Search Documents

By Wayne Wride, Amy Lamb, Debra Sonntag

In today's "information age", we have the ability to collect volumes of data about a company's performance. The challenge is to turn that data into information employees can understand and use to fine-tune equipment, modify work processes, and ultimately manage production. Software programs have increasingly given end users control over what data is used and how it is presented. Kennecott has implemented an information system capable of collecting and storing data at the primary level. This enables plant personnel to transform historical data into information for action. Kennecott plans to expand its data collection and use trending and reporting capabilities to move toward a fully optimized operation.

Jan 1, 2000

By C. J. Newman

Before 1995, the smelting process at the Kennecott Utah Copper Corp. (KUCC) smelter consisted of Noranda reactors and Pierce-Smith converters. When considering expansion, it was decided that the existing process would not lend itself to a program geared toward processing the total output of copper precipitate and copper concentrate from KUCC mining and concentrating operations. During 1989 and 1990, several smelting options were evaluated. The final selection was the Outokumpu flash smelting process, coupled with the new Kennecott-Outokumpu flash converting technology. Facilities were designed and installed to process 1 Mt/a (1.1 million stpy) of copper concentrate, with the ability to expand to 1.2 Mt/a (1.3 million stpy). The smelter facility that used the Noranda technology was shut down in May 1995. The flash smelting furnace operation began in June with the flash converting furnace start-up a few weeks later.

Jan 1, 1999

By C. J. Newman

Prior to 1995, the smelting process at the Kennecott Utah Copper Corporation (KUCC) smelter consisted of Noranda reactors and Pierce-Smith converters. In the consideration of expansion opportunities, the existing process did not lend itself to a program geared towards processing the total output of KUCC mining and milling operations. During 1989 and 1990, a number of smelting options were evaluated. The final selection was the Outokumpu flash smelting process, coupled with the new Kennecott-Outokumpu flash converting technology. Facilities were designed and installed to process 1.0 million tonnes per year of copper concentrate, with the ability to expand to 1.2 million tonnes per year. Following the shutdown of the smelter facility utilizing the Noranda technology in May 1995, the flash smelting furnace commenced operation in June with the flash converting furnace startup following a few weeks later. The smelter has achieved design production targets and environmental goals. Current operating rates are at or above design rates for concentrate and matte processing. Emissions are lower than the permit levels and equate to less than 3.5 kg of S02 per tonne of copper. This paper outlines the design, construction, startup and the first two years of operation of the modernized KUCC smelter.

Jan 1, 1998

By C. J. Newman

Prior to 1995, the smelting process at the Kennecott Utah Copper Corporation (KUCC) smelter consisted of Noranda reactors and Pierce-Smith converters. In the consideration of expansion opportunities, the existing process did not lend itself to a program geared towards processing the total output of KUCC mining and milling operations. During 1989 and 1990, a number of smelting options were evaluated. The final selection was the Outokumpu flash smelting process, coupled with the new Kennecott-Outokumpu flash converting technology. Facilities were designed and installed to process 1:0 million tonnes per year of copper concentrate, with the ability to expand to 1.2 million tonnes per year. Following the shutdown of the smelter facility utilizing the Noranda technology in May 1995, the flash smelting, furnace commenced operation in June with the flash converting furnace startup following a few weeks later. The smelter has achieved design production targets and environmental goals. Current operating rates are at or above design rates for concentrate and matte processing. Emissions are lower than the permit levels and equate to less than 3.5 kg of SO2 per tonne of copper. This paper outlines the design, construction, startup and the first two years of operation of the modernized KUCC smelter.

Jan 1, 1998

By D. Janney

Kennecott's Utah Smelter commenced operations in June 1995 utilizing Outokumpu Flash Smelting (FSF) and Kennecott-Outokumpu Flash Converting (FCF) technology. After some initial teething and equipment problems the smelter achieved its design capacity in mid-1997 and now processes over 1.0 million tonnes of copper concentrate per year with exceptional environmental performance. The smelting furnace has operated for 11 years and the converting furnace for 5 years without major shutdowns. The first major smelter shutdown commenced in September 2006 after extensive planning. The FSF was completely re-bricked and the latest above and below bath containment systems installed. The FCF was inspected and re-bricked with some improvements made to the above bath containment system. The FCF life is now anticipated to be the same as the FSF. Numerous improvements and modifications were made to the rest of smelter facility including extensive upgrades to the dry electrostatic precipitators. Production ramp-up was smooth with the smelter now frequently operating at acid plant capacity.

Jan 1, 2007

By D. S. Bird

The Kennecott Utah Copper Modernization Project, initiated in 1986, was directed to provide an expansion and modernization of mining and process facilities at the property's Bingham Canyon Mine and ore concentrators. Major components in the project included installation of an in-pit ore crusher, transfer conveying system, and construction of a new copper ore concentrator with a design capacity basis of 70,000 tonnes/day. The Copperton Concentrator was commissioned in February 1988. A principal feature of the plant is the grinding circuit, comprised of three identical lines, each consisting of a 10.37 m (diameter) by 4.57 m (length) Semi-Autogenous Grinding (SAG) mill and two 5.54 m (diameter) by 8.62 m (length) ball mills. The SAG mills are driven by two variable-speed 9,000 kW DC motors coupled through a clutch-pinion gear-ring gear assembly. The ball mills are driven by 4,125 kW synchronous motors coupled through a typical clutch-pinion gear-ring gear system. The expansion and particularly the Copperton Concentrator performance was so successful that by early 1989, management began examining options to further expand production capacity. With regards to the concentrator, numerous alternatives were considered, ranging from installation of a grinding line similar to one of the existing lines, to a "super" line consisting of a 12.8 meter (diameter) SAG mill and a 20,000 kW motor with a capacity of 50,000 tonnes per day. The technical and economic analysis of the various scenarios indicated that one "large" 11.0 meter (diameter) by 4.88 meter (length) SAG mill with a production capacity of 32,000 tonnes per day and a 12,000 kW drive would be optimum. The key question to be answered in the project was whether to continue with the pinion-ring gear combination, or install a gearless drive. The following paper outlines many of the items that were evaluated in the mill selection process followed by actual plant performance, and a discussion of ongoing plant continuous improvement projects.

Jan 1, 1995

By Gene D. Clayton, Robert R. Dimock

A time-consuming and expensive preshearing program to minimize the adverse effects of blasting on slope stability at Kennecott Copper Corp.'s Ruth Pit in east-central Nevada has been eliminated in favor of down-the-hole, nonelectric delayed blasting which can produce a smooth wall effect and improve blast fragmentation. The new blasting approach resulted from a Kennecott engineering investigation aimed at improving the stability of the extremely variable rock conditions found throughout the pit by reducing the vibrational energy imparted to the walls with conventional bench blasts.

Jan 4, 1977

By J. K. Buehler

With the rapid acceleration of the cost of shovel dippers and major standard shovel clipper rebuild components, maintenance management at Kennecott Copper Corp.'s Bingham Canyon mine initiated a dipper maintenance and rebuild program. The program focused on extending the service life of the shovel dipper, reducing field labor in maintaining dippers, and lowering shovel dipper rebuild costs. While comprehensive evaluation of the program is still underway, preliminary benefits of the program indicate: •Reduced field ,gelding for shovel dipper field maintenance, •Fewer dipper rebuild units entering the shop, and •Reduced dipper rebuild costs per unit.

Jan 1, 1979

By Pekka Hanniala

The Outokumpu Flash Smelting process today is the most feasible method for copper matte smelting. The economic feasibility of the process has always been one of the main decision making criteria in smelter projects. Thus, today about 50 % of the world primary copper production utilizes Outokumpu Flash Smelting Technology. However, in the future, environmental criteria will have stronger and stronger impact on decision making. Flash Smelting technology offers the best pollution control features of any process. today. It is foreseen that, in the near future, the global trend will be that all the smelters must decrease their emissions at an accelerating rate, compelling the smelters to make increasingly larger investments on environmental protection. In most of smelters ?today, Peirce-Smith converting and transfer of the molten material in ladles are the number one pollution source. The key today for copper converting and minimizing emissions is the Kennecott-Outokumpu Flash Converting process, which has proven to be the most effective converting method in terms of pollution control and, production efficiency including capital and operational costs. Outokumpu Flash Smelting technology is applicable also for small to medium scale smelters but the most interesting area is the upper capacity limit for smelting in one line, which has not yet been reached. We predict that by the year 2000 to 2005, there will be at least one smelter which produces 500,000 tonnes of Cu per year based on one Flash Smelting and Flash. Converting unit. The current state-of-the-art of the Outokumpu Flash Smelting - Flash Converting process is presented in this paper as well as some new options for copper production to be utilized in the near future but which are available already today.

Jan 1, 1998

By Gale L. Hubred

Kennecott?s Ledgemont Laboratory developed the Cuprion Process to recover metal values from manganese nodules in the early 1970s. A reducing leach of monovalent cuprous ion attacks the manganese oxide matrix, converting the manganese dioxide to manganese carbonate and releasing the copper, nickel, cobalt, and zinc as ammine complexes. Cuprous ion is generated by contacting leach liquor with carbon monoxide. Copper, and nickel, are recovered by solvent extraction and electrowinning. Cobalt is precipitated as cobalt sulfide and recovered as cobalt powder. Manganese, molybdenum, and zinc can be recovered optionally but have not been included in this process. Kennecott authors have described aspects of the process, but the Cuprion process has not been revealed except in patents. Tables are included for capital and operating costs and revenue. Even though economic recovery of nodules is not anticipated in the foreseeable future, some of the process steps may have application in other places. The Ledgemont Laboratory was a unique operation we think worth documenting. The report is based upon work done up until the mid 1970s. The report represents the work of the entire Kennecott nodule team. It is this author?s intention to save this result and credit the work of that nodule team. The paper is dedicated to the memory of Dr. Herbert Barner, a key member of the team who died in 2003.

Jan 1, 2005

By F. Julius Fohs

CENTRALLY located with relation to the largest iron- and steel-producing districts of the United States, the fluorspar-deposits of Kentucky possess increasing interest and importance. As typical of the numerous fluorspar-mines of Kentucky and Illinois, I have selected for description the Memphis., because it and others of its immediate group exhibit the conditions characteristic of all. I. THE MEMPHIS MINE. This mine lies 5 miles NW. of Marion, in Crittenden county, Kentucky, a station on the Chicago and Nashville division of the Illinois Central R. R. For the first mile and a half out of Marion we see only Birdsville or Middle Chester sandstones of Mississippian age. Then we cross a fault of some 350 ft. displacement, and the Ste. Genevieve oolite sets in. Beyond the fault, oolite is the predominant rock, except that the bills to the north have a capping of Cypress or lowest Chester sandstone, 80 ft. below which is an outcrop of from 6 to 10 ft. of Ste. Genevieve (Rosiclare) sandstone. Occasional sink-holes are noticed, and as the mines are approached evidence of faulting is again seen.. A line of crude head-frames and open-cut dumps, extending for more than a quarter of a mile, marks the Klondike vein. The open-cuts are from 15 to 20 ft. deep, and in most of them, from the surface down, was found the reddish gravel which is really fluorspar-some of it white or purple and crystal-clear (if the red clay is washed off), and some carrying iron and silica, and stained by waters from the decaying limestone walls. In one of these cuts, at a depth of 20 ft., white and purplish honey-combed fluorspar was found, in which the larger cavities are due to limestone and calcite leaching, and the minute ones to the leaching of zinc-blende.

Apr 1, 1909

By Frederick W. Slack

This paper will discuss the inherent value engineering associated with the design and construction of approximately 184,000 SF of anchored tieback wall, installed as part of the widening and drainage improvements for KY9 in Campbell County, Kentucky. The total project is 2.2 miles in length. The anchored walls, excavation grading and drainage total to a complete project cost of $28.4 million. This is one of the largest design-build projects undertaken by the Commonwealth of Kentucky. It also features another first for the Transportation Cabinet - the general contractor is responsible for quality control/quality assurance. The project is located just south of Cincinnati, OH and is situated along the east bank of the Licking River. The slopes along this stretch of the river have had a long history of movement and instability. The Kentucky Transportation Cabinet advertised the anchored wall portion of this project to be designed and constructed by pre-approved specialty contractors. The Transportation Cabinet provided the basic design parameters to each specialty contractor. Aspects to be discussed include the site and project history, previous attempts at slope stabilization along existing KY9, the technical proposal and bidding process, and the actual design and construction.

Jan 1, 2003

By J. S. Gardner, R. Woolacott, P. D. Robinson

In 1917, U.S. Coal and Coke Company, a subsidiary of U.S. Steel, opened Mine 31 and built the community of Lynch, Kentucky. For the time this was truly a major engineering accomplishment. It was documented in Howard N. Eavenson’s 1939 AIME paper, “Coal Through the Ages.” In 1996, Arch Coal donated the Portal 31 property to Harlan County for public use. In 2003 the Southeast Education Foundation, Inc. and the Kentucky Coal Museum plan to open the Portal 31 Exhibition Mine to the public to tell the story of Kentucky coalmining through the decades. This presentation will summarize the history of the project, efforts to bring it to reality, the engineering problems, and the challenges of providing a safe environment for visitors.

Jan 1, 2003

By J. C. Potvin

Although the occurrence of deposits of titanium minerals on Kenya’s present day beaches and adjacent dune systems has been well documented, the potential for older formations to host economically viable deposits had not been recognised until recently. The Magarini sands formation in Kenya has been found to contain deposits of ilmenite, rutile and zircon in quantities and grades that have the potential to be commercially exploited. Since 1995, Tiomin Resources Inc. has explored these deposits and has identified one deposit, the Kwale project, as being able to support the development of a mine producing some 300,000 tpa ilmenite, 75,000 tpa rutile and 37,000 tpa zircon. Tiomin plans to start production by late 2002. Construction of a US$137 million operation is set to commence in the first half of 2001.

Jan 1, 2001

By H. Tanner, T. Heikkinen

In1950 studies concerning mining and milling of the approximately 17 million tons of ore remaining at Outokumpu revealed the surface facilities for economical treatment were inadequate. The two shafts would soon be too far from the mine workings. Moreover, in spite of several extensions, mill capacity was insufficient and recoveries were not satisfactory. Therefore it was decided in 1951 to sink a new shaft and to build a new mill and auxiliary surface buildings around the shaft. The new shaft was sunk near the center of the remaining orebody, about 650 ft from the ore to the footwall side. This location placed the main part of the shaft as well as the crusher rooms and the ore bins around the lower end of the shaft in the firm and strong mica-schist.

Jul 1, 1955

By Herman Poole

WHEN finely divided ferrous sulphide, FeS, is roasted at a moderate, carefully regulated temperature, the iron and sulphur are oxidized, the first products being probably ferrous oxide and sulphurous acid. In the presence of oxygen of the air the ferrous oxide soon becomes ferric oxide and in the presence of oxygen and the ferric oxide the sulphurous acid oxidizes to sulphuric acid. These facts are well known, having been established by Plattner many years ago. As a further reaction, some of the sulphuric acid parts with a portion of its oxygen to oxidize more ferrous oxide to ferric oxide, and a portion of it escapes uncombined or else unites with the iron oxides to form sulphates. Ferrous sulphate is usually soon oxidized to ferric sulphate and if the heat becomes sufficient this is then decomposed into sulphuric acid and ferric oxide. As a result of these reactions a mass of more or less pure ferric oxide is formed which is generally made porous by the escaping gases and, if rabbled properly, practically all the sulphur is expelled. If ferric sulphide or ordinary pyrites, FeS2, is roasted, a portion of the sulphur sublimes and usually burns to form sulphurous or sulphuric acid, although at times and under favorable conditions some of the sulphur is driven off uncombined and can be collected as such. Under ordinary methods of roasting, however, only a small portion escapes combustion. By the combustion of the sulphur an increase of heat is de¬veloped and, as a consequence, the reactions mentioned take place more rapidly and actively-more sulphuric acid is formed and the oxidation is more complete-nearly all the iron being left as ferric oxide with practically no sulphate or ferrous oxide. When the iron sulphide is in lumps the roasting proceeds generally as with fines, but with some changes due to mass. The

Sep 1, 1905

By J. W. Baker

"The Kerr-Addison mine is on the northeast shore of Larder Lake in the township of McGarry, District of Timiskaming, Ontario. It lies just south of the highway leading to the town of Kirkland Lake, 25 miles to the west.The property was first staked in the summer of 1906, by a party of prospectors led by a Dr. Reddick of Ottawa. Subsequent assessment work resulted in the erection of a 20-stamp mill in 1908. Gold from this mill was used in the first gold coins to be minted in Canada. The operation did not prove successful, however, and mining was suspended. In 1914 a consider-able amount of underground development was undertaken by the Associated Goldfields Co., without success.In 1936 Kerr-Addison Gold Mines Co. carried out large-scale sampling from four adits driven into the hillside at the mine. Results were not satisfactory, but it was decided to drill one last deep diamond drill hole from surface. The hole cut a wide section of gold ore. With this encouragement, further development outlined a large tonnage of ore, and a 500-ton mill was put into production in May, 1938. In 1939, its first full year, the mine produced 54,480 ounces of gold and 2,732 ounces of silver. By 1955 the mill had been expanded to a rate of 4,549 tons daily, and in this year 427,193 ounces of gold and 23,490 ounces of silver were produced.From 1938 to the end of 1955 the total production, from 17,473,797 tons milled, has been 3,607,462.74 ounces of gold (0.2064 ounces per ton), and 182,278.56 ounces of silver, with a total value of $131,073,037."

Jan 1, 1949

With a mine output as high as 5000 tpd and mill capacity of 7000 tpd, the uranium mining and milling complex owned and operated by Kerr-McGee Nuclear Corp. in the Ambrosia Lake area is the largest in the U.S. and is likely to remain so for some time. Next year, Kerr- McGee expects to have in production another mine in Section 19 of the Ambrosia area-and will begin ore production in 1976 at its new $15-million mine at Church Rock, located northeast of Gallup, N. M., where the company has already completed the shaft work and is in the early stages of project development. Ore from Church Rock will be transported to the company's facilities at Ambrosia Lake for processing. Kerr-McGee's existing eight mines in Ambrosia Lake go to depths of about 800 to 1500 ft to tap the various horizons of uranium-bearing sands in the Westwater Canyon of the Morrison formation.

Jan 8, 1974

By R. R. Irrinki

Abstract -The Key Anacon deposit consists of four sulfide zones called, from south to north : Key Anacon No. 1, Key Anacon No. 2, Key Anacon No. 3, and Key Anacon Copper Zone. Massive sulfides of zones 1, 2, and 3 are underlain by rocks correlated with the Nepisiguit Falls Formation and are overlain by matie volcanic rocks correlative with the Boucher Brook Formation. In contrast to zones 1, 2, and 3, narrow northwesterly-trend.ing, copper-rich fracture zones occur within the Patrick Brook Formation. Sulfides in zone 2 occur as three mineralogical associations, namely: pyrite-chalcopyrite, pyrite-sphalerite-galerta, and pyrrhotite-sphalerite-galerta. The distribution of lithologies and en-echelon patterns of the three sulfide lenses of Key Anacon No. 2 zone are the result of F1 and F2 folding. Zone 2 is the most promising economically, with proven reserves of 1.11 million tonnes grading 0.2207o Cu, 3.47% Pb, 8.41% Zn, and 96 g/t Ag; the zone is open below a depth of 427 m.

Jan 1, 1992

By V. Ross

"Bench-scale flotation tests play a major role in the geometallurgical process value chain. Despite their apparent simplicity, these tests pose pitfalls in terms of operation, as well as the interpretation and modelling of results. In this paper we highlight key aspects to consider in generating accurate and reproducible experimental results, and critically review some assumptions relating to the estimation of entrainment and froth recovery. We subsequently focus on first-order equations to model kinetics and propose a method that accounts more realistically for the decay in kinetics over the duration of a float, and the contributions of froth stability and hence mass pull. The method was applied to three case studies on platinum group metal (PGM) ores and matched or outperformed first-order, two-component models. Also, it allows for a deeper analysis of the integrity of the bench-scale flotation results. IntroductionGeometallurgy is a structured, multidisciplinary approach that integrates key data from the geological, mining, mineralogical, and metallurgical aspects of the value chain to construct spatial models of an ore deposit such that the overall economic benefit and sustainability of an operation can be optimized. Process geometallurgy is aimed primarily at enhancing metallurgical efficiency and plant throughput by the application of appropriate mining and processing strategies, as well as supporting production planning and operational strategies to reduce the impact of highly variable ores. With flotation being the dominant concentrating process in the mineral value chain, the bench-scale flotation test is an important characterization tool – a relatively cheap, simple, and rapid way to obtain key information about the ore and its amenability to economic extraction of valuable minerals. This includes the evaluation of different ore types and the implications of mineralogical composition and texture for comminution and floatability, the effect of the grinding environment on the liberation of minerals, the electrochemical environment in the pulp (Bradshaw et al., 2006), the screening of reagents to improve floatability (Ekmekci et al., 2003), and the role of hydrodynamics in the recovery of valuables and the entrainment of gangue (Amini et al., 2016; Wang et al., 2016). It is also a critical tool in auditing the performance of a flotation plant by hot floats, paving the way for concept and feasibility studies and providing essential data on kinetics for the purposes of scale-up, optimization, and simulation of flotation circuits."

Mar 1, 2019