Pre-concentration consists of the preliminary discarding of a fraction of the mineral processing plant feed which contains little or none of the mineral of interest, reducing the mass to be processed in downstream operations (e.g. milling, concentration and dewatering), as well as the capital and operational costs. In this context, this study investigates the performance of density and sensor-based sorting separation methods in the removal of carbonate gangue of a zinc ore, in size fractions typical of crusher products, using sink and float tests with heavy liquids, jig stratification and laboratory scale ore sorting tests using an X-Ray Transmission (XRT) sensor. The best results were obtained through sink and float in heavy liquids, which indicated the possibility of discarding 30% of the feed mass, removing over 60% of the carbonates (CaO and MgO) and losing only 2% of the zinc. The ore sorting tests also presented positive results, with approximately 93% of metallurgical recovery in 70% of the mass for both size fractions tested. The jig stratification results were worse, since the zinc content discarded with this method was high. The results indicate significant reduction potential for Capex and Opex costs using pre-concentration strategy.

Sizing High-Pressure Grinding Rolls (HPGR) requires a large quantity of material, making it not attractive and costly to be considered for new mining projects regardless of their energy consumption reduction benefits. Ongoing efforts are being made at the University of British Columbia to predict the behaviour of the HPGR using a low quantity of material on a piston-and-die press apparatus. Although the energy requirements and size reduction predictive models are already developed, there is still a need to predict the HPGR throughput on a small-scale test. This paper presents a new model to predict the HPGR throughput based on the previously developed model to predict the operational gap by using less than 2 kg of sample. The throughput model was developed using machine learning techniques and calibrated using pilot-scale HPGR tests and piston press tests. The resulting model has an R² of 0.91 with an average prediction error of ±4.2%. The developed methodology has the potential to fill the gap of the missing throughput model. Further pilot-scale HPGR testing is required to continue validating the model.

The use of vertical stirred mills in the mining industry has increased remarkably over the past few decades as a result of the growing demand for finer ore grinding. This equipment is recognized to deliver higher energy efficiency in fine grinding operations when compared to conventional tubular mills. Methods of designing vertical stirred mills involve operational experience, pilot plant tests and bench tests. An important issue is that the laboratory-scale test, conducted in the standard 8"×10" jar, requires at least 10–20 kg of material, depending on ore density, which is not available in many cases, particularly in the early stages of greenfield projects. For regrinding of flotation concentrates, several bench scale flotation tests are required to generate such a sample. The paper describes the development and validation with six different ore samples of a simplified laboratory jar mill test using a 6"×8" jar, which is smaller than the 8"×10" size, the latter commonly used which requires about one-tenth of the mass required in the standard test. The proposed test indicated similar results as compared to the standard procedure.

The geological context of this study is established in the iron oxide-copper-gold (IOCG) deposit of Sossego (Canaã dos Carajás, Brazil), where hydrothermal alterations in shear zones concentrated the metals of interest and added new characteristics to the metavolcanic-sedimentary and granite rocks. The mineral transformation of rocks by hypersaline fluids enriched in metals and silica also modifies some metallurgical properties, such as abrasiveness. Special bench tests on rock drill cores are used in mapping the abrasiveness of rocks, with the Bond abrasion test being more commonly used in the mining industry, but it has a restrictive sampling protocol and mass requirement for geometallurgical studies. As a counterpoint, the test of the Laboratoire Central des Ponts et Chaussées/Central Laboratory of Bridges and Roads (LCPC) requires a smaller amount of fine material and a finer granulometric range. The study on the use of LCPC was implemented in 40 samples, using Bond Ai as a reference. The results showed a strong correlation between both methodologies (R² = 95%), validating the use of LCPC to quantify abrasiveness in the Sossego mine. It was also possible to classify the most abrasive lithologies.