For more than 30 years, sulfide gold ores were treated in metallurgic plants located in Nova Lima, Minas Gerais, Brazil, and accumulated in the Cocoruto tailings dam. Both flotation and leaching tailings from a deactivated circuit, as well as roasted and leaching tailings from an ongoing plant, were studied for their acid mine drainage potential and elements’ mobility. Detailed characterization of both tailings types indicates the presence of fine-grain size material hosting substantial amounts of sulfides that exhibit distinct geochemical and mineralogical characteristics. The samples from the ongoing plant show high grades of Fe in the form of oxides, cyanide, and sulfates. Differently, samples from the old circuit shave higher average concentrations of Al (0.88%), Ca (2.4%), Mg (0.96%), and Mn (0.17%), present as silicates and carbonates. These samples also show relics of preserved sulfides, such as pyrite and pyrrhotite. Concentrations of Zn, Cu, Au, and As are higher in the tailings of the ongoing circuit, while Cr and Hg stand out in the tailings of the deactivated circuit. Although the obtained results show that the sulfide wastes do not tend to generate acid mine drainage, leaching tests indicate the possibility of mobilization of toxic elements, namely As and Mn in the old circuit, and Sb, As, Fe, Ni, and Se in the tailings of the plant that still works. This work highlights the need for proper management and control of tailing dams even in alkaline drainage environments such as the one of the Cocoruto dam. Furthermore, strong knowledge of the tailings’ dynamics in terms of geochemistry and mineralogy would be pivotal to support long-term decisions on wastes management and disposal.

Since the mid-nineteenth century, gold ores, mainly hosted in sulfides, have been processed at metallurgical plants located in Nova Lima, Brazil. The generated wastes have been accumulated over the years in tailings dams or in piles. These materials represent wasted from old circuits, as well as from plants still in production. In this study, geochemical, mineralogical, 3D modelling, and metallurgical analyses wastes were carried out to evaluate potential reuse of these wastes. The performed characterization detected residues of very fine grain size containing sulfides and oxides. The wastes show high grades of Au hosted in different minerals. In addition to Au, samples contain S, Fe, Zn, Pb, Sc, Si, and As. The 3D modelling for spatial definition of Au was performed using ordinary kriging with dimensional variograms. The results indicated the occurrence of Au enrichment zones and allowed to reveal the most attractive tailing deposits in terms of Au content. Metallurgical tests showed recovery of 70% of Au and suggested other potential reuse of the wastes, such as aggregates for the civil construction sector and recovery of other metals. The present work highlights the importance of an integrative characterization within the scope of the circular economy and the value of tailings in the production chain of the mineral sector.

From the colonial era to modern times, gold mining has played a crucial role in shaping Brazil’s economy, culture, and landscape, particularly in the Iron Quadrangle region. Therefore, resulting waste has accumulated in tailings structures, either from deactivated circuits or plants still in production. The present study reveals the potential assessed based on a set of metallurgical tests, assuming specific scenarios depending on the occurrence modes of interesting economic elements. For Au, calcination, leaching, and flotation are promising techniques to recover this element. Tests indicated that toxic elements such as Sb and As could be effectively reused in the form of glass. The generation of other products from dry cleaning techniques was not effective but promising since there was an enrichment of elements with Au, Fe, Al, and K in specific fractions.

The mining sector has a fundamental financial and economical role in the country where it practices these activities. In addition to employment creation and social-cultural development, the mining sector brings economic growth to the country. However, the sector is facing challenges due to COVID-19, incidents involving tailings dam facilities, rising energy costs, low grade ore deposits, restrictions in mining regulations and access to the available resources. Currently sensor-based sorting (SBS) is well known and applied worldwide in the food, recycling, grain separation industries, and processing of metals, such as diamond, gold, platinum, and feldspar. In the mining industry, ore sorting technology can result in significant improvement in ore quality by removing gangue, uplifting grades, reducing cost reduction and recovering minerals. In this article, we discuss the ore sorting test work and modeled cost-benefit analysis (CBA) for refractory gold ore at Córrego do Sítio Mineração, based on the test results and operating parameters.

Cross-stream cutters are widely used in the mining and resources industry to obtain representative samples of particulate flows. Discrete element modelling (DEM) and analysis can be used to investigate influences of operational parameters, sampler design and material physical properties in the generation of the Increment Extraction Error (IEE), which when present, results in a frequently biased, non-representative sample. The study investigates the practicality of the rules and recommendations proposed by Dr. Pierre Gy that were developed and established as principles for the correct extraction of samples in industrial sampling equipment. Results validate Pierre Gy’s sampling theory using DEM in a cross-stream cutter of a sulphide gold plant. Importantly, the outcomes indicate that careful consideration must be given to physical ore properties and, consequently, that sampling systems should be developed specifically to each application.