Use of Geometallurgy to Predict

Tailings Leach Acid Consumption at

Olympic Dam
E Macmillan1, K Ehrig2, V Liebezeit3, P Kittler4 and C Lower5

ABSTRACT
For any processing plant there will be deleterious elements or minerals which affect production or
quality, and a strategy to predict their occurrence and mitigate their impact is required. An early
objective of the Olympic Dam geometallurgy program was prediction of the acid consumption
and gelling behaviour of the ore, which affects leach recovery, throughput and circuit availability.
The geometallurgical test program measured the response of a wide range of ore types, and then
relationships between mineralogy, metallurgy and chemistry were developed. Thus the drivers of
acid consumption and triggers for gelling events could be described in ways that were meaningful
to plant operations.
To enable optimisation of the mine planning and ore blending processes, the parameters driving
metallurgical response must be translated to the block model. Data support is critical in populating
a block model. Assay information is easily obtained, but mineralogical and metallurgical
information is more expensive and time consuming to collect. Hence population of a block model
with mineralogical and metallurgical values using a conventional geostatistical approach is not
always possible.
An alternative approach employed at Olympic Dam was the development of a suite of assay-to-
mineral algorithms. These algorithms were calibrated using all available mineralogical information,
and this enabled the calculation of mineral abundances for more than 1.5 million assayed samples.
Estimation of the minerals in the block model, and the generation of acid consumption values for
each block could subsequently occur.
The use of back-calculated mineralogy from assays as part of process model generation is an
innovative tool which can be used for mine planning and optimisation and to ensure the plant
does not receive any unwelcome surprises. Ultimately, one purpose of geometallurgy is to predict
potential processing issues and their drivers so that these can be mitigated. A strategy to achieve
this is outlined hereafter.

INTRODUCTION
One of the objectives of geometallurgy is to develop
relationships between mineralogy, metallurgy, geology and
chemistry which can be used to explain and predict behaviour
of the ore in a process plant. The following paper aims to
describe a geometallurgical strategy for a process issue, which
has resulted in the creation of a large resource block model
populated with process plant information.
Background – Olympic Dam
Located 560 kilometres north of Adelaide, South Australia,
Olympic Dam is a multi-mineral orebody. It is the world’s
fourth largest remaining copper deposit, fifth largest gold
deposit and the largest uranium deposit. It also contains
significant quantities of silver. The subsequent description
gives an appreciation of the geological and processing
complexities at Olympic Dam.
Geology
The Olympic Dam breccia complex is a ‘granite’ which has
been intensely brecciated and altered/mineralised to produce
localised iron oxide rich zones which may, or may not, be
economically mineralised. Minerals in the ‘granite’ have been
progressively replaced by iron oxides, hematite and magnetite,
and a suite of hydrothermal minerals.
There are over 70 minerals which occur in Olympic Dam
ores. These include, but are not limited to – economic minerals
(bornite, chalcocite, chalcopyrite, coffinite, brannerite,
uraninite, Ag-Au bearing minerals); sub-economic minerals

1. MAusIMM, Project Geometallurgist, BHP Billiton, 55 Grenfell Street, Adelaide SA 5000. Email: edeltraud.macmillan@bhpbilliton.com
2. Principal Geometallurgist, BHP Billiton, 55 Grenfell Street, Adelaide SA 5000. Email: kathy.ehrig@bhpbilliton.com
3. Senior Engineer Long-Term Planning, BHP Billiton, 55 Grenfell Street, Adelaide SA 5000. Email: vanessa.liebezeit@bhpbilliton.com
4. MAusIMM, Senior Geometallurgist, BHP Billiton, 55 Grenfell Street, Adelaide SA 5000. Email: paul.kittler@bhpbilliton.com
5. Geometallurgist, BHP Billiton, 55 Grenfell Street, Adelaide SA 5000. Email: chantelle.lower@bhpbilliton.com

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E MACMILLAN et al
(Co-, Zn-, Mo-, REE-, As-, Se-, Bi-, Te-, Sb-, Pb- bearing
minerals), and gangue minerals (hematite, quartz, sericite,
k-feldspar, chlorite, siderite, fluorite and barite).
Felsic, mafic, and ultramafic volcanic rocks are also present
in the orebody and are an integral part of the genesis of the
Olympic Dam breccia complex. The volcanic rocks have been
subjected to the same alteration processes as the granite.
Processing
The processing plant at Olympic Dam is complex, and includes:
grinding, flotation, leaching, solvent extraction, smelting, and
refining. The saleable products are copper, uranium, gold and
silver.
Grinding at Olympic Dam consists of crushing the ore
in a primary crusher underground, then milling the ore
in autogenous mills. Flotation of the ore then occurs to
separate the valuable copper minerals (chalcopyrite, bornite,
chalcocite) from the gangue minerals. The concentrate
produced from flotation is leached to extract the fluorine and
uranium contained in the copper concentrate. The resultant
copper concentrate is processed in the smelter and refinery
to produce electrorefined copper cathode, gold bullion, and
silver bullion.
The tailings leach process extracts copper and uranium
from the flotation tailings. Leaching is conducted with sulfuric
acid and sodium chlorate. After leaching the slurry is sent to
a series of counter-current-decantation (CCD) units, with
the tailings being sent to deslimes and disposal, whilst the
liquor containing dissolved copper and uranium is sent for
clarification. The clarified pregnant leach solution is then sent
to copper solvent extraction and the electrowinning plant.
Finally, uranium solvent extraction occurs, producing yellow-
cake, which is subsequently calcined to produce uranium
oxide concentrate.
Leaching and acid consumption
Sulfuric acid is used to leach both flotation concentrate and
tailings. Sulfuric acid is produced on site via treatment of
the smelter off-gases and supplementary sulfur burning.
The prediction of acid demand is important in ensuring the
leaching circuit has sufficient acid available. In terms of
acid consuming minerals, the dominant naturally occurring
minerals are siderite, chlorite and sericite. Another acid
consumer can be cement aggregate fill (CAF), which is used
for stope backfill.
Events termed ‘gelling’ and ‘thickening’ may occur in the
tailings leach circuit under certain conditions. These events
can lead to reduced throughput, reduced recoveries and
significant equipment downtime. There is a requirement to
understand and predict the drivers of these events in order to
eliminate, reduce or mitigate the effects of their occurrence.
Furthermore, in evaluating future options for expansion, it
was identified that acid consumption was a driver of value.
Therefore acid consumption and gelling propensity are
important metallurgical performance parameters which
influence the optimisation of the current Olympic Dam
operation and future possible expansions.
Geometallurgy
The geometallurgy program at Olympic Dam aims to quantify
relationships between chemical assays, mineralogy and
metallurgical performance with the aim of populating the
resource block model. As discussed by Dunham and Vann
(2007), geometallurgy is a field which looks at identifying
either direct measures or proxies for throughput, recovery
and concentrate quality from various forms of data.
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In the current work, whole-rock assay information was
utilised and mineralogical algorithms generated from these
to predict mineral abundances in every assayed sample.
Ultimately this mineralogical information is used in the
modelling process as input parameters so that equations
can be developed which predict various geometallurgical
parameters (including acid consumption and recoveries).
These geometallurgical attributes are then modelled spatially
so that their impacts can be recognised for mine planning and
mineral processing purposes.
GEOMETALLURGY STRATEGY
Figure 1 is a diagrammatic representation of the process
used to populate the Olympic Dam block model. In practice,
there are numerous iterative steps in this process. The
first step involves the collection of data from metallurgical
tests, assay, geological and also mineralogical information.
From these data, proxies are identified which can be used
to identify key parameters, which may be modelled to
predict geometallurgical parameters (acid consumption in
this case). All of these key input parameters, proxies and
geometallurgical parameters can then be spatially modelled
using geostatistics. From these spatial models, zones in the
orebody can be identified which may contain minerals that
are deleterious to the plant. With this knowledge, optimised
mine plans and schedules can be produced which reduce ore
variability and take into consideration the location of these
deleterious minerals to reduce the likelihood that they will
significantly impact the operation.
Data collection
The first part of the journey in creating a geometallurgy
enabled mine plan is the collection of data. There are
numerous sources of data that may be appropriate to predict
geometallurgical parameters. From this data, the rock to be
mined can be characterised.
Data support is the key in ensuring all models adequately
reflect the variability of the orebody. Assay information is
most easily obtained, with mineralogical and metallurgical
information being more expensive and time consuming to
collect. Usually, due to the number of metallurgical tests
which are carried out, this precludes direct estimation of the
test result into the block model via the use of geostatistical
methods because of a lack of sample support. This is dependent
on the orebody and the metallurgical parameter in question,
and must therefore be determined on a case by case basis.
Various approaches can be taken to overcome this limitation
when it is required to populate the block model with a
metallurgical parameter. One approach is the development
of a small-scale, cheap test which can be performed on a
much larger number of samples without the cost becoming
prohibitive. An alternative is the determination of suitable
proxies which can be used to predict the metallurgical
responses. Once these proxies have been validated by
laboratory scale metallurgical tests, these can be scaled
up to yield relationships which can determine various
characteristics of the deposit (Dunham and Vann, 2007).
There is also the approach taken by Olympic Dam which is
to develop a relationship between the required metallurgical
response and variables which are available in every block
model (for example elements, minerals and density). In order
to develop a relationship which is valid across the required
range, sufficient metallurgical tests need to be performed on
a wide range of samples. Hence, this information is usually
collected for selected samples and models are generated
 USE OF GEOMETALLURGY TO PREDICT TAILINGS LEACH ACID CONSUMPTION AT OLYMPIC DAM

FIG 1 - Geometallurgical strategy at Olympic Dam.

THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011 95
E MACMILLAN et al
which may indicate potential key drivers for particular issues.
These models are then used to populate parameters in the
block model.
Assays
At Olympic Dam, over 1.5 million resource samples have been
assayed for 26 different elements (K, Al, Si, Fe, Ca, Ba, S, CO2,
Cu, U3O8, Au, Ag, As, Co, Mo, Ni, Pb, Zn, La, Ce, Mg, Mn, Na,
P, Ti, Zr). Density and magnetic susceptibility data have also
been collected for these samples. These samples have been
sourced from approximately 10 000 diamond drill holes
which have been drilled within and around the periphery of
the deposit.
Mineralogy
Fourteen minerals (hematite, quartz, sericite, feldspar,
chlorite, barite, fluorite, siderite, pyrite, chalcopyrite, bornite,
chalcocite, sphalerite, and molybdenite) account for at least
98 per cent of the minerals in altered and mineralised breccias
at Olympic Dam. Mineralogical analyses are not conducted for
every sample. However, metallurgical performance is a function
of the behaviour of minerals, not simply the concentration of
metals. The starting point at Olympic Dam was that whole-
rock chemical assays could be used to calculate mineralogy,
producing sample support for block model estimation at the
same scale as assays. Sufficient measured mineralogy must be
conducted to validate the mineralogy calculations. A variety
of techniques are used at Olympic Dam including automated
mineralogy techniques (mineral liberation analyser or MLA,
and QEMSCAN®), quantitative x-ray diffraction (QXRD) and
use of an electron microprobe to define the stoichiometric
compositional ranges for key minerals.
Metallurgical test work
The cost, time and sample size required to conduct
metallurgical laboratory tests generally limits the number of
samples that can be tested. The approach at Olympic Dam is
to relate the metallurgical response from the applicable test
to the data about the primary sample which is available in the
block model.
A set of tests under so-called ‘standard’ conditions form the
basis of the metallurgical test component of the Olympic Dam
geometallurgy program. Currently the leach test is executed
as a batch laboratory test on laboratory and plant generated
flotation tailings. The laboratory leach uses conditions that
are in line with current plant practice, and the leach method
has been validated using plant-generated tailings to show
it gives a comparable result to the plant with respect to the
key metallurgical responses. There has been some limited
investigation into development of a ‘diagnostic’ leach test for
Olympic Dam tailings. This methodology will continue to be
developed.
The primary purpose of an Olympic Dam geometallurgy
standard leach test is to determine acid consumption and
uranium extraction under standard conditions. A wide
range of other quantitative and qualitative data about the
leach behaviour is also collected, including the propensity
of each sample to thicken or gel, reagent consumption,
minor element extraction and leach rate. This data is stored
in the geometallurgical database. More than 1000 samples
have been tested to date. As part of the wider geometallurgy
program, the primary sample is also extensively characterised
using the assay and mineralogy techniques described in
previous sections. Data relating to the primary sample and its
metallurgical response can then be analysed.
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Mineralogy algorithms
In an ideal scenario, mineralogy would be measured on all
assayed samples so that the mineral abundances could be
estimated on all blocks in the block model. However, it is
not practical to directly measure mineral abundances on all
assayed samples at Olympic Dam due to the large number of
samples which are routinely assayed. Fortunately, at Olympic
Dam the concentrations of the 14 most abundant (and
important) minerals can be predicted on all samples that have
been assayed for the defined suite of elements.
The use of calculated mineralogy algorithms to estimate the
abundance of various minerals in unaltered or unmineralised
rocks from whole-rock chemical assays has been used for
decades (Best, 1982; Carmichael, Turner and Verhoogen,
1974). In order to create these mineralogy algorithms, it is a
requirement that all elements be unambiguously partitioned
to minerals. After intense alteration and/or mineralisation of
rocks this is often a difficult process to complete. At Olympic
Dam, many of the silicate minerals are not stoichiometric
which makes this process more difficult. However, in general
terms many of the minerals at Olympic Dam are chemically
quite simple, and hence this partitioning of elements can
occur reasonably easily. Mineralogy algorithms that offer
a good ‘global’ estimate of calculated mineralogy for in situ
Olympic Dam ore have been produced. These algorithms
can also be applied to calculate the mineralogy for some of
the plant streams, including flotation streams, tailings/
concentrate leach feeds and residues. The algorithms utilise
head assay information to predict the mineral speciation in
a sample. This is advantageous, as it means that mineralogy
measurements do not need to be conducted for every sample,
but can be back-calculated from head assays. These assay-to-
mineral algorithms have been used at Olympic Dam for more
than 15 years and are validated from measured mineralogy
(e.g. QXRD and MLA) results.
Process model generation
Examination of the minerals present in Olympic Dam tailings
leach feed with respect to their solubility in sulfuric acid at
current operating process temperatures suggest that carbonate
minerals (siderite, ankerite and dolomite), chlorite, fluorite,
sericite, and hematite (to some extent) could be soluble.
Jansen and Taylor (2002) identify chlorites as powerful long-
term acid consumers in their discussion of gangue mineralogy
issues in heap leaches.
Empirical models for acid consumption were generated
from the measured test data and the three aforementioned
sets of input parameters for the primary sample, namely:
measured mineralogy, assays, and calculated mineralogy.
Various statistical programs are used for the generation
of model development initially focusing on multiple linear
regression techniques. Minitab statistical software was used to
identify correlations, construct model equations and calculate
statistical parameters.
The input parameter pool
In order to use the acid consumption relationship to populate
the block model, the input parameters to the model must
be constrained to the variables which are estimated in every
block in the resource model. Currently for Olympic Dam,
geostatistical estimation occurs for the 26 assayed elements,
density and the 14 calculated minerals. The geometallurgy
team also opted to use the measured mineralogy as an input
data set.
 USE OF GEOMETALLURGY TO PREDICT TAILINGS LEACH ACID CONSUMPTION AT OLYMPIC DAM

Acid consumption not been significantly reduced. This therefore strengthens the
It was found that the best models produced were based on case that the parameters and coefficients in this model offer a
mineralogy rather than assays, and were of the form: robust representation for the prediction of acid consumption.
The acid consumption model is tested against each new data
Acid consumption = a + b × (% chlorite) + c × (% carbonates) set produced by the geometallurgy program which provides an
+ d × (% sericite) important model validation step. Figure 2 shows results from a
proposed new mine area at Olympic Dam where the measured
(where a, b, c and d are coefficients generated from statistical acid consumption is compared with the modelled value. Leach
analysis). tests were conducted on selected discrete geometallurgy
samples. These samples do not represent blended feed, but
When models were generated using only elemental feed
represent extreme examples of ore types present in the new
assays as inputs, the standard error for these models was high,
mine area. The acid consumption values from the new mine
and linear regression generally showed poor data fit. Therefore
area were not used to generate the model. Comparing the
the assay-based models were not pursued as an option.
predicted and measured acid consumptions for the new mine
This empirical mineral-based model makes logical sense area, as displayed in Figure 2, hence validates that the model
based on the theoretical knowledge about the solubility of the predicts acid consumption very well. The error of prediction
gangue minerals. Fluorite does not completely dissolve under can hence be assessed and compared against the known test
Olympic Dam standard leach conditions. The data did not precision to determine if model improvement opportunities
show a strong correlation of fluorite with acid consumption are possible.
despite an extremely wide range of fluorite concentrations,
and there was no benefit to the predictive power of the model Gelling and thickening
with its inclusion. The extent of dissolution of hematite is The ‘gelling’ phenomenon identified in the operational tailings
extremely low, but it is the dominant gangue mineral so its leach circuit was also identified in the laboratory leach test. In
contribution could be significant. However, as with fluorite, the laboratory it is often difficult to record these qualitative
the empirical data analysis showed no strong correlation of observations and hence a rating system (gel rank) was
hematite with acid consumption. developed whereby samples were assigned as: non-gelling,
Numerous revisions of the acid consumption models thickening or gelling samples. An example of a ‘gelled’ tailings
have occurred overtime as the data set of tested samples sample is shown in Figure 3, where the thickness of the slurry
has increased. For each of these revisions, the model terms can be appreciated by its ability to hold a spatula vertically
have not changed, with chlorite, siderite and sericite always without any assistance. The observations were confirmed
being the main drivers of predicted acid consumption. The using rheological measurements on a sub-set of the samples.
presence of all three minerals always improves the model (in Data analysis was conducted on these three groups of
terms of standard errors), hence showing that each mineral samples to determine whether or not any of these sample
makes an independent and quantifiable contribution to acid sets were statistically different based on both chlorite content
consumption. Also, the model coefficients changed only and acid consumption. From the results of this work, the
slightly with each model update and the standard error has propensity for a sample to thicken or form a gel during leach

350
predicted acid consumption from model (kg/t)

300

250

200

150

100

50

1:1 line new mine area

0
0 50 100 150 200 250 300 350
measured acid consumption (kg/t)

FIG 2 - Example of model validation with a new data set of discrete (unblended) geometallurgy samples.

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E MACMILLAN et al
FIG 3 - Photograph of ‘gelled’ Olympic Dam slurry in the laboratory.
was linked to chlorite content. The geometallurgical testing
program identified a higher likelihood of gelling in tailings
leach when the chlorite abundance is greater than a threshold
value of 3 weight per cent. This threshold value is used by the
mine planning team as a blending constraint.
Block modelling
One of the most critical parts of geometallurgical evaluation
is the spatial resource model. Grades of various elements
(both economic and deleterious), mineral abundances,
metallurgical recoveries and throughputs are all parameters
that may need to be represented spatially in a block model.
This can be done via estimation, simulation or by block
calculation. The main purpose of incorporating all of the
geometallurgical parameters into the block model is to allow
for processing costs and predictions to be evaluated and taken
into consideration during the mine planning process.
In order to achieve an estimate which best represents the
data, numerous iterations are required. The iterative nature
of the estimation process allows flaws in each estimate to be
realised and will allow for the creation of a method that best
represents each variable. This method may be unique for each
variable, or very similar for each variable. If the estimation
process is considered as a continuum, then the application of
a global value could be considered as representing the starting
point of the spatial representation of a variable. After several
iterations, once the known geological/structural constraints
are well represented, the ideal estimate should be achieved.
Unlike grades, both proxies and absolute measures of
geometallurgical variables are not necessarily linear or additive
and therefore require very careful geostatistical consideration
(Dunham and Vann, 2007). To overcome this problem, as
well as the issue of sample support, the geometallurgical
parameters in the Olympic Dam block model have been block
calculated. These block calculations use variables that have
been geostatistically estimated. An example of this is with
acid consumption, where chlorite, siderite and sericite are all
estimated in the block model, whilst the acid consumption
98 THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
value is calculated on a block-by-block basis using the
relationship developed from empirical data.
In terms of the estimation of minerals and elements at
Olympic Dam, numerous estimation techniques are used.
Kriging and other common spatial estimators are all based on
weighted averages, which presume additivity of the attribute
being estimated (Dunham and Vann, 2007). For this reason
the properties of each parameter that are being modelled
must be well understood.
When creating spatial estimates for geometallurgical
variables, using proxies that rely on data measured directly
from the drill hole or rock samples will yield results that should
produce enough data density to enable adequate estimation.
Due to the plethora of assay results available for Olympic
Dam, there is sufficient data support to estimate any of the
assayed elements. Samples used for estimation consist of 5 m
drill hole composites. Measured mineralogical information
is not as abundant as assay information, and for this reason
the calculated mineralogy algorithms are used to predict the
minerals present in each sample. Subsequently, geostatistical
estimation of these calculated mineralogy values can occur.
Once mineralogy block models have been generated, these
may be used in conjunction with developed process models
to yield a calculation for the acid consumption, or any other
parameter on a block scale.
Mineral and element block models
At Olympic Dam numerous estimation techniques (ie inverse
distance, ordinary kriging and multiple indicator kriging) are
used to produce spatial block models for each element/mineral.
Block model estimation at Olympic Dam occurs on a 5 m ×
10 m × 5 m block size. The estimation process is a continuum,
the most basic method of element/mineral distribution across
a deposit is to assume a global value over the entire deposit.
If further spatial resolution is required, an inverse distance
weighting (IDW) estimation method is performed. If geological
or structural factors are well represented and constrained, the
iteration process can be stopped and no further estimation
 USE OF GEOMETALLURGY TO PREDICT TAILINGS LEACH ACID CONSUMPTION AT OLYMPIC DAM
techniques need to be sought. This is rarely the case and hence
the complexity of the estimation technique is increased, but
so too is the computational time to attain an estimate. Due to
the complex nature of the Olympic Dam orebody, these more
complex estimation techniques are commonly used.
Geometallurgical block calculations
The values that are estimated for various elements and minerals
on a block-by-block basis are available for use via block
calculations. In order to attain geometallurgical information in
a block model, the easiest method to employ is the use of block
calculations. Data support is the key in generating accurate
block models, and even large geometallurgical programs may
not provide sufficient data support to allow population of a
block model with mineralogical and metallurgical values via
a conventional geostatistical approach. Hence via the use of
block calculations, the block model can be populated with
various geometallurgical parameters.
An advantage of using block calculations to populate the
geometallurgical parameters is the ease in which changes
to the process models can be updated in the block model.
Geostatistical modelling takes a significant amount of time, but
block calculations are relatively quick as their only requirement
is that all input values for the process model are available
in each block. For this reason, to generate geometallurgical
parameters in a block model, a script is run which calculates
the appropriate geometallurgical parameters. When revision
of these models occurs, it is simply a case of modifying the
equations in these scripts and re-running the script to over-
write the block calculated values. This ease of modification is
particularly important as block model iterations commonly
occur as new information is added to the database. As a result
the estimation of chlorite, siderite and sericite may change,
and these changes need to be updated in the determination of
acid consumption values on a block scale. Currently there are
over 50 calculated geometallurgical parameters in the block
model, hence having a method of calculating these reasonably
quickly in the block model is vital.
In terms of acid consumption, overall acid demand is
expressed as acid consumption per unit of mill feed. The
mass of concentrate and the mass of tailings, enabling the
acid demand estimation, is explicitly calculated for each
block. Further, the acid generated from on-site smelting is
calculated and this allows an acid balance to be generated for
each block. Two examples of acid consumption as populated
in the Olympic Dam block model can be seen in Figure 4
and Figure 5, with plan view sections of -350 mRL and
-450 mRL respectively. These have been coloured to
display the relative variations of acid consumption over the
deposit, such that black represents lower acid consumption
while lighter grey represents zones which have higher acid
consumption. From these two plan view sections it can be
seen that higher acid consumptions are expected around the
periphery of the deposit. The variation in acid consumption
across the deposit can thus be realised. This further highlights
the necessity of acid consumption prediction at Olympic Dam,
and the importance of mine planning in ensuring the mine
delivers ore that can be processed in the plant.
MINE PLANNING AND OPTIMISATION
Ultimately, the geometallurgy enabled block model can be
used to optimise mine planning, so that there are no surprises
when it is time to process the ore. Geometallurgical data can
also be used to examine the likelihood and consequences of
THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
processing certain materials, especially those containing
materials that are deemed to be deleterious, as a risk
management strategy. For this reason, production plans can
be generated which decrease variability via blending. An
alternative is to change the process in some way. These options
can be evaluated to determine the optimal result according to
the business objectives.
As described earlier, at Olympic Dam the acid consumption
is calculated for each block in the resource block model and
remains a scheduling variable throughout the medium- and
long-term mine planning process. The acid consumption
in new mine areas can be examined at a preliminary design
phase prior to obtaining results from expensive metallurgical
testing.
Olympic Dam uses a value-based mine planning process
which aims to optimise the Net Present Value to evaluate
various long-term options for exploitation of the Olympic
Dam resource. The acid consumption, and the resultant acid
balance, is an input to the overall optimisation model. It is
used to determine the requirements for site-generated acid
via sulfur-burning acid plants. The capital cost and timing of
building the acid plants were included in the high level mine
planning software, so that for various configurations the value
could be maximised.
The amount of chlorite in the feed remains as a constraint,
subject to process mitigation options. Hence the availability
of any parameter in a block model which may yield insight
into potential processing issues is a powerful way to minimise
impact to an operation. By methods such as blending,
knowledge of operating thresholds and reagent consumption
limits, these potential issues may be mitigated.
CONCLUSIONS
One purpose of geometallurgy is to identify and predict
potential drivers of processing issues so that their effect can
be evaluated and mitigation strategies developed. At Olympic
Dam, the acid balance and the related issue of gelling in the
tailings leach circuit provides a relevant case study for the use
of geometallurgy and the production of a geometallurgically-
enabled block model.
The geometallurgical test program results showed that acid
consumption is correlated with the abundance of chlorite,
siderite and sericite. A robust empirical model was developed
to predict tailings leach acid consumption. The data was
further analysed to show that the likelihood of thickening or
gelling based on chlorite content could be predicted.
The abundances of acid consuming minerals in all assayed
samples at Olympic Dam are determined via the use of assay-
to-mineral algorithms, and minerals are therefore available at
the same level of data support as assays. Spatial block models
are produced for each element and mineral based on the most
appropriate estimation techniques, which include: inverse
distance weighting (IDW), ordinary kriging (OK) or multiple
indicator kriging (MIK).
The eight million 30 × 30 × 15 m block Olympic Dam
resource block model thus contains a value in each block
for 26 elements and 14 minerals. The acid consumption and
resultant acid balance is calculated for each block using the
geometallurgical model developed from the test data. There
are over 50 geometallurgical parameters in the block relating
to the metallurgical response of the four valuable minerals
at Olympic Dam, as well as the behaviour of deleterious
elements and other metallurgical parameters which affect the
economics of the operation.
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High

400 m

FIG 4 - Plan view section (-350 mRL) of acid consumption for the Olympic Dam deposit.

100 THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
 USE OF GEOMETALLURGY TO PREDICT TAILINGS LEACH ACID CONSUMPTION AT OLYMPIC DAM

Mine N

True N

Low Low
Medium
Medium

High High

400 m

FIG 5 - Plan view section (-450 mRL) of acid consumption for the Olympic Dam deposit.

THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011 101
E MACMILLAN et al
The acid consumption value is carried in the medium- and
long-term mine planning process and is reported as part of
the standard mine schedule. The acid consumption for new
mine areas can therefore be reviewed based only on the
assay drilling which has occurred in that area. Validation
geometallurgical testing and mineralogy measurements may
then occur. However, the operation planning cycle already has
valuable information about an important value driver, in this
case acid consumption, which can be incorporated into the
economic analysis of the various mining options.
This example is one method of generating a
geometallurgically-enabled block model which has proved
beneficial in an existing operation and future planning for the
deposit.
ACKNOWLEDGEMENTS
Permission from BHP Billiton to publish this paper is
gratefully acknowledged.
Geometallurgy involves the cross pollination of many
disciplines, and hence numerous people have been involved
102 THE FIRST AUSIMM INTERNATIONAL GEOMETALLURGY CONFERENCE / BRISBANE, QLD, 5 - 7 SEPTEMBER 2011
in either data collection, generation of assay-to-mineral
algorithms, process modelling, statistical analysis and
geostatistical modelling. The authors would like to thank key
collaborators – Tania Helms, Nick Green, Dave Hartman,
Shane O’Connell, Colin Badenhorst, Anthony Bottrill and
Michelle Smith.
REFERENCES
Best, M G, 1982. Igneous and Metamorphic Petrology, 630 p
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Carmichael, I S E, Turner, F J and Verhoogen, J, 1974. Igneous
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Dunham, S and Vann, J, 2007. Geometallurgy, Geostatistics
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need to know? in Proceedings Project Evaluation Conference,
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Jansen, M, and Taylor, A, 2002. Overview of gangue mineralogy
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