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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 Ken Wood

"A reliable source of water of an acceptable quality is vital to the success of any mineral processing plant using wet methods. For Cerro Verde, a new 108,000 t/d copper mill in southern Peru, the main source of raw water is the Chili River. The Chili River is heavily contaminated with raw sewage, industrial wastewater and agricultural runoff, and can also receive high sediment loads during the rainy season. The initial water treatment plant could not supply design flows of water due to the exceptionally poor water quality. Problems with treated water quality caused significant difficulties with water consuming equipment, such as the plant cooling systems. This paper details the Cerro Verde water system and changes from design through to start up from a mineral processing perspective.INTRODUCTIONMining, and mineral processing in particular, is a water intensive activity. Improving water system design and practice are key strategic requirements in moving toward a more sustainable mining industry. This case study forms a basis for ongoing research into water use and reuse at mines and mineral process plants, conducted by AJ Gunson, under the supervision of Dr. Bern Klein and Dr. Marcello Veiga at the University of British Columbia. The case study material was gathered through involvement with the design, startup, and redesign of the Cerro Verde water system.Cerro Verde is a low-grade copper porphyry mine, located near the city of Arequipa in southern Peru, at an elevation approaching 2,800 m. In 1972, one of the world’s first copper Solvent Extraction – Electrowinning (SX/EW) facilities was built on the site, processing oxide ore from two main open pits. In 2004, the operator, Sociedad Minera Cerro Verde S.A.A. (SMCV), approved a 108,000 t/d expansion project to process sulfide ore reserves through a new concentrator plant. The plant was designed under extremely tight schedule and capital constraints, with a mandate to intentionally avoid any overdesign."

Jan 1, 2008

By The Staff

THE property of McKenzie Red Lake Gold Mines, Limited, consists of eleven claims located on McKenzie island in Red lake. The mine is about 4,Y:l miles by water from the Howey townsite on the same lake, and about 95 miles north of Kenora, Ont. (see Figure 4). Mail and express are flown-in daily, winter and summer, from Sioux Lookout, Hudson, Kenora, and Winnipeg. All heavy supplies are freighted-in during the summer over a water route, using four marine railway portages, from Hudson, Ont., a distance of about 180 miles. During the winter, freighting over the same route is clone by tractor if necessary, but costs are three to four rimes the summer rate. Due to these conditions, large inventories of supplies must be kept on hand, varying from a spring minimum of $45,000 to a peak of $110,000 early in November. The average cost of all freight brought in from steel during 1937 was $0.01 per pound.

Jan 1, 1938

By C. Allen, V. Hensel, J. S. Stachulak

"Vale has been actively evaluating new technologies to curtail diesel emissions. This paper discusses the selection, installation, operation, and evaluation of the MANN+HUMMEL SMF®-AR diesel particulate filter system to reduce diesel particulate matter emissions in underground mines. The system uses a sintered metal filter element, an iron fuel-borne catalyst with an onboard dosing system, an electric heater that uses onboard power, and a sensor-based control unit. More than 6,000 h of testing demonstrated that the system represents a breakthrough in the successful control of soot emission from light-duty vehicles with differing soot emission levels, exhaust temperatures, and duty cycles.RÉSUMÉ La compagnie Vale évalue activement de nouvelles technologies pour réduire les émissions de diesel. Le présent article discute du choix, de l’installation, du fonctionnement et de l’évaluation du système MANN+HUMMEL SMFMD-AR de filtrage des particules de diesel pour réduire les émissions de particules de diesel dans les mines souterraines. Le système utilise un élément filtrant en métal fritté, un catalyseur à base de fer dans le carburant avec un système de dosage intégré, un élément de chauffage électrique qui utilise l’alimentation incorporée et une unité de contrôle avec un capteur. Plus de 6 000 heures d’essais ont démontré que le système représente une avancée pour réussir à contrôler les émissions de suie des véhicules légers avec différents niveaux d’émission de suie, différentes températures d’échappement et différents cycles opératoires."

Jan 1, 2015

By Brian A. Ferguson, Raynald O. Vezina, Marielle Gaudet, Raoul R. Boissonneault

"Kiena has been committed to developing a fresh management and employee relations approach since the commencement of production in 1981. The functional organizational structure encourages joint participation and commitment on the part of all employees to common goals in safety and production. The results over the last four years have been extraordinary. Kiena won the John T. Ryan Canada Trophy for 1983 for its safety record and has experienced a steadily increasing productivity through the application of new mining equipment and technology in the hands of a well-trained and motivated team of employees.This paper serves to highlight the fact that productivity, safetyand technical innovation are closely linked to employee participationand involvement which are likely to be the key to theCanadian mining industry's survival in the years ahead.This presentation follows up on an earlier unpublished paper, given at the 84th Annual Meeting of CIM in Quebec City in April, 1982, which discussed the philosophy and the planning which took place before implementation of the management and employee relations system at Kiena. This present paper reviews and expands on material given in the earlier work. IntroductionThe mining industry, which has always been considered as rather conservative in its approach, has experienced with some regularity, cyclical periods related to metal prices. These cycles, previously foreseeable to some extent have become less coherent over recent years during which time the industry has had to face fierce international competition. The issue to productivity is without doubt the major concern of the mining industry in Canada today and it represents the greatest challenge facing us during the present decade. Developments that have been made in mining technology over the precious two decades have failed to completely produce the significant advancements in higher over-all productivity that were expected."

Jan 1, 1987

By Flavio Rojos-Tapia, Oscar Pereira-Cerda, Samuel Sánchez-Pino, Samuel Sánchez-Baquedano

"Pneumatic flotation was introduced to the Chilean Copper Mining Industry in 1993 by Ingeniería de Minerales S.A. (IDM). The technology is based on the designs of Dr. Rainer Imhof from Germany, who is the designer of several different types of pneumatic flotation cells, already sold through his Company Maelgwyn Mineral Service Limited (MMH). The company is represented by Ingenieria de Minerales S.A. (IDM) in South America.Pneumatic flotation, has been used in tough industrial applications .It has been successfully used for metallic ores such as copper sulphide and oxide minerals, copper slag, silica and silicates from iron magnetic preconcentrate (reverse flotation) and gold. It has also provided promising results when applied to molybdenum flotation. The latest applications, with ultrafine molybdenum particles in operating plants, is showing the V and G Cell (end model designed) as a real technological alternative to conventional flotation., The G Cell is an extremely high speed flotation machine with high selectivity which introduces the possibility of producing a final molybdenum concentrate with only one stage of cleaning. This is a completely new development in molybdenum flotation in the industrial circuit which has the potential to dramatically reduce the circulating load in the cleaning circuit. As a consequence the capital costs of future Molybdenum plants may also be reduced. The suitability of the G Cell will have to be determined on a case by case basis but it provides the metallurgist with an alternate flowsheet for consideration.The good performance of the G Cell can be explained by the high gas hold-up and very effective micro-turbulence which helps improve the attachment of solid particles to the bubbles. This technology may change our traditional concept of residence time in flotation. Additionally, the rotation phenomena introduced in the vessel of the G Cell ,creates radial separation forces which are critical to achieving a more rapid separation of the target minerals from the tailing. This results in a much reduced residence time requirement in the flotation machine. Some benefits associated with the use of the new G Cell are: less energy consumption, less maintenance costs, simple and reliable circuit to operate and a small area required for installing the circuits.As a result of the industrial experience in the Chile, the pneumatic flotation type G Cell can be regarded as a technology which must be considered as a replacement technology for the rougher and cleaner stages for fine particle flotation."

Jan 1, 2008

By F. R. Archibald

SINCE the opening of the Beattie mine, in 1933, the concentrate produced by flotation has been considered refractory. As the gold extraction by cyanidation was poor, the concentrate, during the first four and a half years of operation, was shipped to a smelter for further treatment. After the installation of the cyanide plant, in 1934, seventy per cent of the gold in the concentrate was recovered before shipment to the smelter. In 1937, a roasting plant was built so that treatment might be complete at the mine. Much experimental work had been done by a number of investigators prior to the installation of the roasters, but none of them had seriously attempted to identify the causes of, or the elements responsible for, the refractory behaviour of the concentrate. Intensive investigation in this direction commenced in the Beattie lab-oratory in July, 1938, has led not only to the identification of several causes contributory to the refractory behaviour, but also to revisions in procedure and principles with respect to roasting Beattie concentrate in particular and arsenical concentrates in general. The accuracy of the identification of these causes and the soundness of the principles is borne out by interpretation of roasting plant records, by improvements and simplification since applied. to plant operation, and also by laboratory and test-plant results on arsenical concentrate produced by another mine. It is the purpose here to present an account and interpretation of the laboratory investigation, together with a correlation of laboratory and plant results. Incomplete extraction of the gold by cyanidation after roasting is due primarily to the nature of the material roasted, and secondarily to the manner in which it has been roasted. There is a possibility that better extraction may be obtained by improvements in both particulars.

Jan 1, 1939

By L. H. Van Loon, E. G. Crayston, A. F. Heather

"IntroductionTHE PROPERTY of Madsen Red Lake Gold Mines. Limited. comprises fifty-eight claims located between Russet and Faulkenham lakes in Baird and Heyson townships of the Patricia portion of the District of Kenora. The mine is seven miles •by road from the hamlet of Red Lake. This latter centre is .connected to the Trans-Canada Highway at Vermillion Bay, Ontario, by provincial highway No. 105 which has a total length of one hundred and thirteen miles.The Madsen property went into production on August 11th, 1938, with a milling plant rated at 300 tons per twenty-four hours. Changes made in the crushing plant during October, 1938, allowed a •finer feed to be delivered to the mill and increased the milling •capacity to 400 tons per twenty-four hours. During 1948, steps were taken to add an additional 400-ton capacity unit to the milling plant. This latter work was completed by May, 1949, giving the present total milling .capacity of 800 tons per twenty-four hours.It was realized in the early 1940's that, eventually, considerable material suitable for backfilling in the mine would be required. As there were no large deposits of gravel or sand anywhere near the mine, officials of the Company considered it advisable to investigate the feasibility of using mill tailings for mine •backfill. Since Madsen mill tailings contain approximately 80 per •cent of minus-200-mesh material, it was not considered practical to use them for underground backfill without first removing the finer material. as the slimes present in a product of this fineness would without doubt preclude any drainage whatsoever. Table I gives a sizing analysis of Madsen mill tailings and Table II a quantitative chemical analysis of the ore."

Jan 1, 1954

By J. C. Gathje

Newmont&apos;s Phoenix Project is located near Battle Mountain, Nevada and is scheduled to produce copper concentrates containing high precious metal values. High temperature pressure oxidation (PDX) of the concentrates was considered as a treatment option during process development. The metals content in Phoenix concentrates range from: 15-25% for Cu, 1-10% for Zn, 0-2% for Pb and ?27% Fe. The precious metals content of the Phoenix concentrates can range up to ?300 g/t Au and >3,000 g/t Ag. As a consequence it was necessary that any process for consideration should have the capability of recovering both the copper and precious metal values. Typically, gold can easily be leached from the autoclave discharge solids, but silver is chemically bound with the jarosite formed and cannot be directly leached. Laboratory investigations led to the development of a patented PDX process that minimizes the formation of jarosite so that the silver can be leached easily along with the gold. The process was confirmed with extensive pilot plant testing. Excellent solution extraction of copper and zinc was achieved, and both iron and lead were precipitated in the PDX residue. The process produces clean PDX discharge liquors with very low iron concentrations. As an example, conventional PDX techniques resulted in pregnant liquors containing ?5 g/L Fe. However, the Newmont process, which controls the iron and sulfate species, achieved high iron precipitation in the PDX solids and pregnant liquors containing <0.5 g/L Fe. High gold and silver recoveries were achieved by direct cyanidation of the PDX solids. This process has the added benefit of producing PDX solids that demonstrate superior settling and filtration characteristics.

Jan 1, 2006

By H. W. Smith, C. L. Lewis

"A process control computer has been installed in the Lake Dufault concentrator to: (a) control the on-stream X-ray analyzer and convert chart readings to elemental percentages, (b) calculate the flow rates required for the most important flotation reagents, using the amount of material entering the process, the analyses and the slurry pH, and (c) set the reagent feeder to these flow rates automatically. Although this project was largely experimental, to gain knowledge and experience in flotation process control, the objectives have been met and fully automatic computer control is now the normal mode of mill operation.This paper describes project planning and defines the system with respect to both control design and functional design. System operation -as seen by the mill operator -is detailed. Implementation of the system is described and the system is discussed in terms of its success, economic justification and future plans."

Jan 1, 1969

By Terry A. Kirk

"This paper describes Derrick High Frequency Vibrating Screens and their process performance in grinding circuit applications. The benefits of screen sizing in closed circuit grinding are illustrated by case histories from a wide spectrum of mineral industries.INTRODUCTIONHigh capacity, reliable wet screening equipment is increasingly in demand by the mining and allied industries for separations finer than 1/.7 5mm (I/ mesh). The continuing search for improved energy efficiency and reduced steel consumption in comminution has Jed to greater scrutiny of every aspect of circuit design and operation, including the classifier efficiency (selectivity) function.Derrick Manufacturing Corporation has been developing high frequency screening machines designed specifically for grinding circuit applications since 1973. Successful installations are currently operating in iron ore, copper, coal, uranium, phosphate and other extractive industries."

Jan 1, 1984

By T. H. Janes

"IntroductionSULPHUR is a constituent of many industrial products. It is part •of almost anything we eat, wear, or use. In fact, sulphur is so important that there has been an increasing tendency in recent years to measure industrial growth in terms of sulphur consumption.The uncertainty of obtaining adequate supplies •of elemental sulphur from the Frasch-mined domes. of Texas and Louisiana in the United States led all countries in 1950 to seek alternative sources of supply of this necessary element.Canadian industry has been supplied, for many years, with most of its sulphur requirements by United States Frasch-mined sulphur. World demand for this sulphur has necessitated the imposition of controls on its distribution, as production has not kept pace with demand. Until the third quarter of 1950, Canadian manufacturers of pulp and paper, heavy chemicals, explosives, and textiles •experienced little difficulty in obtaining their needs of elemental sulphur from the United States. However, at that time, low producers' stocks and declining reserves threatened to reduce shipments from producers, with the prospect of a continuing shortage for some time. These conditions, together with higher prices, stimulated the search for alternative sources of supply in Canada."

Jan 1, 1952

By M. H. Ali

Codelco, a multi-process primary copper producer, is undertaking a full life cycle inventory (LCI) of all its commercial products based on copper and molybdenum. During this work, many questions have surfaced regarding the contribution of process unit design to specific aspects of a product&apos;s LCI and, more importantly, how such designs could be improved using a life cycle perspective. Management strategy efforts were undertaken to improve the LCI footprint, however it was found that the corrective actions were almost impossible to apply at the operation level in plant, given the ongoing timing pressures of extractive mining, and costs saving priorities. Additionally, it was found that most of the important comparative differences between operations had structural reasons. In this circumstance, the LCI practitioner group from 1M2, and the environmental managers from Codelco, decided to shift its efforts to place the critical LC1 aspects to the design process of future developments. Hatch Associates has developed unique tools in their Sustainable Plant Design (SPD) package that compliment and enhance LCA methods; these effectively drive sustainability into the heart of the design process. By using LCA and SPD in a project design phase, you cannot only address potential hotspots, but also decide on materials, location and size of certain facilities to optimize for energy efficiency. Moreover, you can avoid the shifting of environmental burdens upstream or downstream within the plant and finally it is extremely useful in identifying opportunities for greenhouse gas reduction.

Jan 1, 2007

By Ioannis K. Kapageridis

The lignite deposits of the Kozani-Ptolemais-Amyntaio basin in western Macedonia (North-West Greece) present a difficult modelling problem. Each deposit consists of several thin lignite layers ranging from a few centimetres to a few tens of centimeters in thickness, and thin intercalated sterile layers of marly limestones, marls, clays, and sands. These layers are practically impossible to model individually due to fast lateral transition of lignite layers to humus clay and vice versa and the lack of reliable and detailed stratigraphic correlation, leading to compositing methods being applied prior to any interpolation and modelling. The complexity of the deposit is further increased by the presence of a number of faults. This paper presents the modelling and estimation procedures applied during the most recent study of the South Western Field ? a new deposit that is considered for development and lignite production over the next years and will support the operation of a new power station in the area. Special focus is given to drillhole database structuring, fault modelling, stratigraphic correlation, mineable lignite intervals compositing, and resource estimation. The use of specialised mine planning software in all stages of modelling and estimation is thoroughly explained.

Oct 1, 2009

By S Sokhanvaran

Electrodeposition of silicon from a cryolite based electrolyte at a relatively low temperature (1000°C) is a promising approach to generate high purity silicon. In order to obtain fundamental data pertaining to electrowinning of silicon from Cryolite?SiO2 melts, density and electrical conductivity measurements were made. A range of temperatures and SiO2 contents was studied for each property. It was found that while density has an inverse relationship with temperature, the dependence for electrical conductivity is direct. Increasing silica content up to the saturation limit (~ 5 wt%) increases the density whereas further increase in SiO2, lowers the melt density. On the other hand, the conductivity is lower for the melts with greater SiO2 content, at any temperature.

Jan 1, 2011

By D. L. Morgan, J. A. Butterfield

"Geological data, production trends and current projects underway suggest that enough molybdenum will be available from more diversified sources to meet the world's growing demands. The growth in molybdenum consumption has been primarily related to its beneficial effects as an alloying agent in steel. This rapid growth has been deliberately fostered by stable prices, adequate supply and application research. The molybdenum industry is now in a process of change which has been seen in several other metals, such as aluminum and nickel. As supply sources have become more diversified, the market has become more competitive. The recent drop in consumption has led to excess production capacity, accumulation of substantial producer inventories and increased market uncertainties. While consumption is expected to increase in the next two to three years, it will take some time to absorb the excess capacity and inventory. The increased proportion of by-product capacity indicates that prices may become more variable. Producer discipline will be required to prevent serious price erosion in times of surplus. Future prices may not continue to increase with inflation. For the longer term, several factors favour the increased consumption of molybdenum. Engineering requirements are becoming more severe and molybdenum alloys can help to meet these changing needs. In addition, consumers can rely on a large and increasing supply of molybdenum. A 7 per cent growth rate in consumption can probably be sustained through the next decade, but new applications and reasonably stable prices will be needed to make this possible."

Jan 1, 1972

By M. Board, R. Pakalnis, S. Seldon, R. Brummer

The Kidd operation mines roughly 10 000 tpd of copper and zinc ore from underground and employs about 700 personnel. In the late summer and fall of 1997, major movements in the proximity of the east wall of the Kidd open pit had been observed. The Kidd pit had been mined from 1965 to 1977 to depths of 260 m (850 ft), followed by subsequent mining by underground methods to current depths in excess of 1830 m (6800 ft). The No. 1 Mine (2600 Level to pit bottom) is approximately 90% extracted, with most of the remaining reserve between 2000 and 2500 levels. Although initial concerns centred on the stability of the pit walls, the potential ramifications of the movements to the underground were recognized and measures were implemented to ensure the safety of personnel as well as to minimize the potential damage to existing operations. In late October, damage to underground operations was observed as deep as the 2000 Level. In the final assessment, the global mobilized mass was a “wedge”-shaped hangingwall block extending from surface to about 610 m (2000 ft) below surface. The “wedge” boundaries are defined by a fault and shear zone which have continuous lengths in excess of 1070 m (3500 ft); its base by shearing through the host rock mass; and its eastern face by deep tension cracks (Fig. 1). Mined and filled excavations at the western face of the “wedge” allowed mobilization of a mass in excess of 30 M tonnes. Movements in excess of 75 cm (30 in.) per day were recorded on the surface stations that preceded the complete shutdown of operations on October 29, 1997. The evaluations in the days following the shut-down were centred on mitigation of immediate and future possible negative impacts on infrastructure and mining of the remaining No. 1 Mine reserves while ensuring the safety of the operators. This effort required the rapid assessment of the potential damage of the block movement on underground infrastructure, stope access, drainage and ventilation, as well as airblast potential due to the falling of a large block into the pit near the ventilation intake at the base of the pit. These assessments were presented in a previous paper (Seldon et al., 1999). In total, the lateral movement of the block on the ground surface was over 4.3 m (14 ft). This paper describes the detailed studies performed to understand the failure mechanism and to assess the impacts on future mining in No. 1 Mine.

Jan 1, 2000

By M. Lahtinen

Traditionally, there have been three main methods for iron removal in the hydrometallurgical production of zinc. These methods are atmospheric precipitation of jarosite or goethite and pressurised precipitation of hematite. Jarosite precipitation is without doubt the leading and the most commonly used technology for iron removal. However, jarosite precipitation has some drawbacks, such as a low iron content (and, thus, high residue volume), high moisture content after filtration and often a high zinc content. These features make any environmentally acceptable way of using or disposing of jarosite more expensive, as compared to hematite and goethite. The importance of environmental regulations has grown in the zinc industry during the last decade, which will have an increasing effect on new investments. Hematite has several advantages over jarosite, such as a high iron content, low moisture and low zinc content. An important advantage of hematite is that it is suited for further use in the cement industry. However, until now the need for autoclave equipment has limited the spread and implementation of hematite precipitation in the zinc industry. Outokumpu Technology Oy has recently developed an alternative method for iron removal, which is the atmospheric precipitation of hematite. A patented method for precipitating hematite at atmospheric pressure is presented and compared with conventional methods for iron removal. The process conditions, the quality of the hematite precipitate and the environmental aspects are also discussed.

Jan 1, 2006

Operations and maintenance departments have had a long-standing adversarial relationship. The widespread evolution and adoption of modern management techniques, such as reliability centered maintenance (RCM) and Lean, however, has driven interest in working co-operatively to optimize overall plant performance. Mining and minerals operations have long adopted RCM in maintenance and are now adopting Lean throughout organizations. Such modern management initiatives explicitly call for co-operation between the two disciplines of maintenance and production and many advances have been made in terms of people and methodology. One area that has lagged behind in supporting these developments, however, is information systems. Enterprise asset management (EAM) systems in maintenance and newer manufacturing execution systems (MES) in operations have not been truly integrated in the needed ways. Complicated plants, different software architectures, continually changing conditions and many other variables have led to systems problems, which have contributed to the maintenance/operations divide. Master data synchronization (the plant tree) and integrated reporting of real-time data with transactional data are just two of the issues that are being solved by new approaches in information technology, including web services and service orientated architectures. New technologies are coming on-stream to enable the final bridging of the gap.

Jan 1, 2009

By A. G. Roach

Introduction The plant described in this paper is located at Coniston, Ontario, the smelting centre of the former Mond Nickel Company. Coniston is situated some eight miles east of Sudbury on the main line of the Canadian Pacific railway and on the Toronto-Capreol branch of the Canadian National-railways. The plant is now under control of the International Nickel Company, as a result of the merger of the two companies in 1929. The smelter proper includes four 50-in. by 240-in. blast furnaces and five 13 ft. by 30 ft. converters, and has a capacity of about 65,000 tons of ore charge per month. As accessories to the smelter there are a mill, where some 10,000 tons per month of low-grade ores are concentrated, and the sintering plant, which is the subject of this paper. The present 6-unit sintering plant replaces a former 4-unit installation. Here, fine ores, concentrates, and flue-dust are sintered on Dwight-Lloyd machines, the sinter produced being charged into the blast furnaces. At the time of writing (1931), only the concentrator is operating at capacity, due to present world conditions.

Jan 1, 1932