseline model of the grinding circuit with fine feed

Due to this fine feed size the SAG mill is operated at high ball charge levels to achieve target throughput rates. The ratio of ball charge to rock charge is kept between 2 and 3 to maintain high impact grinding rates. Hence higher throughput rates. The mill grinds best and has the highest throughput at a particular charge weight. The optimum charge weight depends on ball charge, ore hardness and feed size. Any attempt to increase the rock charge beyond 4-7 % on top of already existing ball charge level results in the SAG mill filling very quickly, dramatically reducing grinding rates. A partial or full mill grind-out is then required to reduce power draw and charge weight to acceptable levels. Consequently the grind-out represents a loss of throughput as well as a loss of opportunity.

I-254 Conduct simulations using the baseline circuit model to predict the performance of the circuit with coarse feed If the results of simulations are promising, conduct two circuit surveys with coarse feed (ie. primary crushed only) Conduct JK Breakage tests on coarse ore samples for ore characterization Modify the baseline circuit model for fine feed, to include the coarse feed size range Investigate the circuit performance with coarse feed and scats crushing using the modified circuit model

I-255 During these surveys, the SAG mill load and power draw stayed reasonably stable while scats rate fluctuated slightly. Immediately after finishing the survey, the SAG mill was crash stopped for total mill load measurement. Breakage and Work Index tests JKSimMet accepts ore breakage parameters as input along with machine related parameters. There are two types of ore characterization tests, which must be done on representative samples of SAG feed material. These are: 1. JK drop weight tests: carried out to determine the impact breakage characteristics of rocks. These tests produce two parameters as the output A and b. Although the individual A and b parameters are input to the model, Axb gives a clearer indication of ore hardness with respect to SAG milling. The smaller the Axb the bigger the resistance to impact breakage in a SAG mill. 2. Abrasion tests: carried out to determine the abrasion resistance of particles in a SAG mill environment. This test produces a single parameter as its output ta. The smaller the ta the higher the resistance to abrasion breakage. A detailed explanation of these tests can be found elsewhere (Mineral Communition Circuits, T.J Napier-Munn et al, 1996). The size range of rock samples collected from SAG mill feed conveyor did not cover the full size range required for JK breakage tests as the feed material was very fine. Therefore samples for breakage tests were collected from individual ore stockpiles on the ROM pad. The estimated ore blend of SAG feed material during surveys is given as follows: Intrepide open pit ore: Leviathan open pit: Santa Anna open pit ore: Junction underground ore: 40 % 20 % 20 % 20 %

Circuit Surveys with Secondary Crushed Feed Prior to conducting surveys the SAG mill was ground out to determine ball load. Two surveys of the grinding circuit were then conducted with the objective of collecting data for mass balancing and producing a model for the circuit using JKMRCs JKSimMet process simulator. The summary results of mass balancing for surveys-1&2 are given in Table-1. Table-1. Mass balance results with fine feed (survey-1 and survey-2) SAG Mill Feed (TPH) F80(mm) F20(mm) Power (kW) Ball load (% of mill volume) Total load (%) T80(mm) calc T50(mm) calc Survey-1 Survey-2 412 416 19.5 21.0 < 0.038 < 0.038 2,710 2,708 15.0 15.0 19.1 19.4 1.519 1.983 0.425 0.300 36.0 32.3 %<106m Scats Ratio (% of new feed) 10.6 10.5 Ball Mills (average of two ball mills Power (kW) 1,934 1,908 Recycle load (%) 171 172 155 161 Cyc. Overflow P80 (m) Overall (Ball+SAG) kWh/t Operating Work Index 15.96 21.82 15.68 21.81

Table 2 page I-9 shows the JK breakage parameters and Bond Mill Work Index values for these ore types. The drop weight test that was conducted on feed sample was modified as the feed material did not have sufficient coarse particles. Also, using the measured ore breakage parameters for each ore type, blended ore breakage parameters for the feed Axb and ta were estimated.

I-256 Table 2: Ore Breakage parameters for secondary crushed ore trial Ore type Intrepide Junction Leviathan Santa Anna Feed Sample A 54.8 62.5 65.0 54.0 80.0 b 0.74 0.64 0.65 1.27 0.36 Axb 40.57 39.97 42.24 68.63 28.80 ta 0.19 0.30 0.37 0.43 0.22 WI1 17.1 13.3 13.9 14.1 15.6 WI2 13.2 -

I-257 Circuit Surveys with Coarse Ore A SAG mill ball charge level of 14 % was targeted for the trials with coarse feed. To achieve this target, SAG mill ball addition rate was reduced before the surveys. A grind out was performed immediately before the circuit surveys to confirm the target ball volume load had been achieved. Secondary crushing was stopped to reduce the level of the main stockpile. Any fine ore that had been left on the stockpile was pushed aside from the top of the feeders to make room for coarse feed. Primary crusher closed side setting (CSS) was set to 100 mm. Two plant surveys were conducted under steady state conditions. In the first survey recycle scats were returned to the SAG mill, whilst during the second survey they were removed from the circuit. Process flow data were collected from the plant distributed control system. Immediately after finishing surveys, the SAG mill was crash stopped for charge volume measurements. Rock samples were collected from the SAG mill feed conveyor for feed size determination and ore characterization. Figure 3 shows process mass flow trends during survey with no scats return to the SAG mill. Figure 3. Mass flow trends for survey with no scats return to SAG.

1: closing screen size=212 m, 2: closing screen size=106 m

The calculated ore breakage parameters for the ore blend during surveys were then used in the model. Table 3 below shows these parameters: Table 3. Blended ore breakage parameters. Sample Blended ore A 57.74 B 0.78 Axb 44.82 ta 0.30 BWI (kWh/t) 15.1

Effect of Coarse Ore Simulation Results Mass balancing and model fitting of the survey data with fine feed produced good results. Simulation scenarios were conducted to investigate the performance of the SAG mill with varying feed size. The simulation results are summarized in Table 4. Table 4. Results of simulations with coarse feed Ball Load = 15 % With scats recycle Without scats recycle Feed Ore Survey Survey Survey Survey F80 (mm) 74 85 74 85 Feed Rate (TPH) 190 180 210 195 SAG Power (kW) 2,472 2,478 2,472 2,475 Total Load (%) 24.0 24.2 24.0 24.1 Recycle Rate (%) 14 14 11 11 T80 (mm) 1.71 1.68 1.57 1.54

Simulations predicted throughput rates between 180 TPH and 210 TPH with the coarse feed. In these simulations, the discharge grate open area was kept at 30 %, the current practice.

SAG mill operation was relatively stable with coarse feed during both surveys. As expected, slightly higher throughput rates were achieved when the recycle scats were not returned to the SAG mill. Table 5 summarizes operating conditions for both surveys. Due to the lower feed rates only one ball mill was operated during coarse ore trials.

I-258 Table 5. Summary of operating conditions for Coarse Ore Trials SAG Mill Feed (TPH) F80(mm) F20(mm) Power (kW) Ball load (% of mill volume) Total load (%) T80(mm) calc T50(mm) calc %<106m Scats Ratio (% of new feed) Ball Mill-2 Power (kW) Recycle load (%) Cyc. Overflow P80 (m) Specific kWh/t Operating Work Index With Scats 171 103 9.7 2,565 14 21.4 0.370 0.100 4.6 3.5 2,029 178 96 26.86 27.14 Without Scats 201 104 6.7 2,665 14 21.7 0.504 0.118 6.2 5.1 2,023 225 106 23.32 24.80

I-259 Table 6. Ore breakage parameters for the coarse ore trial Ore type Intrepide Junction North Orchin Feed (scats) Feed (no scats) Blended Ore Discussion The SAG mill model, which had been derived for fine feed was modified to include the breakage rates for coarse particles. The resultant model was used to investigate the performance of the grinding circuit under a number of conditions. The most promising results are being further investigated to determine any potential for application. The main parameters, which will be investigated in these simulations are: Increase in discharge end grate open area Pebble port size, number and position Effects of scats crushing Effects of scats crusher closed side setting Ball charge, total charge Feed size and ore hardness Increased SAG mill discharge screen A 80.0 62.7 54.8 57.8 47.8 b 0.44 0.68 0.86 0.63 0.82 Axb 35.2 42.5 47.1 36.4 39.2 ta 0.28 0.34 0.52 0.34 0.24 WI 17.4 13.6 11.6 15.1 14.0

It must be noted that actual throughput rates obtained with the coarse feed compare well with model predictions. This increased confidence in the model for the third stage of this project. Breakage and Work Index Tests Ore blend was sourced from three different sources during the coarse ore trial. The composition of the ore blend was as follows: Junction underground ore: North Orchin open pit ore: Intrepide open pit ore: (33.3 %) (33.3 %) (33.3 %)

In the preliminary simulations the SAG mill discharge end open area was increased from 3.0 % to 7.5 %. It is also assumed that all the open area was provided by 75 mm pebble ports. Scats crusher closed side setting was set to 10 mm. The results of most promising simulation showed the following: Throughput rate: Scats rate: Power draw: Cyclone overflow P80: 345 TPH 91 TPH (26 % of new feed) 2,500 kW 118 micron

As previously described, samples of SAG mill feed material was subjected to JK breakage and Bond Ball Mill Work Index tests. Additionally each ore type which formed the ore blend was sampled from the crusher ROM pad for ore characterization tests. The results are summarized in Table 6 page I-12.

The SAG mill ball charge and total charge were kept to 14 % and 21.5 %, respectively in these simulations. Results produced an overall specific power consumption of 18.8 kW/t, giving a calculated work index of 21.1 kWh/t. This operating work index, calculated from the simulation results compared well with the actual operating work index of 21.8 kWh/t.

I-260 FUTURE WORK

I-261

REFERENCES The preliminary simulations carried out so far have shown that the maximum throughput rates, which can be achieved with a coarse feed may be less than those achieved with a fine feed. However there is room to improve upon these results. Future work will concentrate on the following areas: It appears that the SAG mill may be the one limiting higher throughput rates. The St.Ives ball mills rarely operate at above 2,000 kW power. This leaves a total of 800 kW power available for use. If some of the load can be transferred to the ball mills by increasing the aperture size of the SAG mill discharge screen then it may be possible to further improve the throughput rates. For this to happen, capacity of the transfer and cyclone feed pumps must be adequate. Also, the impact of the final product specifications on the downstream recovery process must be carefully examined. The effect of the new lifter bars with 25 degree face angle on the grinding rates has to be assessed and incorporated into the future predictions. Capacity, type and CSS of proposed recycle crusher must be further investigated It is has been well demonstrated in many other operations that the SAG mill feed size distribution has a big impact on throughput rates. The SAG mill feed size distribution can be improved by better blasting practices in the open pits. This should, in turn, impact on the throughput rates. CONCLUSIONS The results, which have been reported in this paper are only preliminary in nature. The model developed to optimize the St. Ives grinding circuit requires fine tuning to explore all the issues addressed in the previous section. Currently, the ore to the SAG mill is sourced from a number of open pits and underground mines and scheduled to remain so for immediate future. The future ore blends will have a significant impact on the performance of the SAG mill. Therefore future mine plans will have to be taken into consideration and future ore production schedules will need to be incorporated into the model before a decision is made. ACKNOWLEDGEMENTS The authors would like to thank the management of WMC Resources Ltd-St.Ives gold mines for their permission in publishing this paper. They also acknowledge the assistance of the St. Ives Gold plant production and maintenance personnel during the test work period. Napier-Munn, T.J. et al, 1996, Mineral Communition Circuits-Their Operation and Optimization, JKMRC publication, pp 69-85. Corder, Glen, 2001, Grinding Model Development and SimulationsSt.Ives Gold SAG Grinding Circuit, JKTech Technical Report, 30 pp