M.W.N. Buxton
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This chapter provides a comprehensive review of techniques, instruments, and methods suitable for mine residue sampling and characterization, using the potential recovery of critical raw materials (CRMs) from bauxite residues as an example. The sampling methods address diverse strategies for assessing the suitability of CRMs recovery, including screening, detailed characterization, determination of acid rock drainage generation and wastewater, and the implementation of a geometallurgical approach. The methods for characterizing mine residues are a selection of geochemical, mineralogical, and other techniques that can be used either in field environments (e.g., portable X-ray fluorescence, infrared spectroscopy) or in the laboratory (e.g., inductively coupled plasma-based techniques, scanning electron microscopy) to study the main properties of the waste material. Other techniques used for the remote characterization, such as earth observation are also addressed. Approaches for data analytics and the impact of digitalization in the characterization of mine residues are briefly discussed. Overall, this chapter aims to help practitioners and researchers to implement better practices in the sampling and characterization for the revalorization of mine residues.
Geometallurgical characterisation with portable ftir
Application to sediment‐hosted cu‐co ores
Cobalt (Co) mine production primarily originates from the sediment‐hosted copper (Cu) deposits of the Democratic Republic of Congo (DRC). These deposits usually consist of three ore zones with a supergene oxide ore blanket overlying a transition zone which grades into a sulphide zone at depth. Each of these zones display a mineral assemblage with varying gangue mineralogy and, most importantly, a distinct state of oxidation of the mineralisation. This has direct implications for Cu and Co extraction during mineral processing as it dictates which processing method is to be used (i.e., leaching vs. flotation) and affects the performance of these. To optimise resource effi-ciency, reduce technical risks and environmental impacts, comprehensive understanding of varia-tion of ore mineralogy and texture in the deposit is essential. By defining geometallurgical ore types according to their inferred metallurgical behaviour, this information can serve to classify the re-sources and improve resource management. To obtain insight into the spatial distribution of mineral grades, it is necessary to develop techniques that have the potential to measure rapidly and, preferably, within the mine at relatively low‐cost. In this study, the application of portable Fourier transformed infrared (FTIR) spectroscopy is investigated to measure the mineralogy of drill core samples. A set of samples from a sediment‐hosted Cu‐Co deposit in DRC was selected to test this approach. Results were validated using automated mineralogy (QEMSCAN). Prediction of gangue and target mineral grades from the FTIR spectra was achieved through partial least squares regression (PLS‐R) combined with competitive adaptive reweighted sampling (CARS). It is shown that the modal mineralogy obtained from FTIR can be used to classify the ore according to type of mineralisation and gangue mineralogy into geometallurgical ore types. This classification supports selection of a suitable processing route and is likely to affect the overall process performance.
Geochemical and mineralogical datasets from Tropicana Gold Mine, Australia, have been used to define Au-mineralised fingerprints. VNIR-SWIR spectral data were represented by four normalised wavelength regions and were clustered to form spectral classes. Sequentially, these spectral class proportions within a block and co-located pXRF data were clustered to discriminate material types (fingerprints). The hardness of each type was further explored using collocated BWi, Axb, Equotip rebound hardness and penetration rate datasets, but also by considering spatial contextual relationships and the within material type variability. The Tropicana orebody example gave a good illustration of how a phengitic-epidote K-feldspar rich domain (schistosity and softer, ∼15–18 kWh/t) separated from a harder (>20 kWh/t), shorter wavelength phengitic plagioclase-rich feldspar dominated domain. Exploring the within material type differences using the white mica composition (wAlOH) and a new w605 spectral feature demonstrated how the effects of shearing were captured within material types. Such findings will ultimately improve the understanding of the constitutive material hardness and have significance for process optimisation and blending strategy design.
Multi-element (ME) datasets provide comprehensive geochemical signatures of an orebody and are commonly used to gain insight into the mineralogy, lithology, alteration patterns and to identify target-pathfinders. However, little effort is made in using these data to explain comminution or recovery characteristics. This paper describes an agglomerative hierarchical clustering approach applied to ME data from the Tropicana Gold Mine, Australia, and investigates the relationship between the resultant classes and run-of-mine comminution and recovery parameters. First, it is demonstrated how an industry scale ME dataset is prepared for clustering. The preparation consists of verifying the absence of interlaboratory and intralaboratory bias between measurements, centred log-ratio transformation (clr), normalisation and principal component analysis (PCA). Afterwards, the first case study indicate that the clustering separation is primarily driven by geochemical differences caused by major rock-forming mineral signatures (felsic vs mafic, alteration vs no alteration, chert or quartz lithologies, unmineralised vs mineralised material). This case study separates the ME dataset into five unmineralised and two Au-mineralised material classes. The second case study continues with the two identified mineralised material classes and further separates these samples into five new classes. These classes are explored geochemically and by using the spatial context (within domains) better matched with metallurgical test results. It is found that domain-related material class proportions assist in interpreting different processing proxies such as the Equotip hardness (Leeb), Bond Work index (BWi), Axb, and processing recovery and reagent consumption. Knowledge of the processing parameters per domain and class composition can be used to infer such characteristics in the absence of standard metallurgical tests. This new approach of gaining insights into comminution and recovery parameters through geochemical analysis demonstrates the benefit of the conceptualised material fingerprinting concept.
Sensor technologies provide relevant information on the key geological attributes in mining. The integration of data from multiple sources is advantageous in making use of the synergy among the outputs for the enhanced characterisation of materials. Sensors produce various types of data. Thus, the fusion of these data requires innovative data-driven strategies. In the present study, the fusion of image and point data is proposed, aiming for the enhanced classification of ore and waste materials in a polymetallic sulphide deposit at 3%, 5% and 7% cut-off grades. The image data were acquired in the visible-near infrared (VNIR) and short-wave infrared (SWIR) regions of the electromagnetic spectrum. The point data cover the mid-wave infrared (MWIR) and long-wave infrared (LWIR) spectral regions. A multi-step methodological approach was developed for the fusion of the image and point data at multiple levels using the supervised and unsupervised classification techniques. Several possible combinations of the data blocks were evaluated to select the optimal combinations in an optimised way. The obtained results indicate that the individual image and point techniques resulted in a successful classification of ore and waste materials. However, the classification performance greatly improved with the fusion of image and point data, where the K-means and support vector classification (SVC) models provided acceptable results. The proposed approach enables a significant reduction in data volume while maintaining the relevant information in the spectra. This is principally beneficial for the integration of data from high-throughput and large data volume sources. Thus, the effectiveness and practicality of the approach can permit the enhanced separation of ore and waste materials in operational mines.
In response to the growing demand for sustainable products and services, the kaolin calcination industry is developing practices that optimise the use of resources. The main challenges include more efficient use of raw materials and a reduction in the energy consumed by the calcination furnace. An opportunity to achieve this lies in the optimisation of the calcination process. This can be done by giving real-time feedback on the quality parameters of the generated calcined kaolin. This study proposes the use of infrared spectroscopy as a monitoring technique to determine the chemical properties of the calcined kaolin product. The basis of the monitoring system is the measurement of the kaolin soluble alumina content as one of the most important quality parameters; this property is an indicator of the over- or under-use of raw materials and energy during the calcination process and can advise the operations regarding the optimisation of the working conditions of the furnace. The implementation of an infrared-based monitoring system would lead to increased efficiency in the production of calcined kaolin.
Material attributes (e.g., chemical composition, mineralogy, texture) are identified as the causative source of variations in the behaviour of mineral processing. That makes them suitable to act as key characteristics to characterise and classify material. Therefore, vast quantities of collected data describing material attributes could help to forecast the behaviour of mineral processing. This paper proposes a conceptual framework that creates a data-driven link between ore and the processing behaviour through the creation of material “fingerprints”. A fingerprint is a machine learning-based classification of measured material attributes compared to the range of attributes found within the mine’s mineral reserves. The outcome of the classification acts as a label for a machine learning model and contains relevant information, which may identify the root cause of measured differences in processing behaviour. Therefore, this class label can forecast the associated behaviour of mineral processing. Furthermore, insight is given into the confidence of available data originating from different analytical techniques. Taken together, this enhances the understanding of how differences in geology impact metallurgical plant performance. Targeted measurements at low-confidence unit processes and for specific attributes would upgrade the confidence in fingerprints and capabilities to predict plant performance.
Near-infrared (NIR) and short-wavelength infrared (SWIR) hyperspectral imagery can be used to detect certain alteration minerals. At epithermal deposits, the formation of alteration minerals is, in theory, related to the mineralisation of gold and silver. In order to provide foundations for developing sensor-based sorting applications at a mine that exploits such a deposit, it was investigated if NIR-SWIR hyperspectral imagery can be used to distinguish between ore and waste particles by characterising the alteration mineralogy. Maps were produced from the NIR-SWIR hyperspectral images of 827 drill core samples that show mineral occurrences, mineral absorption feature intensities and characteristics of the iron oxide mineralogy. Partial least squares discriminant analysis (PLS-DA) was applied to the information contained in these maps to investigate if this information can be used to discriminate between ore and waste. The results showed that NIR-SWIR hyperspectral imagery could be used to segment a population of waste samples by detecting occurrences of pyrophyllite, dickite and/or illite. This result can be explained by the fact that these minerals are commonly deposited further away from the ore-bearing epithermal veins, while the absence of SWIR-active minerals or detected occurrences of alunite are more closely associated with these structures. The ability to identify waste with NIR-SWIR spectral sensors means there is potential that sensor-based sorting can be used to remove this waste from mineral processing operations. Additional research is still required to assess the economic feasibility of such a sensor-based sorting application.