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"This paper deals with the reconciliation of open stope performance at Olympic Dam, South Australia, with a focus on stope stability, recovery, and operational aspects of stope reconciliation in relation to the expected or planned stope design. The observed stope performance is inconsistent with the equivalent linear overbreak sloughing criteria for assessing the performance of large open stopes. The aim is to investigate new stope performance criteria using quantitative (overbreak, underbreak, maximum depth of wall failure) and qualitative (stope productivity, observed fragmentation) information that correlates with the observed stope behaviour, providing a process for improving future stope designs.RÉSUMÉ Le présent article traite de la réconciliation de la performance des chambres ouvertes à Olympic Dam, Australie du Sud, en ciblant la stabilité des chambres, la récupération et les aspects opérationnels de la réconciliation des chambres par rapport à la conception attendue ou planifiée des chambres. La performance observée des chambres ne concorde pas avec les critères d’épaisseur équivalente du bris hors profil pour évaluer la performance de grandes chambres ouvertes. L’objectif est d’étudier de nouveaux critères de performance des chambres au moyen de données quantitatives (rupture hors profil, rupture à l’intérieur du profil planifié, profondeur maximale d’effondrement du mur) et qualitatives (productivité de la chambre, fragmentation observée) qui concordent avec le comportement observé des chambres, fournissant ainsi un processus pour améliorer les futures conceptions des chambres."

Jan 1, 2015

By G. Reuben Yourt

This paper consists of two main parts. The first, under the heading Preparations, deals with suggested preparations to be carried out in advance so that loss of life might be prevented should a fire occur. The second part, under the heading Fire Procedure, deals with actual organized procedure to be followed for the preservation of life if and when a fire occurs. The writer realizes that these preparations and procedures may be to some extent applicable to only a few mines with a relatively simple vein system and that each mine would need to formulate a procedure to conform to its own particular conditions, scope, and degree of complexity. Preparations 1. - Ventilation Control The objective in ventilation control in the event of a tire underground is to keep the travelways, through which men must pass to reach surface, supplied with air not deficient in oxygen and free from gases and smoke. Without some control of the volume and direction of the main air currents flowing through the mine, the success of removing men to surface might be seriously hampered. ? This control is achieved by means of mechanical ventilation forcing air through desired airways and workings with the assistance of doors to regulate the volume and direction of the air flow. In connection with fans and doors, the possibility of short-circuiting should always be taken into consideration, as it can often nullify the value of a fan and possibly trap men in dangerous atmosphere if the short-circuiting involves the fire area. Main fans are often installed so that they can be reversed in a short time. However, fans should not be reversed unless this is found absolutely essential by those in authority. Misjudgment in this respect could cause the loss of life to men who might naturally take refuge in what they believe by experience to be a fresh air stream. Another precaution to be taken is to see that doors in airways are fastened in a fixed position so that they cannot be sucked or blown open when the fan is reversed, otherwise short-circuiting could possibly render the fan useless.

Jan 1, 1947

By S. Abu-Samra

By virtue of its complex nature, the construction industry comprises a wide spectrum of interrelated variables and factors. This multifaceted character of the construction industry puts the use of engineering modeling tools and techniques on top of project management necessities. This research introduces a macro-level earthmoving management system using Genetic Algorithms (GAs) to reach the optimum allocation of earthmoving equipment. The Earthmoving Equipment Management System (EEMS) functions through four integrated modules: (1) A Central Database containing information about projects and available equipment; (2) An Equipment per Segment Selection module that calculates the cut and fill quantities, plots the Mass Haul Diagrams, and selects the equipment types to be used for each segment; (3) An Equipment Pool module which determines the production and cost for each available equipment, based upon the project site conditions; and (4) An Optimization Engine equipped with a GA optimization solver. This engine formulates the optimum earthmoving cost for all projects, by changing the number of allocated equipment. The Optimization Engine takes into account the number of available equipment and calculates the weekly equipment allocation. The EEMS model was implemented on an earthmoving company conducting five different projects on hand. The model proved to be an effective tool in providing decision makers with optimum equipment utilization on a multi-project scale to minimize the earthmoving cost. The results were then compared with the company?s existing micro-level management system, demonstrating better performance on the level of savings, amounting to 13% of total earthmoving cost.

Aug 1, 2013

By Christian M. Bauer

Modern surface mines are among the world's largest single consumers of diesel fuel. A typical mine site can consume in excess of 200 million liters of diesel fuel per year. Delivered diesel fuel is not necessarily clean. Depending on the mode of transportation, handling practices and local climate, incoming bulk fuel can contain up to 20 mg/L suspended solid contaminants and also significant quantities of free water, which can amount to substantial quantities ? for a typical mine site 200 to 400 kg of dirt per year. Standard on-board fuel filters are not designed to handle high levels of contamination, and most engine manufacturers have specific fuel cleanliness requirements to ensure reliable engine operation. New developments in fuel injector technology, such as high pressure, common rail injectors require even cleaner fuel. In order to ensure reliable operation, it is therefore recommended to control particulate contamination throughout the entire Diesel supply chain - from the bulk storage on mine sites to the injection systems on-board through the use of particulate filtration and liquid coalescence technologies. In this work, the author introduces a comprehensive approach to contamination control for the entire fuel supply chain, and discusses the benefits of using advanced filtration and separation technologies, with a particular focus on the requirements of modern high pressure, common rail (HPCR) fuel injection systems.

Nov 1, 2011

By R. M. de Carvalho

Empirical and phenomenological models of SAG and AG mills have dominated the scene for the last few decades, being used nearly every time a mill is scale-up or an attempt is made to improve its performance. However, in spite of their success, these models fail to describe the details of both the grinding environment and the breakage mechanisms. The result is a generally good track record, with a few – but very important – instances when these models fall short in their predictions, which can be very costly. Further, nearly all of these models require detailed calibration to industrial and pilot plant data, being costly in their application, although still with limited predictive capabilities. Recognizing these challenges, a new model framework has been proposed which overcomes the limitations of currently used models by coupling the microscale population balance model, the discrete element model and functions that describe internal classification at the mill grate. This model framework has already been applied to describe breakage in ball mills, with showing very promising results. However, in the case of SAG and AG mills a much greater level of complexity is involved in the model, given the interaction between the mechanical environment that is formed totally or, in part, by the ore itself, and the breakage response in the mill. The paper describes the model framework, demonstrating how it can address appropriately effects such as mill speed, mill filling and size distribution, on the response from the mill. Some of the advantages of the model are related to its intrinsic multi-component and dynamic nature, which allows simulating appropriately mixtures of ores of different competences in a transient manner.

Jan 1, 2012

By Garston H. Blackwell

For ageing open pit mining operations where the economic viability of another pushback is questionable, mine life can be extended by increasing the wall slope. If the steepening is started where ore intersects the pit wall, the capital outlay for waste stripping is minimal. Such a venture must be conducted safely, and a basic requirement would include loading equipment capable of working remotely. In the application described, alternatives in the choice of loader included equipment available on site, or the purchase and assembly of used equipment. Only electric cable shovels were in use at the operation, and it was thought that these would be more capable of digging high muck piles at the productivity demanded by an increasingly efficient mill, and in a challenging environment less suited to a rubber tired loader or hydraulic front shovel. A decision was made to convert an older electric cable shovel to remote controlled operation and to include the application of semi-robotic control. The conversion was completed successfully and is described, along with methods developed for remote operation of a shovel, and the application of various sensors for semi-robotic operation. A plan of operations to mine out several completed double benches and make two quadruple benches with wide catchment berms is depicted. On completion of this task, the working benches developed would be wide enough to operate at near full production. Prior to moving the remote controlled shovel back into the pit, a large wall instability became active, eventually closing the operation. The instability could have been safely mined using the remote controlled shovel.

Aug 1, 2013

By J. R. Perumareddi, V. S. Sastri, M. Elboujdaini

It is well known that high strength steels used in aerospace industry, are generally susceptible to hydrogen embrittlement during surface treatment such as electroplating with zinc on cadmium. Hydrogen embrittlement reduces ductility and results in brittle fracture rather than failure by plastic deformation. Hydrogen embrittlement of high strength steels is mitigated by surface treatment such as plating with other metals. Data on the hydrogen contents of steels before and after surface treatment by hot extraction-thermal conductivity, secondary ion mass spectrometry (SIMS) and UV-visible spectroscopy along with the mechanism are presented.

Jan 1, 2006

By R. Shamsodini, A. Poor Zaeif Doost, H. Haji Amin Shirazi, M. R. Garmsiri

"With columns being installed in rougher section at Miduk Copper Complex, the rougher feed mainly reports to rougher-scavenger cells. To evaluate the efficiency of regrinding circuit, we conducted flotation experiments on samples of the feed and the products of the regrinding circuit. The grade difference of these products at 85% recovery was considered as the efficiency index. Results show that, with weight recovery of the rougher-scavengers the efficiency of the circuit increases. Exclusion of the rougher-scavenger concentrate from the feed to the regrinding circuit, resulted in an increase in the efficiency index from 10.12 to 17.6%.INTRODUCTIONThe flotation circuit at Miduk Copper Complex consists of five flotation columns as roughers and ten mechanical cells as rougher-scavengers. According to design criteria, 75% of the final product was expected to be produced by the rougher columns, while most of the feed consisting of liberated valuable particles is introduced into rougher-scavengers. To liberate locked particles, the rougher-scavengers concentrate is introduced into the regrinding circuit (see Figure 1 below). The regrind mill is in reversed closed circuit with a secondary hydrocyclones cluster, and the cyclone overflow is introduced into three parallel cleaner columns. Cleaners concentrate reports to concentrate thickener and the column tailings is introduced into six mechanical cleaner-scavenger cells. The cleaner-scavengers concentrate reports to the regrind circuit(Figure 1)."

Jan 1, 2012

By Richard W. Hutchinson, Christopher Osterman

The Selebi-Phikwe deposits are hosted by amphibolite to granulite facies gneisses of the Limpopo belt. The sulfide orebodies are generally stratiform and conformable to the foliation of the wallrock gneiss. Sulfide remobilization has occurred during metamorphism and has produced discordant sulfide veins, called piercement structures, which project into the hanging wall and footwall gneisses. These piercement structures are compositionally similar to the stratiform sulfides, consisting mainly of pyrrhotite, pentlandite and chalcopyrite. However, texturally the piercement sulfides are coarse grained and inclusion-free, whereas the stratiform sulfides are fIne grained and packed with tectonically produced wallrock inclusions. The piercement structure sulfides and adjacent stratabound sulfides were sampled and analyzed for major base metals and PGE's for comparative purposes. Most of the piercement structures were enriched in Cu, Ag and Au, whereas they were generally depleted in Ni, Co, Fe and PGE's. Changing elemental associations were observed from the stratabound sulfides and along the length of the piercement structures. This and the degree of depletion or enrichment of various major and minor elements in the sulfide piercement structures may reflect the relative mobilities of metals under metamorphic conditions. The similarities between sulfIde piercement structures and the footwall Cu-PGE veins in some Sudbury deposits are reviewed.

Jan 1, 1994

By A. A. Nourbakhsha

The main application of refractories based on andalusite in ferrous metallurgy are in air heaters of blast furnaces, mobile mixers, and hot-metal transfer, pig iron ladle, steel-casting, and intermediate ladles. Three specific properties of andalusite are very interesting for the production of high-quality shaped and unshaped mullite refractories: being free of water, its crystal a remains stable without changing its density or volume after firing and therefore has no internal porosity .Graphite additives due to its great wetting ability play an important role in raising the property of refractory bodies. In order to improve properties of andalusite graphite bodies, oxidant agent for increasing in hot strength and oxidation resistance can not be avoided. In this research, firstly 8 pig iron ladles from ESC(esfahan Steel company) with different conditions selected and monitored during usage to determine of main factors affecting on corrosion of refractories. Results showed that tap to tap time, undischarged pig iron ,penetrated pig iron are the main ones.Literature studies showed that the graphite addition help to thermal shock resistance and liquid penetration(steel,pig iron) effect. In this research particle size distribution of aggregates containing andalusite and graphite determined by andreazen equation. Then different mixes with different percentage of graphite,Si, FeSi, SiC prepared by uniaxially pressing under 1500kgf/cm2 pressure by adding 4%wt novalak resin and 0.4%wt HMTA as hardner. Samples fired at 1100-1500oC under reduction atmosphere. According to specific standards density, porosity and CCS measured. Analytical tests such as XRD, SEM were carried out on sample selected from point of view of mechanical properties at different temperatures. Results showed that optimized amount of Si and Fe-Si for _-SiC formation in body is 4 and 6 %wt respectively at 1500OC. XRD and SEM analysis on sample with Fe-Si additives showed no destructive phase through the matrix, also SiC additives not only increase oxidation resistance but also no effect on thermo-mechanical properties.

Oct 1, 2011

By A. F. Banks

"IntroductionThe typical potash processing plant recovers and/ or upgrades from 10% to 20% of its production through the recrystallization process. The feed to the recrystallization section consists of preconcentrated slurries of fine crystal size that cannot be raised to the required product grade by flotation and fine dusts also of low grade and too fine for compaction feed. It produces high grade white potash crystals that can be marketed as a high grade product or blended into the flotation products to raise their grade. In this chapter, a typical leaching (dissolving) and recrystallization operation will be discussed.The crystallization process makes use of the three phase system chemistry of NaCl, KCl, and H,O. The normal potash process operates on a temperature range of 75°F to 95 °F. A three phase slurry feed to the dissolving circuits will be within that range. The potash (KCl) is dissolved by heating the slurry in the presence of sufficient brine to a temperature of 190°F to 200°F. As the slurry is heated, the potash (KCI) dissolves and the salt (NaCI) precipitates. The potash rich brine is then clarified and the salt and other undissolved solids removed by thickening. Clarified brine becomes the crystallizer feed.The hot brine is cooled in evaporative cooling crystallizers. In cooling, the potash precipitates as a high grade white crystal. Crystallization is done in multiple effects to permit energy recovery and control of the process. In a four effect crystallizer the cooling is done by recycling mother liquor counter currently through the first two effect condensors and using brine pond brine for the cooling of the last two.The crystallizer product is removed from the last effect as a slurry at normal process temperature and is fed either to its own centrifuging and drying circuit or blended with the flotation product for centrifuging and drying."

Jan 1, 1989

By R. T. Seaman

There are several hydrometallurgical alternative processing options under development for high enargite and arsenic containing copper concentrates ranging from biological, atmospheric, medium temperature oxidation to total oxidative leaching. The most developed of these options is the CESL process boasting pilot campaigns totaling more than 8760 hours of fully integrated continuous operation, as well as, over two thousand batch scale oxidation tests performed on dozens of concentrates for flowsheet development. This paper reports the observed deportment of arsenic under varying arsenic, iron and acid oxidation conditions; it also describes the impact of iron to arsenic ratios and residue recycle on overall arsenic behavior and its stability in residue. INTRODUCTION The CESL Hydrometallurgical Process (CESL) was originally developed to compete with smelting of clean chalcopyrite concentrates. High Treatment Charges and Refining Charges (TC/RCs) combined with premiums on London Metal Exchange (LME) grade copper from onsite refining made treatment of copper concentrates using CESL a viable option at the time. As world demand for copper increased and a subsidized Chinese refining market developed, smelting contracts became more favourable for the miner and focus was placed on modifying the CESL Hydrometallurgical Process to handle concentrates with elevated deleterious elements. Dozens of pilot campaigns processing concentrates containing elevated concentrations of uranium, fluoride, mercury and nickel all led to further developments of the CESL Hydrometallurgical Process. In 2016 a United States patent was granted for a novel modification of the CESL Hydrometallurgical Process for recovery of copper from arsenic-bearing and/or antimony-bearing copper sulphide concentrates, Henry Salomon de Friedberg (2016). To date, over 2000 bench scale tests along with five fully integrated closed loop pilot campaigns, totaling over a year of online operation time, have been conducted processing arsenic bearing copper concentrates. This paper summarizes the observed behavior of arsenic under varying autoclave and process conditions.

Jan 1, 2019

By G. H. Hope, D. Green

"Recent process advances at Lac Minerals Est Malartic Division are discussed. The Est Malartic mill treats massive sulphide, copper/gold ore from the Bousquet 2 mine, to produce a gravity gold product, a copper flotation concentrate and a gold precipitate. The mill operation has been improved by the application of Knelson concentrators to replace jigs, the application of Outukumpu high grade tank cells and optimizing the cyanide leach to minimize cyanide consumption.IntroductionThe Est Malartic mill is located near the town of Malartic in the Abitibi Region of north western Quebec. The mill has been in production since the mid- J 930's processing mainly clean, free milling gold ore. Active mining from the Est Malartic mine ceased in 1980 and the mill was switched to custom processing of ore from La Mine Doyon located some 45 km to the west. This custom processing arrangement continued until 1987 when the expanded mill at Doyon became available to process all of the Doyon production. In 1987, Lac Minerals commenced development of a second mine at the Bousquet site located 40 km west of Malartic. This mine, Bousquet 2, is the down dip extension of the La Ronde mine developed by Agnico Eagle. During pre-feasibility evaluations, it was determined that modification of the Est Malartic mill to handle this new ore source was economically more attractive than building a new facility on site. Modifications to the mill to process the high copper/gold ore from the Bousquet 2 mine began in late 1989 and the new circuits were commissioned in mid-1990. Modifications included the addition of both gravity and flotation concentration circuits to recover coarse, free gold and the copper. The existing leach circuit continued operating on the copper flotation tailings with some minor modifications to the solution handling systems. An SO,/air cyanide destruction circuit was also added at this time."

Jan 1, 1993

By Michael Klichowicz, Holger Lieberwirth

"For a detailed prognosis of mineral comminution processes, simulation tools like DEM still pose various challenges. Less realistic mineral structures can affect the results of simulation models such as bonded-particle models (BPM). Hence, in order to design mineral processes with these models as tools, representative mineral input data should be used. The article shows, how realistic 2D-structures can be modelled by taking advantage of the parameters identified by the Quantitative Mineralogical Analysis (QMA). Important quantitative parameters can be derived by analyzing three orthogonal thin or polished sections. For this reason point, line, and area analysis are applied. The mentioned parameters precisely describe the texture and structure of minerals. The newly developed software is able for the first time to semi-automatically analyze images of mineral structures using QMA. Moreover, statistically equivalent structures of minerals can be modelled using the QMA- parameters. Generating synthetic, but equivalent mineral structures opens the door for more reliable BPM based simulations. Within future research, the procedure will be adopted to generate 3D-structures. Therefore, QMA-based routines that already have been applied to generate 2D-models shall be utilized as basis. The aim of this procedure is to synthesize realistic microstructures based on certain statistical figures in order to improve comminution simulations.INTRODUCTION Due to its increasing capability, the use of computer technology is permanently intensifying in the design of mineral processes. The recent past has impressively shown that computer models can enhance the understanding of mineral processing. There is in fact a rising number of research activities, which are using simulation approaches to study various aspects of it. Weerasekara et al. (2013) give a comprehensive overview over the application of discrete element modelling (DEM) in the science of comminution.Nonetheless, using simulation tools such as DEM in general still poses a challenge. For a detailed simulation of a mineral comminution process with DEM, bonded particle models (BPM) appeared suitable in the past. The following issues, however, affect an appropriate prediction when modelling with BPM:• Simulations with high numbers of particles may need a lot of time for computation. • Internal modeling parameters like the spring and damper constants in DEM have to be adjusted by comparing its specific crushing behavior in the simulation to reality.• In order to use DEM for prediction of mineral processing, it is essential to validate the correctness of the models and assumptions, which is sometimes difficult. As Weerasekara et al. (2013) have stated it is crucial that the DEM method as well as the DEM code work properly.• It is challenging to implement the complex geometric structures of real minerals into the model."

Jan 1, 2016

By Giles St. Pierre

"The purpose of this paper is to report in a general way on the use of the Portaspec X Ray Spectrograph.At Manitou Barvue, we are milling two types of ores, copper and zinc. The control assay practice was to take grab samples at 4 hour intervals. These samples were dried in the mill, then taken over to the Assay Office where two operators would process them. Three hours later results were available at almost the same time as the operator was ready to take his set of grabs again, leaving no time for adjustments, if any were needed.After a reduction of personnel, there were no assays available on night shift. This practice was slow and inadequate, and a new way of doing control assays was investigated.After investigation the Portaspec was found suitable for the type of operation that we had in mind. The Portaspec is a conventional dispersive type of X Ray spectrograph. The instrument consists of three parts:The Power Supply The Spectrographic Head The Digital ScalerIn our case, where dried powder samples are analyzed, the instrument was provided with a two sample holder using one for the standard and the other for the sample. The operation of the instrment does not require any degree of skill or knowledge of chemistry or spectrography.Previous to buying the instrument, six sets of six to ten samples were sent to the supplier along with the assay for each sample. These samples were Cu. HDS., Cu. Conc., Cu. tls, - Zn. HDS., Zn. Conc., Zn. tls. A definite pattern was observed. For example - six Cu. HDS. samples ranging from .40 to .90 gave 10400 counts for the lowest to 16.040 counts for the highest. The number of counts were then plotted to give percentages."

Jan 1, 1971

By M. Hamamoto, M. Furuta, S. Tanaka

The Tamano smelter and refinery has expanded its production from 228kt/y to 260kt/y since 2006. It was not a big jump, but efficient and economical improvements were executed. These were not only de-bottlenecking and modernization of the smelting plant, including the acid plant, but also additional processes were commissioned, e.g. slag cleaning furnace and steam dryer. On the other hand, a conversion to permanent cathode process in the #2 tank house made the biggest impact on production efficiency for the refinery plant. In order to overcome the drastic change of copper business, although each scale is not so big, continuous improvements are very important to survive. This paper mainly describes the recent improvements of the smelting plant.

Jan 1, 2007

By Ken G. Stowe, Stephen L. Chryssoulis, Christian Bendel, Joe Y. Kim, Ewald Niehuis

"TOF-SIMS (Time-of-flight secondary ion mass spectrometry) was used to detect collectors sorbed onto the surface of mineral particles in concentrate and tailings samples from the Brunswick, Matagami and Kidd Creek concentrators. This technique uses ion beams from either Cs or Ga sources to sputter the particle surface, a method which reduces fractionation of the collector molecule during sampling.In the Brunswick Zn circuit, sphalerite particles lost to the scavenger tails had less amyl xanthate and isobutyl xanthate compared to sphalerite recovered to the Zn final concentrate. Xanthates were detected on the surface of sphalerite particles floating to the CuPb final concentrate.At Matagami, significantly more isopropyl xanthate and isobutyl dithiophosphate were detected on sphalerite recovered to the Zn final concentrate, compared to sphalerite lost in the Zn rougher tails.In the Zn circuit of Kidd Creek, sphalerite lost to the tails had on average ten times less xanthate compared to sphalerite recovered into the Zn final concentrate. Xanthate was also detected on the floated pyrite particles. In addition to isobutyl xanthate, amyl xanthate was also detected on the floated sphalerite and pyrite particles.This preliminary investigation has (a) demonstrated the ability of TOF-SIMS to detect individual collectors on particle surfaces from plant samples and (b) shown that TOF- SIMS is an excellent tool, complimentary to TOF-LIMS, in establishing the surface chemistry of minerals as related to mineral processing."

Jan 1, 1995

By P. Gautier

Current feedstock in the aluminum hot forging processes can be used in the cast or extruded forms. The microstructural variation between as-cast and extruded materials could result in different mechanical properties and corrosion resistance for hot-forged products. Corrosion performances were examined for forged parts produced by two AA6082 feedstocks at different conditions using the following corrosion tests: open circuit potential, anodic polarization, salt spray exposure and corrosion fatigue. With the help of optical and scanning electron microscopes, metallographical investigations were carried out on cast-forged and extruded-forged materials before and after corrosion. The corrosion behavior of both materials was compared in both as-forged and aged tempers. Results show that there is no significant difference in the corrosion performance for final cast-forged and extruded-forged products.

Jan 1, 2011

By I. M. Gordon

"INTRODUCTIONThe Hollinger tailing disposal plant is situated about 1 1/4 miles south of the mill. The area available for tailing covers 620 acres and is roughly 1 ¼ miles long by ¾ mile wide.Tailing was first deposited on the northeast section of the present site. This section, 1 mile long by ~ mile wide, sloped from northeast to southwest, the slope amounting to 106 feet between the northeast corner and the low land to the south west. The low land was wet and a considerable area was covered with muskeg up to 17 feet deep. It was drained by a creek running across the property in a southwesterly direction. Later, when more ground was needed, the low lying mining claims adjacent to the south and west boundaries were acquired to allow for expansion of the plant. This entailed some extra difficulties and expense that would not have been necessary had the whole of the present site been acquired with the original purchase.At the conclusion of milling, May 7, 1968, the site contains nearly 56 million tons of tailing. The top of the deposit is from 70 to 90 feet above the original low lying ground along the northwest, west and south boundaries."

Jan 1, 1969

By Jaana Romppanen, Satu Jyrkönen, Tiina Ranki, Peter Björklund, Markku Lahtinen, Kaj Eklund, Päivi Suikkanen

Outotec is continuously developing our existing process equipment and new equipment solutions to enhance the Flash Smelting process. Thanks to the long operating history of the Outotec Flash Smelting process feedback from the numerous operating references are available and is utilized. The general goals for development work are to improve equipment performance, thus realizing savings in Smelter plant operation costs by increasing the process efficiency and online availability. Digitalization also opens new possibilities for the feeding equipment and furnace operation monitoring. These solutions will improve the safety and performance of the smelter, and provide process and equipment related information which has not been available earlier. INTRODUCTION The year 2019 marks the 70th anniversary of Flash Smelting. The technology was operated on industrial scale for the first time at the Outokumpu Harjavalta copper smelter in Finland in 1949. The Flash Smelting technology, is now owned and developed by Outotec Oyj and the first plant, is now owned by Boliden Harjavalta Oy. The two companies have been evolving throughout history by optimizing the process for various feeds and raw-materials, as well as through developing the equipment and operating practices. Even though sustainability was not a hot theme/topic during the first days of Flash Smelting, it has nevertheless been the key principle in guiding the development. This is well proven by the wide adoption of Flash Smelting for the processing of copper and nickel concentrates, mostly due to its ability to fulfil the economic and resource efficiency criteria demanded by its operators. Along with the process technology development, also development of the equipment has taken place over time. Outotec is continuously working on developing our equipment to better suit the changing need of our customers in the continuously changing operational environment. Orebodies are getting more challenging with lower ore grades and more impurities. Achieving high recoveries for all valuable elements becomes more difficult with high slag quantities and with the need to tackle the high impurity concentrations. There is a need for higher capacities in greenfield and brownfield smelters. The role of the Loss-in-Weight Feeder, the Air Slide and Concentrate Burner is to ensure even feed into the reaction shaft of the Flash Smelting Furnace, and to enable controlling the process well, thereby enabling the best performance for the customers smelter. The design of the Flash Smelting Furnace aims for high availability, long campaign and safe operation.

Jan 1, 2019