Search Documents

By M. L. Goble

"Inco Metals Ltd. (Manitoba Division) operates a mining, milling, smelting and refining complex, 500 miles north of Winnipeg in central Manitoba. The Thompson Mill is presently operating at 12,000 S.T.P.D. on ore from both underground and open pit mines. The ore is treated in two separate milling and flotation circuits utilizing a common crushing system which is located inside the main mill building. The milling facility employs approximately 43 operating employees, 30 maintenance employees and 20 staff in supervisory or process development roles.In recent years an increasing awareness of the potential hazards of contaminants in the work place has made it mandatory that all employers maintain careful and accurate records of the work environment to which each employee has been exposed during his working career.The importance of this record keeping and general observation of the work place cannot be over emphasized. Proper monitoring of the work place provides an accurate and complete record of the contaminants and physical agents to which an employee is exposed during his work career. This can aid in studies which might be conducted in the future and can also be used as a basis for instituting improvements to the workplace."

Jan 1, 1980

By James F. Archibald

Research has been conducted for the Workplace Safety and Insurance Board of Ontario (WSIB) to characterize thin, spray-on lining materials (TSLs), as well as combinations of TSLs and conventional spray supports, and to assess their capacity for inhibiting damage created by mining-induced rockbursts. This study has been performed to assess the capabilities of such support systems for preventing rock and support material damage that often results due to rockbursting. A variety of TSLs and other spray support media were subjected to the effects of simulated rockbursting, through use of explosive detonation trials, to evaluate their damage mitigation capacity. Results have validated that TSLs and variant layer combinations may be as effective as or better than conventional support materials for mitigating rockburst or like damage in highly stressed mine environments. In civil engineering construction, and typically in underground tunneling operations where concrete linings are applied, liner deterioration is a continuing and pervasive problem that often requires expensive and time-consuming rehabilitation effort. The ability of TSLs to provide effective concrete structural reinforcement while providing sustainable resistance against underground or restricted environmental hazards, as with fires or dynamic failure events, may permit wider use of TSLs than is currently foreseen by the mining industry. Significant benefits for use of TSL materials in concrete liner rehabilitation and for concrete material protection have been assessed.

May 1, 2006

By L. Connolly, F. R. De Luca

"Rubber liners at Denison Mines Limited are used in 10 1/2x 24' low discharg0 pebble mills. These were originally 10 1/2 x 13 Dominion overflow type ball mills. Experience here shows that the wear of rubber and ni-hard lifters is approximately the same in the feed end half of the mill, while the wear of rubber lifters is much greater in the discharge half. The wear of rubber plates is considerably less than white iron in the feed end half of the Mill and slightly more in the discharge end half of the Mill. Rubber components are lighter to handle but their installation is time consuming. This leads to the conclusion that a combination of ni-hard lifters a~~ rubber plates is the most economical compromise in Denison's case, for the Mill. Rubber discharge grates are superior to steel grates, while steel feed end liners are superior to rubber.The Use of Rubber Mill Liners at Denison Mines LimitedGrinding is done in two identic0al circuits each consist-ing of one 10 1/2 x 14' Dominion overflow rod mill, two Dorr Oliver quadraplex rake type classifiers, two 10 1/2 x 24' Dominion low discharge grate pebble mills and ancillary pumps and conveyors for pebbles. There is one centrally located distributor box that receives the discharge of the 4 pebble mills and splits it out to the classifiers."

Jan 1, 1974

By Funsho K. Ojebuoboh

With several “green” applications on the horizon, bismuth has become an even more important minor metal in the smelting and refining of lead. Smelters with a complex sulphide feed invariably deal with bismuth. Its behavior during the smelting of lead in conventional sinter-blast furnace operation is discussed. Because it readily deports to the lead phase during the refining of lead, its separation from refined lead remained unsatisfactory in early lead production. When commercial requirements of bismuth in lead became more stringent early this century, the procedure where by calcium and magnesium is used todebismuthise lead was developed. The present conduct of this 1936 process, the Kroll-Betterton process, is discussed with emphasis on operational improvements.

Jan 1, 1996

By R. Rosenblum, J. Y. Kim, D. Shink, K. G. Stowe

"A small scale continuous flotation cell was designed and constructed at the Noranda Technology Centre to develop a mobile testing flotation circuit located next to the production circuit. This mobile small scale flotation pilot plant can easily and economically be set up at any circuit in a mill and used to evaluate and predict plant performance against a given flotation condition. The main feature of the cell, beside the provisions of automatic pulp level and feed rate control, is to provide a reduced surface to volume ratio approaching to that of an industrial machine.This paper describes the basic design and the results of various testwork carried out to date including aeration, conditioning, reagents, recirculation, flotation gas, etc. are presented in comparison with the plant production results. INTRODUCTIONStudy of the behaviour of an ore during concentration by flotation process starts, in general, with a series of tests in laboratory cells. Given the discontinuous nature of these tests, the information obtained by such a study is somewhat limited. It has long been recognized that laboratory test results are not always reproducible in pilot plant tests and subsequently, the pilot plant results do not always predict plant performance. The differences are often blamed on batch vs continuous operations, grinding media, size distribution, aging (oxidation), water quality, equipment, operator's skills, etc."

Jan 1, 1992

By K. P. Wright

"Twenty-five years ago, there were about thirty-two gold mines operating in Canada; nine of these have been in continuous operation since then and are still operating. Three of these are part of the Dome Group. Operations of these three and of the newer mines in the Group are referred to in discussing process development over the last twenty-five years.Of the Dome Mines Group, Dome Mines Limited, Sigma Mines (Quebec) Limited, Campbell Red Lake Mines Limited, Detour Lake Mine and Kiena Gold Mines Limited, three have been in continuous operation for the last twenty-five years. Dome has operated for seventy-seven years; Sigma about to complete fifty years, and Campbell approaching forty. Overall, milling processes are virtually the same as they were twenty-five years ago. Tota1 go1d production from the three mines has hardly changed; 1960 production, 416,700 ozs. versus 411,300 in 1985. Milling costs have risen by a factor of six or seven and gold price from $35/oz. in 1960 to $322 in 1985.Basic flowsheets are relatively unchanged. Sigma is an all cyanidation mill grinding in cyanide solution; Dome operates gravity concentration and cyanidation; Campbell gravity concentration, flotation, roasting and cyanidation. All three use Merrill-Crowe zinc precipitation.Detour and Kiena are two examples of the major change in gold processing in the last twenty-five years - carbon-in-pulp. This process has brought along with it other changes, such as, carbon stripping and reactivation, electrowinning, and induction furnace melting. Modern mill design with its use of outside thickeners and agitators, bulk handling of reagents, instrumentation, etc., has made a radical change in operating conditions and appearance of the new plants."

Jan 1, 1987

By Alex Cormode, Carlos Perucca

"Sylvinite ore from the Saskatoon area typically contains about 5% insolubles, occurring as clays and carbonates. These insoluble slimes must be removed sufficiently well to permit an efficient subsequent potassium chloride flotation, due to their high adsorptive capacity for amines used as potash collectors. The insolubles are liberated from sylvinite by high attrition scrubbing in a slurry. The liberated slimes are separated by multistage cycloning or by a selective flocculation-flotation process.An outline of the potash processing operations at Agrium Vanscoy Potash Operations is given, emphasizing the insoluble slimes froth flotation separation process. This process was originally implemented at the Agrium plant in the mid- 1970's and replaced a hydrocyclone system.IntroductionAgrium Vanscoy Potash Operations is located 40 Km southwest of Saskatoon, almost midway between the communities of Vanscoy and Delisle. Processing operations started in 1969, and the annual production capability was subsequently increased to the current 1.8 MM tonnes per year of muriate of potash.The mining operation at Agrium Potash which was described in a paper by Jones and Pruggerl , is done underground using four large continuous double rotor boring machines for the main production with development done by heliminers. Annual ore production is 5.5 MM tonnedannum. Ore is hoisted 1,100 m to surface for processing."

Jan 1, 1999

By Thomas M. Barczak

A critical safety component for all underground mining is intrinsic and standing support systems. Specifically, tabular hardrock mining exploits a wide variety of deposits that require various methodologies to safely mine the ore material. Several new support systems have been developed in recent years for hard rock applications which have been modified or applied in a variety of ground control applications. These include prestressing devices, improved cribs, and free standing supports. Various standing support and prop-type systems have been designed for hard rock applications with seismic loading conditions to accept prestressing. The prestressing, using water-filled cells, creates an active load upon installation and is considered essential to maintain support during and after the blasting of the mine faces. Heavy seismic activity is also present in these mines and the prestressing units can provide some energy absorption capability to help preserve the integrity of the support. This paper presents an overview of these innovations in support technology.

May 1, 2007

By Hossein Aminian, Daniel Hodouin, Claude Bazin, Claude Jacob

"Solvent extraction followed by electrowinning (SXEW) is an economical option for the processing of low grade and oxidized copper ore. Phenomenological models were developed to simulate the copper solvent extraction and the electrowinning processes. The two models were linked together to make a SX/EW simulator. The simulator is used to predict the operation of the mines Gaspe pilot plant put in operation in 1996. Results confirm the potential of the simulation that would subsequently be used for student training, process optimization and to assess the performances of control strategies.INTRODUCTIONSolvent extraction followed by electrowinning (SXEW) has become in the last two decades a key process for the recovery of copper from solution obtained by leaching low grade copper ore. Several operations have been commissioned in North and South Americas in the last decade (Arbiter, 1994). In Canada, Gibraltar Mine (Scott, 1991) operates a SX plant followed by electrowinning (EW) to produce copper cathode from leached low-grade ore dumps. From 1996 to 1997 Mines Gaspe operated a pilot plant to test the economical feasibility of leaching an oxidized copper ore, followed by solvent extraction and electrowinning of copper. Despite copper SX/EW processes have the reputation of being low cost operations, plant engineers should always look at way to make the plant more efficient. Process models provide an economic platform to learn, control and ultimately optimize the operation of a plant.Several models have been independently proposed to simulate the SX process (Cadman and Hsu, 1970; Medina Gomez, 1980; Wilkinson and Ingham, 1983; Garcia et al., 1988; Aminian et al., 1997) and the EW process (Bryson, 1981; Barton and Scott, 1992; Barton and Scott, 1993). However few papers, if any, deal with the integration of the two process models into a single simulator of a SX-EW plant. This paper describes the development of an integrated simulator for the SX-EW process and shows some steady-state simulation runs of an actual SX-EW pilot plant. The paper consists of four sections. The first section shows the general layout and principles of operation of a SX-EW plant.The second section describes the SX model while the third section deals with the process model used for the copper electrowinning process. The last section shows how the two process models are linked to simulate the operation of the Gaspe pilot plant."

Jan 1, 1999

By C. Veloo

"Westmin Resources operates a mine/mill complex at Myra Falls and produces copper and zinc concentrates with minor associations of gold, silver, and lead from a polymetallic, massive sulphide orebody. Mill flotation performance has historically been plagued by periods of uncontrollably high circulating loads leading to low concentrate grades and below optimal tails. This led to a detailed examination of the flotation process. Locked cycle, and pilot plant data are presented. In addition, plant design and commissioning as well as column cell details are discussed. A comparison between actual and predicted performance is also presented. Benefits realized are higher copper and zinc concentrate grades and improved zinc recovery.PrologueMyra Falls Operations is located at the south end of Suttle Lake in Strathcona Provincial Park. Access to the mine site is provided by a 90km paved highway from Campbell River, British Columbia.The mine and facilities are nestled in the narrow Myra Valley between Mount Phillips and Mount Myra. These steep, rugged mountains rise from the valley floor at an elevation of 900 feet to summits of almost 6000 feet. The steep slopes are heavily wooded with fir, hemlock, and cedar up to an elevation of 4000 feet where a transition to alpine meadows occurs. The summits are craggy rock faces, some capped with glacial ice. Myra Creek winds its way through the valley dropping several hundred feet into Suttle Lake. Precipitation is high at over 100 inches per year, which may include up to 10 feet of snow in winter. The temperature may range from 32° C in summer to -18° C in winter.Myra Falls began production in 1965 with the Lynx Mine, supplemented by the Myra and Price Mines in subsequent years, feeding a 950 stpd mill up until the middle of 1985 when the H-W mine was brought into production. The original mill was replaced with a modern 2700 mtpd facility and in 1988 production was increased to 4000 mtpd.Both Lynx and H-W mines are currently in production producing an average of 3650 mtpd. The ore minerals are primarily sphalerite and chalcopyrite, with subordinate galena, bornite, tetrahedrite, and electrum."

Jan 1, 1992

By P. Leo

The Al-Zn-Mg alloys (e.g. 7004, 7020) are employed for land transport and architectural applications whereas the Al-Zn-Mg-Cu alloys (e.g. 7075, 7050) provide the high strength aircraft alloys. The Cu gives rise to suitably sized and distributed precipitation but causes high quench sensitivity. Their hot work processing also has marked differences; the Cu-free alloys have good extrudability whereas the Cu-bearing alloys have low extrudability and are difficult in rolling as well. The behaviors of the two classes are described in terms of flow stresses and ductility over 300 - 500°C, along with constitutive contrasts. The ductility of the alloys with Cu is much reduced above 400°C by precipitation of a phase at the grain boundaries that can be avoided by suitable heating schedules. The high strength alloys are subject to de-lamination corrosion of sheared edges due to severely pancaked grains; this can be alleviated by holding between passes, in mid-rolling schedule. In torsion tests at 10-1 to 10 s-1/ 250 - 500°C, the stresses (ductilities) at 300°C/ 1s-1 and activation energy Q for 7004 were 118 MPa (2) and 262 kJ/mol. The 7075 was tested after several pretreatments: completely over-aged (softened): 107 MPa (5), Q=150 kJ/mol; whereas, solution and quick cooling to testing caused extraordinarily high peaks related to dynamic precipitation resulting in 160 MPa (1.2), Q=300 kJ/mol.

Jan 1, 2011

By C. Guo

The Mildred Lake Settling Basin (MLSB) is the largest disposal site for mature fine tailings (MFT) at the Syncrude Canada Ltd oil sands plant. Over the past years (since 1997), there has been a marked change in the consolidation behaviour of MFT in the MLSB, which is attributed to microbial activity. Methane-producing microorganisms, known as methanogens, have become very active, and large amounts of biogas (mainly methane) have been produced. In certain regions within the MLSB, gas bubbles are released to the water surface of the tailings pond. Continued field monitoring of the MLSB has provided convincing evidence of the rapid densification process (rapid water drainage from the tailings). This phenomenon contradicts the consolidation models for MFT developed over the past 20 years. The above phenomenon has also been reported at the oil sands tailings ponds operated by Suncor Energy Ltd. in Fort McMurray. This rapid densification has caused pumping challenges in the transfer of fine tailings from the Mildred Lake Settling Basin for the creation of composite tailings. The rapid densification of the MFT may also have potential positive effects in accelerating the reclamation of the oil sands fine tailings. A field and laboratory research program is underway to study the mechanism leading to the rapid densification phenomenon. Systematic field investigations were performed to determine the distribution and characteristics of the rapidly densified MFT. Gas bubble distribution on the water surface was mapped to determine the zones of different biological activities in the pond. These field investigations provided solid ground for further experimental and theoretical research. A number of small-scale column tests were carried out to observe the gas evolution and to measure the changes of some geotechnical parameters under different microbial activity. Also, a series of gassy MFT densification tests are being conducted to study the mechanism of the rapid densification of the MFT under microbiological activity. A review and discussion of the research program is given and some preliminary research results are presented in the paper.

Apr 1, 2005

By P. W. Godbehere, B. W. Brooks

"This paper deals with the milling of slags from the Noranda Continuous Process, in the Horne Concentrator at Noranda, Quebec. The milling of copper slags, although novel in Canada, has been practiced in Japan, Finland and elsewhere for several years.In March 1973, the prototype Noranda Continuous Process furnace or ""reactor'' came on-stream, In this pyrometallurgical process (see Fig. 1), copper concentrates mixed with flux are smelted in a single furnace to form copper or a high grade copper matte, and slag. The conventional smelting processes of roasting, reverberatory smelting and converting have been incorporated in a single 17 ft. diameter by 70 ft. long steel cylindrical vessel (l, 2). The copper or matte is tapped from the bottom of the reactor into ladles and transferred to an anode furnace or to a converter. The slag is tapped into 40 ton capacity ladles, cooled, crushed, and conveyed to the concentrator. At the present time, the reactor is operated to produce matte. The matte slag* containing 4 - 6 per cent copper is milled using conventional ore dressing grinding and flotation equipment. A flotation concentrate assaying 35 - 40 per cent copper is recycled to the reactor. Crushing, conveying, grinding, flotation and tailing disposal equipment previously used for over 40 years for ore treatment has been modified to suit the requirements of slag milling. Slag milling is essentially the scavenger circuit of a pyrometallurgical process."

Jan 1, 1977

By John D. Carr

Introduction The Flin Flon zinc plant operates on what is known as the low density or standard sulphate process, that is, the zinc is carried through the plant solution circuit attached to the SO4 or sulphate radical at a concentration not exceeding 175 grams per litre zinc. The process may be described briefly as follows: The zinc is received in the zinc concentrate chemically combined with sulphur and mixed with many other impurities. The concentrate is roasted and most of the sulphur is burned to a gas, which is discharged from the plant. The roasted concentrate, or calcine as it is called, is leached with a weak sulphuric acid solution so that the resulting leach solution contains a high zinc content but a very small proportion of the impurities. The solution is separated from the solids and is purified further by agitation with zinc dust to remove copper, cadmium, and cobalt. This purified zinc sulphate solution is then pumped to the electrolytic department. The solids from the first leach are again leached, but this time with a stronger acid solution to dissolve all of the remaining zinc which is soluble in the strength of acid available. The solids and solution from the leach are then separated. The solids are stock-piled for further treatment at some future date and the solution, carrying a relatively high amount of impurities, is sent to the first leach, where the chemical action is such that the contained impurities are precipitated as solids. The electrolytic department is nothing more than a large number of electroplating cells in which the zinc is plated on aluminium sheets. Since zinc does not plate tightly to aluminium, the zinc plating or sheet is easily stripped from the aluminium and the sheets are collected to be melted and cast into the standard market bars or slabs. In the electro-deposition cells, the zinc sulphate (ZnS04) is split to metallic zinc (Zn) which plates out, and sulphate (S04) which combines with the hydrogen of the water of the solution to form sulphuric acid (H2S04). When one pound of zinc is deposited, about one and one-half pounds of sulphuric acid are formed. This acid is sent to the leaching section, where it dissolves one pound of zinc from the calcine. The solution is purified and is again pumped to the plating cells. The solution travel forms a complete circuit.

Jan 1, 1935

By John C. Taylor

A resource document, prepared for the Royal Commission on the Health and Safety of Workers in Mines, which outlines aspects of occupational health and safety in the Canadian metallurgical industry has been expanded to provide examples of some practical solutions. General process descriptions are provided in conjunction with some of the major potential hazards associated with each step. Emissions to the working environment, particularly around converters, are discussed. Newer metallurgical processes, the role of automation and other advances in the metallurgical industry are described with respect to their impact on the work place. The role of staff and unit employees in providing safe working conditions in the complex metallurgical plant of today is outlined and the need for close cooperation within the human sector emphasized. The technology is available and is being applied to integrate the complex process requirements with realistic regulations to control emissions and provide a safe, healthy environment in metallurgical plants.

Jan 1, 1978

By F. O. Verret

Several grindability tests were developed over the years to design grinding circuits or optimize existing operations. Each test has its own strengths and weaknesses and it is imperative to select the proper test procedure(s) to meet project deliverables and minimize the risk of a project. Pilot plant testing of large bulk samples historically constituted the traditional approach for AG or SAG design, but was gradually replaced by small-scale tests. Nowadays, conducting grindability tests requiring only a few kilos of material on several samples is a more typical approach to grinding mill design. This paper summarises the requirements and deliverables of various bench-scale test procedures, their strengths and weaknesses, and cases where AG/SAG pilot testing should still be performed.

Jan 1, 2012

By Arthur Notman

Since addressing the Institute a year ago on The Future of the Copper Industry (l), many things have happened, most of them bad. It has been a hard year for profits and prophets. It was, therefore, with consider-able perturbation that I accepted the gracious invitation of your Committee to reappear. On reviewing my remarks of a year ago, I. have wondered whether, under pressure of more important matters, the Committee had neglected to make a note of them, or whether they felt that further explanations from me were in order. In either event, I am glad that I am here and welcome the opportunity to make any contribution I can to a clearer understanding of the problems of copper to those concerned. The English-speaking nations own 80 per cent of the present world-production of the metal. Col. P. E. Barbour, Secretary of the Mining and Metallurgical Society of America, and I recently completed an estimate of the known world resources of copper. We placed the figure, in round numbers, at 100,000,000 tons of metal. Of this amount, about one-third lies in the United States, one-third in the British Empire, and one-third in South America; and all but 4 per cent of this is owned by British Empire and United States capital. Our figures do not include any estimates for Russia, Japan, or Europe, on which there are no available data. It is true, consequently, that the British Empire and the United States are the ones concerned. It seems to me to be a matter of great importance to the world at large, and of even greater importance to those nations themselves, that the known sources of supply of this metal, so essential both in peace and war, rest so strongly in their hands. I cannot believe that in the long run they will neglect their responsibilities in the wise administration of these resources.

Jan 1, 1932

By J. A. Meech, R. J. Tucker

"A dynamic computer model has been developed to simulate the operation of ore crushing plants. The model was created in a general form to allow imitation of a wide variety of secondary crushing circuits with only minor program modifications. The system can be run on either a microcomputer or a large time-sharing main frame computer as required.The size reduction and separation characteristics of crushers and screens are based on standard manufacturers' design and performance data. These calculations are isolated within various subroutines to facilitate tailoring of the model to emulate any particular plant of interest. Input and output data are presented in a variety of formats. Crusher, screen and conveyor amperages and surge bin levels can be presented in a tabular form along with appropriate alarms arising from improper circuit operation or process interruptions. Graphical representation of the circuit together with strip chart data output are features of the system when operated in a microcomputer environment.The program is currently being used at Queen's University as a teaching aid to demonstrate plant operating characteristics, control strategies and design concepts. The acceptance of, and reaction to the program at this level indicates a good potential for it to provide a valuable tool for operator training."

Jan 1, 1985

By P. O. Sandstrom

"Atlas Copco is introducing a new patented method for full-face boring. This paper presents the basic principles of the boring action and discusses the present experience regarding performance and costs. The Atlas Copco ""Full-facers"" are designed for hard-rock applications, although they are successfully boring in soft ground without major changes. The unique patented boring principle referred to as the 'Undercutting Method' permits these machines to bore, economically, in harder ground than machines based on the 'crushing principle'. This is mainly due to considerably lower cutting-tool costs, as the tungsten carbide tips only are in contact with one-third of the bored volume. The remaining rock is 'undercut' and peels off from a slight back pressure.The undercutting method also permits boring of non-circular headings and Atlas Copco has already manufactured two machines for rectangular drifts. This concept could revolutionize development work in mines employing trackless equipment."

Jan 1, 1971

By G. H. Babcock, D. A. Knight, V. G. Medina

"Production commenced at the Golden Sunlight Mine in 1983 and at Kidston Gold Mine in 1985. These projects were both constructed under the management of the Placer Dome Inc. (Technical Services) group of Vancouver, B.C.Golden Sunlight uses a conventional rod mill/ball mill grinding circuit while Kidston uses a SAG /ball mill, and later on, SABC circuit. Since the hardness of the ore and the fineness of the primary grind in both mines are about the same, a meaningful cost comparison can be made. The comparison is made on the basis of capital and operating costs.The result of this study indicates that a significant capital cost savings can be achieved in favour of the SAG /ball mill circuit when the ore is amenable to semi-autogenous grinding. With a good maintenance program, the operating cost for the SAG /ball mill circuit could also be lower that the conventional rod mill/ball mill circuit.HISTORYGolden Sunlight MineGolden Sunlight is a 5 530 t/d gold mine located near Whitehall, a small town 60 km east of Butte, Montana. Originally optioned by PDI U.S. in 1958, the development of the property waited until 1981 when economic conditions became favorable for the project to proceed.Semiautogenous grinding tests were conducted during the final stages of the feasibility study. The hard near surface ore was not quite amenable to semi-autogenous grinding. The best result produced from a series of tests using a 1.83 m diameter mill was a semiautogenous work index of 39. This is substantially higher than the 22 Bond work index of the sample used in the testwork. A conventional SAG/ball mill circuit for this ore will be extremely inefficient, and for this reason, this circuit was rejected in favour of a conventional rod mill/ball mill circuit."

Jan 1, 1991