FOOTPRINT. Sunrise Dam signs up for second Carbon Scout INSIDE UPDATE NEWS FROM GEKKO SYSTEMS PTY LTD MARCH 2018 ISSUE 20
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1 FOOTPRINT NEWS FROM GEKKO SYSTEMS PTY LTD MARCH 2018 ISSUE 20 Carbon Scout Mk4 units in factory testing before they are sent to clients Sunrise Dam signs up for second Carbon Scout Following on from the successful 2017 partnership with Curtin University to commercialise the Carbon Scout technology, Gekko is very pleased to announce that AngloGold Ashanti Australia Ltd (AGAA) has signed the contract for a second Carbon Scout unit for its Sunrise Dam site. This follows the successful installation of the initial unit at Sunrise Dam and a unit at the Tropicana gold mine. Tropicana, located 330 kilometres east-northeast of Kalgoorlie in Western Australia, is a joint venture between AGAA (70% and manager) and Independence Group NL (30%). Designed to assist gold mine operators to optimise process plant efficiency and reduce gold losses to tailings; the new unit will aid carbon management in the second train of the CIL tanks at Sunrise Dam, located 55 km south of Laverton in WA. Installation of the second Carbon Scout is due to occur in March Sunrise Dam s original Carbon Scout unit, built during the technology s alpha development phase, will undergo a program of upgrades bringing it up to the level of the new production unit. An analysis of site data has indicated that improved carbon management utilising Carbon Scout and the automation of the carbon movement has saved a significant quantity of gold that would otherwise be lost to the tailings dam. The benefit of the Carbon Scout is the automated carbon density measurement, in addition to the provisioning of a single sampling point at ground level. Expert interpretation of data will result in real-time circuit optimisation in carbonin-leach and carbon-in-pulp circuits, reducing soluble gold losses and improving cash flow. cont. page 2 INSIDE UPDATE Gekko installs seven InLine Pressure Jigs at Mineros PAGE 4-5 Gekko, CSIRO partner on Online Gold Analyser PAGE 7 Gekko Python charges ahead, processing underground PAGE 8
2 Curtin University forges closer bond with Gekko Collaboration Delivers Real Time Gold Analysis of Process Streams The OnLine Gold Analyser (OLGA) provides insights into process performance that are unobtainable with assayed sample sets The results from the Cadia and Tropicana testwork will be used to contribute to the P420 modelling of gravity recovery from different ore sources Collaboration continues to drive mining innovation. Following on from the sponsorship of the AMIRA P420 project in 2001, Gekko has maintained an ongoing relationship with Curtin University s Gold Group. Late in 2017 Gekko s Metallurgical laboratory carried out 3 Stage Continuous Gravity testwork (CGR) for Curtin University on two ores; Cadia ore from New South Wales and Tropicana ore from Western Australia. The 3 Stage CGR test determines the gold recovery from an ore by gravity concentration and simulates the performance Carbon Scout cont. from page 1 The Carbon Scout can deliver productivity benefits by removing the requirement for manual sampling of the tanks by enabling plant operators to focus on other critical tasks and reducing the potential OH&S risks associated with manual sampling. Current testing in the Gekko research and development facility has the Mk4 Carbon Scout running continuously seven days a week. Evaluation materials and new components in extremely harsh chemical and abrasive conditions is also taking place while testing the soon-to-bereleased ph and dissolved oxygen measurement systems that are to be fully integrated into the Carbon Scout unit. To learn more about Carbon Scout and how it can optimise your plant performance, contact Gekko s Metallurgical Services Manager, Wayne Lodge, WayneL@gekkos.com or visit gekkos.com. of the Gekko InLine Pressure Jig (IPJ). The results from the 3 Stage CGR test can be used to select the size of the IPJ s and overall design of the gravity circuit to ensure optimal gold recovery. In addition, these testworks will also contribute to the AMIRA P420 modelling of gravity recovery from different ore sources. To learn more about Gekko s Metallurgical Laboratory services and how it can help you optimise your plant recoveries, contact Gekko s Metallurgical Services Manager, Wayne Lodge, WayneL@gekkos.com or visit gekkos.com. Gekko and CSIRO are partnering to commercialise a new technology that provides real-time analysis for gold content in a slurry or solution stream. Delivering an updated sub-parts per million (ppm) Au measurement every 10 minutes, the OnLine Gold Analyser (OLGA) provides insights into process performance that are unobtainable with assayed sample sets. While traditionally assayed samples consist of homogenised samples that are collected once per shift and then delayed up to 12 hours by lengthy processing, OLGA provides live data. This enables real time monitoring and adjustment of process systems and empowers mining operators to minimise gold losses from process excursions. Complimenting Gekko s existing Carbon Scout measurement system, OLGA will enhance Gekko s metallurgical accounting system which is currently under development in collaboration with Rockwell Automation. OLGA is a breakthrough in on-line analysis for the gold industry and we are excited to be able to work with Gekko in its implementation" CSIRO Research Director Nick Cutmore Gekkos OnLine Gold Analyser is specifically designed to enable direct measurement of gold in tailings, feed and concentrate slurries streams down to sub-ppm levels, unlike conventional x-ray fluorescence (XRF) systems that have detection limits in the tens to hundreds of ppm range. Gold Concentration (ppm) OLGA Response to Changes in Au Concentration Gold added to slurry Time (minutes) The system is delivered to site fully pre-calibrated using a range of samples representative of the plant stream allowing fast installation and commissioning into the existing process plant. As the system measures a sample slurry stream, it can be taken offline without interruption to production. Following successful in-house testing at CSIRO, OLGA is now ready for field testing. Plans for field trials at a number of Australian gold mining companies are well advanced and should see OLGA undergo full product release early in To know more about Gekko s OnLine Gold Analyser, please contact Gekko s Group Manager Innovation and Collaboration, Richard Goldberg, RichardG@gekkos.com. Gold Concentration - OLGA (ppm) Comparison of OLGA to Assay Results 0.6 Tails 1 + spikes (45w%) Tails 2 + spikes (40w%) Tails 3 + spikes (35w%) Tails 4 + spikes (30w%) 0.4 Tails 5 + spikes (40w%) Tails 6 + spikes (40w%) Tails 7 + spikes (35w%) 0.2 Tails 8 + spikes (35w%) Tails 9 + spikes (35w%) Tails 10 + spikes (40w%) Gold Concentration - Lab Assay (ppm)
3 Gekko Systems installs new Gravity Box at EMR Golden Grove December 2017 saw the successful commissioning of the turnkey gravity circuit installation (gravity box) at EMR Golden Grove. The circuit was designed, installed and successfully commissioned by the Gekko technical services team in close collaboration with EMR Golden Grove teams through late November and early December 2017 and in the process met a critical mine schedule which had high grade gold ore hitting the plant immediately post commissioning. Gekko s Gravity Box Solution commissioned at EMR Golden Grove site in early December 2017 The Performance Consulting Team has a breadth of experience and successfully provides independent, expert services across all commodities. Using Gekko s Services gives you access to all our knowledgeable technical staff. Gekko adds value to customers with Performance Consulting Services The gravity circuit comprises Gekko Systems unique dual Mag-Screen technology and an SB2500 concentrator. Mag-Screen in this instance was key to the success of the process flow sheet given the requirement to maximise gravity concentrate mass yield, remove iron magnetics from the final Zn concentrate product as well as aid the 70m long pumping duty to have gravity gold concentrate reporting to the Zn concentrate thickener. Over the past two decades, Gekko has earned its reputation as a global leader in energy efficient process solutions. Further to offering innovative mineral processing technology, the Gekko Performance Consulting team has experienced an increasing demand for its Integrated Services beyond traditional Gekko products. In each of these programs, the team has been entrusted by the client for timely, independent and professional analysis and reporting of the unique operation, query or challenge. Some of the projects the team have recently been involved include: Geometallurgical program management and analysis: Gekko were engaged to undertake the management, quality control and assessment of a complex laboratory testwork program which included comminution, mineralogy, flotation and leaching tests on 25 future ore samples. The results of this program were then compared with historical tests to assess the relative performance of future ore sources against existing models and processing performance. Operational measurements audits: A client in Western Australia requested verification of the accuracy of independent feed tonnage measurements by cross checking of weightometer measurements against changes in stockpile inventories over time. Supplied operational data needed to be ordered and analysed to enable the assessment and quantification of variation between the independent measurements. The final report provided independent advice on the magnitude of the originally perceived discrepancy so that the client was able to make an informed judgement on the next steps. Operational data analysis: A client requested analysis of routine operational testwork, daily balanced operational data, and historical data. The aim was to identify significant parameters that affect operational flotation performance. The analysis was exploratory in nature, therefore regular communication of the latest findings provided opportunities for the client to incorporate site specific knowledge with the power data analysis techniques. As a result, operational process variables were rated in order of their statistical significance to process performance, allowing targeted programs to be initiated to manage the variables most critical for optimal and stable metallurgical performance. Mechanical Service Audits Gekko was engaged to undertake a service review of the operational and maintenance procedures in relation to the equipment in the gravity circuits, including the Mag Screens, batch centrifugal concentrators and InLine Leach Reactors (ILR) after significant reduction in gravity recovery was identified on site. The Gekko team audit uncovered that most issues were around maintenance and operational procedures, a program of work was implemented which included on the job training for the maintenance team on all relevant pieces of equipment. As result operations were restored to historical levels. For more information on Gekko s Integrated Services and how it can help optimise your processing plant, please contact Gekko s Performance Consulting Manager, Andrew Dixon, AndrewD@gekkos.com. The Gekko team displayed professionalism throughout the process both in the circuit installation and commissioning, demonstrating an ability to work safely and productively. Importantly they were able to deliver on their promises and demonstrated a very strong willingness to work collaboratively with Golden Grove site teams EMR Golden Grove Processing Manager, John Burgess Technical performance of the circuit has been pleasing both during and post commissioning with gravity recoveries ranging between 20% and 45% from gold head grades between ~1g/t and ~4g/t. Significantly objectives set prior to project execution were achieved with gold recoveries up by over 11%. Gekko acknowledge the great support received on site throughout the process by project manager Michael Hogan and EMR automation, operations and maintenance teams. For more information about Gekko s Gravity Box Package, contact Tim Bell, timb@gekkos.com. Screening Capture Cleaning Oversize Feed Rotating Drum Fixed Magnetic Element Magnetic Release Magnetics Undersize Non-Magnetics Magnet Water Spray
4 Gekko Systems installs new gravity recovery equipment at Mineros SA Mineros El Bagre alluvial project is located in the Antioquia (Colombia) mining district and now includes seven InLine Pressure Jigs IPJ2400 and two InLine Spinners ISP30 The Mineros Group recently implemented the first phase of an expansion project at its extensive alluvial gold dredging operations in the Nechi River delta at El Bagre in Colombia. The project was borne out of a successful pilot plant trial on a tethered barge which accepted a representative stream of Dobaibe gravity feed material. Gekko Systems InLine Pressure Jigs (IPJ) were chosen to replace the port side gold recovery jigs on the Dobaibe dredge in mid The existing starboard atmospheric jig remains in place which will allow a comprehensive analysis of the relative performance of each system over time. Early results indicate a substantial improvement in overall gold recovery following the installation of the IPJ circuit. The Gekko plant consisted of six IPJ2400s in primary gravity duty, one secondary gravity IPJ2400 and two ISP30s (InLine Spinner) for tertiary gravity recovery. Due to the nature of bucket dredge operation, the plant was designed to accommodate feed rates cycling between 250 and 590 tonnes per hour, controlled automatically. Close collaboration between Mineros staff, led by Project Manager Carlos Hoyos, and Gekko Design and Process Engineers, resulted in a sophisticated installation characterised by superior process performance, built-in redundancy to achieve high overall availability and improved maintenance scheduling with good equipment access. Gekko s exclusive representative for South America, Diego Mielke said, We are extremely pleased to be working with Mineros in delivering this step-change increase in gold production, and look forward to providing through-life support into the future. A feature of the new plant is its ability to process the constantly changing physical properties of the feed stock whilst maintaining optimum plant performance. The excellent working relationship between Mineros and Gekko has been a hallmark in the continuing optimisation of the Gekko plant, and is testament to Mineros commitment to expand gold production involving a programmed refit of the dredge fleet to Gekko technology. For further information on Gekko s technology and how it can help your mining operations in South America, please contact Gekko s Exclusive Agent Diego Mielke on or via , diegomielke@minetecbrasil.com.br. GoldiLOX: The golden edge From left to right Mineros Project Manager Carlos Hoyos, Automation Manager Joiner Hoyos, Gekko s representative for South America Diego Mielke, Commissioning Engineer Marcus Koot and Mineros Senior Mechanical Engineer Edwin Cossio on the Nechi river, Colombia in transit to the dredge. Gekko is excited to introduce GoldiLOX an advanced leach accelerant able to increase gold recovery while shortening intensive cyanidation times, making gold production a faster and more effective process. Using cyanide-based solution to leach gold is one of the most common processes used by mine operators to extract gold from ores and concentrates. Gekko s all new GoldiLOX has been specially formulated to speed up this process, allowing more gold to be recovered more often, increasing plant throughout and gold production. Lead free and packaged in 10 Kg buckets, GoldiLOX is easy to transport to site and use. It is added either as a single manual addition or prepared as a 5 to 10% solution and dosed automatically. "GoldiLOX is not only an effective leach accelerant, it also costs a fraction of other alternatives in the market today. We have taken orders from a number of mine sites and several others have shown interest" said Ulf Torpman, Gekko s After Sales Support Manager. Gekko s Metallurgical Laboratory works with clients to determine the optimum addition rate to maximise economic recoveries utilising GoldiLOX. To know more about GoldiLOX, contact Gekko s After Sales Support Manager Ulf Torpman, spares@gekkos.com.
5 Python charges ahead with underground processing Once installed underground, Gekko s low-height Python design will assist miners pre-concentrating the ore into ~50% of the original mass, significantly reducing the downstream processing energy requirements and costs. After the successful on-time delivery of two 55 tph modular Python crushing and gravity plants to TMAC Resources Hope Bay mine in Northern Canada in 2016/17, Gekko has progressed in developing a new 30 tph underground model. The newly developed 30 tph system (pictured above) has been designed to be operated and maintained in a 5 m x 5 m (height by width) drive and has several new features to ensure that it complies with underground requirements. The new features that will ensure the safe and reliable operation of the plant include: Mobile, electric powered low profile primary crushing front end Retractable conveyor heads allow ease of equipment maintenance Dust suppression micro-sprays Cooling system for local electrical boxes to combat heat generation Narrow module design to allow adequate clearance for a specially selected maintenance vehicle Maximised water recycling to reduce water consumption Minimised module dimensions to aid transport underground The new design, which has been developed in conjunction with an underground mining company, will look to preconcentrate ore underground prior to being transported to a surface based milling circuit. The project aims to significantly reduce haulage and other related costs, and increase metal production. Nigel Grigg, Gekko s Business Development Manager stated, Despite the obvious challenges, there are a number of real benefits to pre-concentrating underground. By preconcentrating the ore into ~50% of the original mass, it has the potential to double the grade to the milling circuit while achieving very high recoveries and leaving 50% of the original ore down the hole for backfill. Gekko is aiming to introduce the underground Python plant into deep mines, where the cost of haulage is becoming uneconomic or where mineralised waste can be economically treated and upgraded to augment current milling production. Another benefit of pre-concentrating your ore underground, is that if the ore can be upgraded at an economic recovery, then the cut-off grades can be reduced, increasing the mine life or allowing the miners to use mechanised mining methods that might otherwise be prohibitive due to dilution. The new design takes into account the learnings that we have made from the surface based Python plants and will improve its operability underground Gekko Process Engineering Manager, Tim Hughes The Python plant whilst ideal for high grade deposits, also suits mines that are looking to exploit low grade satellite deposits or have mineral waste dumps that are able to be upgraded. To learn more about Gekko s award winning Python processing plant, contact Gekko s Business Development Manager Nigel Grigg, nigelg@gekkos.com. BALLARAT - HQ JOHANNESBURG PERTH VANCOUVER 323 Learmonth Road Ballarat Vic 3350 AUSTRALIA PO Box 244 Wendouree Vic 3355 AUSTRALIA Unit 31 Eastgate Business Park Marlboro Drive Sandton SOUTH AFRICA PostNet #429, Private Bag X29 GalloManor 2052 SOUTH AFRICA Building A, Suite 5A 661 Newcastle St Leederville WA 6007 AUSTRALIA West Pender Street Vancouver BC V6E 2S1 CANADA p f e gekkos@gekkos.com p f e gekkos@gekkos.co.za p e gekkos@gekkos.com p f e gekkos@gekkos.ca gekkos.com
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