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By J. J. Taute, O. S. Tinkler, G. Zárate, K. C. Sole, J. Steeples

Global practice in copper solvent extraction is reviewed, based on individual plant operating data for 2018. The survey respondents account for almost 40% of global copper cathode production by solvent extraction and electrowinning. Regional trends in operating conditions, as related to the prevailing ore mineralogy, leaching processes, and life of mine are evaluated. The adoption and expansion of this technology in the African Copperbelt and Asia are assessed, together with the associated challenges of specific orebody characteristics. Trends in feed and electrolyte compositions and flow rates, and extractant and diluent selection, together with their impact on copper recovery are reviewed. The evolution of equipment design and associated ancillary processes are discussed, and new projects identified. INTRODUCTION Continuing from similar surveys carried out in 1997, 1999, 2003, 2007, and 2013 (Robinson, Davenport, & Jenkins, 1997; Jenkins, Davenport, Kennedy, & Robinson, 1999; Robinson, Sandoval, & Cook, 2003; Robinson, Moats, Davenport, Karcas, Demetrio, & Domic, 2007; Sole, Zarate, Steeples, Tinkler, & Robinson, 2013), global operating practice in copper solvent extraction (SX) in 2018 is reviewed. Contributing operations include established sites in the USA (8), Chile (9), Peru (2), Spain (1), Mexico (2), and Australia (2), as well as newer operations in Africa (7) and Asia (3). This survey represents 2018 copper cathode production of 1.91 Mt, or about 43% of world production by solvent extraction combined with electrowinning (SX–EW). Trends in operating conditions and performance, as well as equipment design and process technology choices are analysed. The significant expansion in production in the African Copper Belt is also discussed. There are currently about 130 operations worldwide producing some 4.6 Mt copper by SX–EW; of these, about half produced more than 10 000 t/a. Figure 1 shows global copper production by country. As it has for several decades, Chile remains dominant, with 36% of global production of cathode copper. Since 2005, the Democratic Republic of Congo (DRC) has increased production year on year, and now represents 23% of the global total (International Copper Study Group, 2017; Statistica, 2018). Copper production in Asia has grown significantly in the past decade, particularly since the ramp-up of Wanbao in Myanmar. There used to be numerous small copper SX plants in China (Schlesinger, King, Sole, & Davenport, 2011), although most of these have now shut down and Chinese production is lower than it was five years ago. The most important trend, however, is the rise of Chinese-owned mining companies, particularly in Central Africa, but also around the world more generally.

Jan 1, 2019

By J. Lu, D. G. Ivey, H. Henein

Microalloyed steels are widely used in the oil and gas industry. They are a class of high strength, low carbon steels containing small additions of niobium (Nb), titanium (Ti), molybdenum (Mo) and/or vanadium (V). These steels have good strength, toughness and excellent weldability, which are attributed in part to the presence of nano-sized carbides, nitrides and carbonitrides. In the pursuit of developing higher strength microalloyed steels, it is of great interest to quantify the size, distribution, volume fraction and chemical speciation of these precipitates. However, characterization techniques suitable for quantifying fine precipitates are limited. Possible characterization techniques include SEM, TEM and matrix dissolution. A comparison is presented of the various techniques.

Jan 1, 2005

By K. J. Daun, C. J. Shi

UsiborThrough the second step heating at 900 °C, the spectral emissivity shows a gradually decreasing trend with increasing soak time, caused by the surface phase transformation from Al® 1500P coupons are austenitized in a Gleeble 3500 thermomechanical simulator using a two-step heating procedure in an argon atmosphere. Variations in spectral emissivity are measured in-situ using a near infrared spectrometer and ex-situ with a Fourier transform infrared reflectometer. Microstructural evolution and surface roughness are investigated using optical microscopy, FE-scanning electron microscopy, and a surface profilometer. A series of phase transformations of Al-Fe-Si intermetallic phases at the coating/steel substrate interface cause the surface phase and surface roughness to change, which in turn influences the spectral emissivity. At the beginning of the first heating step, the coupons have very low spectral emissivity, due to the molten Al-Si coating. Spectral emissivity increases significantly with increasing soak time from 5 to 12 minutes, associated with the surface phase transformation of the coating into Al7Fe2Si intermetallic phase and an increase in surface roughness. 5Fe2 into AlFe intermetallic phase with a decrease in surface roughness.

Jan 1, 2015

By T. R. Carter, A. C. Colvine

"Rocks of the Grenville Province in southeastern Ontario are currently largely dismissed by many geologists as having little or no potential for discovery of significant deposits of metallic minerals. The present study demonstrates that the area contains numerous deposit types which elsewhere are major metal producers. Therefore, there is significant unrealized potential, especially for gold, zinc, uranium, and possibly copper.The variety of deposits of metallic mineralization include stratiform zinc in marbles; stratabound base metal sulphides in volcanic and sedimentary hosts; gold-quartz veins; quartzmagnetite iron formation; copper-nickel and iron-titanium in intrusive rocks; magnetite skarns; molybdenum in skarns and pegmatites; uranium and thorium in pegmatites, veins, and calc-silicate gneisses; hematite veins; dolomite marbles (magnesium); and barite-jluorite-celestite-galena-calcite veins. There has been significant production of iron, lead, zinc, magnesium, gold, silver, and uranium.The vast majority of the metallic mineral deposits are confined to late Precambrian supracrustal and related intrusive rocks of the Grenville Supergroup. Many of the deposits are stratiform and/or stratabound and occur within units toward the top of major volcanic successions and in the lower portions of younger carbonate-clastic sedimentary successions.Processes responsible for mineral concentration in the area include: (I) syngenetic hydrothermal activity related to both volcanism and sedimentation; (2) epigenetic processes related to diagenesis, regional metamorphism, and igneous intrusive activity; (3) magmatic processes related to igneous intrusions; and (4) supergene concentration and enrichment. The genetic classification of the mineral deposits presented is based on observed geological relationships and these interpreted geneses. The deposit types have counterparts in volcanogenic and sedimentary exhalative, Mississippi Valley type, magmatic, contact metasomatic, and lode gold deposits. Many of the exploration criteria for deposits of these types may be applicable in the Grenville Province, despite the generally high metamorphic grades and complex deformation."

Jan 1, 1985

By Etienne Roy Grégoire

Since the early 1990s, the Canadian mining industry has been increasingly defined by the signing of Impact and Benefit Agreements (IBAs) between mining companies and Aboriginal peoples. While these agreements are intended to complement the legal system, they also serve to establish the legitimacy of mining projects and to encourage the harmonious integration of these projects into their social and environmental contexts. Beyond their practical implications, what are the effects of such agreements on the ability of Aboriginal communities to access the institutional space where the authorization of mining projects and the conditions of their implementation are decided? Can we view IBAs as a preliminary step towards the operationalization of the principle of Free, Prior and Informed Consent? This paper aims to explore the potential of IBAs as a sustainable solution to the legitimacy issues that result from the implementation of the formal regulatory framework governing mining activities in this jurisdiction. We highlight what constraints and opportunities the James Bay and Northern Quebec Agreement (JBNQA) engenders for local communities and draw attention to the ways in which the negotiation of the Raglan IBA and the environmental evaluation processes act upon each other. We find that certain structural problems - and problems of legitimacy ? related to mining in Northern Quebec cannot be solved by the sole signature of an IBA, which suggests the need for caution when considering such agreements as a panacea. The Raglan case demonstrates that IBAs, like other modes of regulation relying on the direct interface between companies and communities, would benefit from a stricter framework and more explicit ties with official regulation channels.

Aug 1, 2013

By J. Janzen

The cost to supply ventilation may exceed 40% of the total mine energy cost for underground mines and is often higher for deeper mines. The goal of Ventilation-on-Demand (VOD) is to ensure that the required quantity and quality of air is supplied to underground mining crews and diesel equipment at the least energy expenditure (minimum cost). A VOD system may include control of surface fans (Supply & Exhaust), underground booster fans, auxiliary fans and automated regulators/dampers to regulate the flow of air with more control elements providing more value. Strategically located Air monitoring stations measure air quantity and quality and provide feed-back enabling control. The modular design involving controls, intelligent instrument and intelligent motor control centres coupled with a communication network allows the quick installation, commissioning and expansion of the system as the mine develops. The result is a very robust, flexible system while reducing maintenance costs and spare parts. This paper discusses the impact of sensors, installation and commissioning on advanced controls and provides solutions for in-field applications.

Aug 1, 2013

By S. M. C. Santos

Preliminary bench-scale studies were carried out on the leaching of a zinc sulphide concentrate from Somincor, Portugal, and the purification of the resulting pregnant solution using solvent extraction techniques. The sulphide concentrate contained 36% Zn, 36% S, 2% Fe and 4% Cu. The leaching was carried out with sulphuric acid in the presence of ferric sulphate as the oxidant. Important leaching parameters, such as the effect of reaction time, the solid-liquid ratio, temperature and concentrations of acid and oxidant, were investigated. After leaching, the recovered solution was contacted with an organic phase containing Acorga 5640 to remove the copper. Subsequently, the removal of iron from the leaching solution was achieved with a mixture of Cyanex 272 and TBP. This solvent mixture was relatively selective for iron over zinc. The stripping of the loaded solvent was performed with 200 g/L H2SO4. Six countercurrent extraction stages achieved a separation of about 99% of the iron from the leaching solution. The iron-free leachate can be further treated to recover minor metals by cementation, and finally, zinc by liquid-liquid extraction. The advantages of the suggested process relative to the traditional jarosite process are discussed.

Jan 1, 2006

By R. Hagiwara, S. Kobayashi, K. Yasuda, T. Nohira, K. Kondo

To establish a process for the electrochemical recovery of rare earth elements from used magnet scraps, the electrochemical formation of RE-Ni alloys in molten NaCl-KCl-RECl3 salt at 973 K was investigated. Cyclic voltammetry and open-circuit potentiometry indicated the formation of several phases of RE-Ni alloys. The formation potential for each RE-Ni alloy phase was determined from the results of scanning electron microscopy and X-ray diffraction of alloy samples prepared by potentiostatic electrolysis of a Ni plate electrode at various potentials. The optimum electrolysis conditions for the separation of Nd, Dy, and Pr are discussed.

Jan 1, 2014

By J. Sliwinski, H. Kikutani, J. Atwood, D. Larimer, J. Pyecha

"The Pogo mine start-up milling targets of 2005 are vastly different than the targets of today. Improvements have been driven by unintentional design oversight, continual circuit optimization or optimization due to changing mineralogy. The more significant process improvements to date have occurred in the gravity, flotation and leach/CIP unit operations. Details of the significant improvements are presented along with the impacts to the process.INTRODUCTION Deposit Overview Pogo mine is located along the Goodpaster River, southeast of Fairbanks, Alaska. This deposit sits in the center of the Tintina Gold Province (Figure 1), a region of similar Intrusion Related Gold deposits in Interior Alaska, the Yukon and British Columbia Canada (McCoy et al., 1997). The Pogo deposit is hosted in a rock sequence of amphibolite-grade gneisses intruded by mid-Cretaceous granitic plutons and dikes, which in turn, were cut by and host the auriferous quartz veins of the Pogo deposit.The Pogo deposit is comprised of three distinct zones of auriferous quartz veins spatially adjacent to each other. These are the Liese Zone, North Zone, and the East Deep Zone. The Liese Zone consists of three stacked, massive quartz veins, designated the L1, L2, and L3. Vein thickness averages 3.0 m, with variations from 0.3–18 m thick. The North Zone mineralization is comprised of four veins with more consistent thickness, between 1 and 1.5 m. The East Deep deposit lies northeast of the Liese Zone ore body. It is separated by a post mineralization, quartz diorite pluton. The East Deep Zone is comprised of two stacked massive quartz veins with similar orientation as the Liese Zone."

Jan 1, 2017

By H D. Smith

T HE production of coal in Canada was slightly higher in 1964 than in the immediate past, and the major users continue to be the electric utility and metallurgical industries. There are continuing trends toward the increased use of cokes and chars in various metallurgical applications. Geological Research During 1964, the coal drilling program of the Research Council of Alberta (RCA) was concentrated in the extreme south of the Province (notably in the Milk River area and the region immediately to the northeast of this area). Field work commenced on June 1 and was completed at the end of September, by which time a total of 376 holes, aggregating some 48,500 ft., were drilled in 132 townships. Although no new major coal occurrences were intersected, the pro-gram yielded useful data for defining the extent of the known coal deposits in the area. Detailed results will be analyzed during the winter and reported in due course. Meanwhile, a full report on the

Jan 1, 1965

By E. C. Payne

"IntroductionTHE SMALLER industrial and commercial steam generating plants in the United States are suffering from an ‘engineering deficiency' which, if allowed to continue, will probably result in the extinction of the species• that now burn •approximately 75 million tons of coal. We will classify as 'small' those plants which should require not more than one operating man per shift, including those in which as little .as thirty minutes per day should be adequate for .all service attention. These are the small steam plants that need the most, and get the least, expert attention for fuel :planning, equipment selection, design layout, .and proper operating technique. Dissatisfaction with bituminous coal is usually caused by one or more preventable weaknesses such as excessive or burdensome labour •for firing, .coal or ash handling and manual operation, smoke and fly ash emission above nuisance levels:, high maintenance and premium coal application for acceptable operation, and .finally, overall steam costs which are not .competitive. These 'deficiencies', so .common in the small coal-fired steam plants, can be readily eliminated by competent engineering and modern equipment with automatic controls."

Jan 1, 1953

By K. El-Ouassiti, M. Zouadi, C. Bazin, D. Hodouin

Data reconciliation techniques are used to attenuate the effect of measurement errors and estimate unmeasured variables. This paper illustrates the application of data reconciliation to hydrometallurgy processes using measurements from leaching and solvent extraction obtained from laboratory experiments. The application of data reconciliation provides an efficient way to detect gross and systematic errors and produces reliable performance indices for process evaluation.

Jan 1, 2005

By Frank D. Shepherd

THE Gunnar Gold Mines property is on the west shore of Beresford lake, in the Rice Lake mining division, southeastern Manitoba. Gold was first discovered in place in the Rice-Beresford Lakes area in 1911 on the Gabrielle claim, now included in the San Antonio Mines property at Rice lake. Following an eastward trend of favourable prospecting ground, promising showings were next staked in the vicinity of Long lake during the years 1915 and 1916. At that time, William Walton and associates, among them Gilbert LaBine, staked the Eldorado vein, north of Long lake, and Eldorado Gold Mines, Limited, was formed to develop the property a Company that, later, was to become widely known through successful operation of its radium-silver mine at Great Bear lake, Northwest Territories. Continuing eastward from Long lake, Walton and his partners, Gunnar Berg, Leo Seaberg, and Wm. Quesnel, staked claims during the years 1920-24 in the vicinity of Beresford lake which, later, were to become incorporated into the Gunnar Gold Mines property. The presence of gold-bearing quartz on these claims had been known from the time they were staked, but an opportunity to consolidate them into a group was not forth-coming until early in the year 1933. Although promising gold showings had been disclosed during the performance of assessment work on individual claims, no continuous mineralization having mine-making possibilities was discovered until after the consolidation of the entire group. From this stage onward, progress was rapid. Active exploration was begun on August 1st, 1933, and late in October James Houston reported favourably on the property. On October 27th, Gunnar Gold Mines, Limited, was incorporated in the Province of Ontario to develop and operate the property. The Company is also registered in Manitoba. The authorized capitalization is 3,000,000 shares of $1.00 par value. Gilbert LaBine was appointed president of the Company, with James Houston as mine manager. Following completion of a diamond-drilling programme, planned in 1933, it was decided to install a mine plant capable of carrying development to a depth of 1,000 feet. A transmission line, 5 miles in length, was built to the Great Falls-Central Manitoba line of the Manitoba Power Company, Limited.

Jan 1, 1939

By Mario E. Rossi

Geostatistical conditional simulations are becoming increasingly popular as tools that provide models of uncertainty at different stages of a mining project. They have been used as grade control tools in daily operations, to assess the uncertainty of minable reserves at the project?s feasibility stage, and to assess mineralization potential in certain settings. Other applications include assessment of recoverable reserves, resource and reserve classification, and drill hole spacing optimization studies. All large-scale applications of conditional simulations intend to benefit from the ?correct? (or ?accurate?) characterization of uncertainty, adequately describing the variability observed from the data and its impact on the final objective. The objective of this paper is to compare the ad-hoc ?uncertainty model? provided by a traditional classification scheme with the probability intervals resulting from a conditional simulation model. It is argued that the uncertainty model derived from the use of classification schemes is of little practical use to the mining company or operation. The paper emphasizes differences in uncertainty based on the size of the mining unit considered and the extraction method, and local geological differences. Most importantly, it discusses confidence intervals for these mining units, as compared to the relative precision envisioned by a typical classification scheme. The application described in this paper is taken from a medium-sized Cu open and underground mine in northern Chile, and it demonstrates the impact of several variables on the resulting conditional simulation models. It also compares a more ?traditional? resource classification scheme applied, and the wide difference in local confidence intervals for each mining unit.

May 1, 2001

By Jirí Faltus

The paper deals with studying the impact of structural properties and anodizing of surface on the corrosion properties of extruded rods from commercial aluminium alloys: AA6082, AA6262, AA6012, AA2007 and new lead-free aluminium alloys AA6023, AA2015 and AA2111B. Samples were exposed to the corrosive atmosphere NSS, AASS in the chamber by EN ISO 9227. Surface of samples were either in the original state or anodizing by selected mode. The depth of corrosion attack and the form of corrosion attack are evaluated depending on the type of alloy, the metallurgical condition and surface treatment of the samples.

Jan 1, 2015

By L. Paulino, R. A. Camilli, J. Yamamoto, J. C. Araujo

The first paper presented on this work [1], showed how bath ratio was increased from 78% to over 95% using a structured approach to reduce bath chemistry variability. This update will illustrate the steps taken and update the results presented earlier, showing the effects of long power interruptions and several load reductions as well as load increase during the period from 1999 to 2005. Current efficiency was affected by such processes upset; however, bath ratio in range (±0.05) is still higher than 90%, even after an increment of more than 6 kA. This review will explain each of the steps taken to reach stability in this critical smelting parameter.

Jan 1, 2006

In the present work, the effect of pH, non-ionic polyacrylamide flocculant and anionic polyphosphate on rheology and settling behaviour of colloidal TiO2 suspensions (15 ? 50 wt% solid) is investigated. Maximum particle aggregation, reflecting in the highest suspension settling rate and maximum shear yield stress was achieved at pH 7.2, the isoelectric point (iep), consistent with DLVO expectation. However, the maximum aggregation condition at the iep also resulted in the poorest suspension consolidation behaviour. Significantly enhanced consolidation was achieved for a more dispersed suspension at pH values away from the iep but at reduced settling rate. Thus, when pH alone is used to control conditions which facilitate strong interparticle attraction, a high settling behaviour which is not conducive to compact consolidation results. Improved suspension consolidation may be achieved at the iep via anionic polyphosphate addition which leads to attenuation of the strongly attractive van der Waals forces and emergence of "soft" repulsion due to weak inter-particle electro-steric forces. The weak repulsion act to lubricate particles involved in the hydrodynamic interactions which controls the compressibility of the sediment bed, allowing a compact consolidation of solids to be obtained. Alternatively, non-ionic polyacrylamide homo-polymer (Magnafloc 333) was fairly effective in flocculating titanium dioxide suspensions leading to high settling rate and acceptable pulp consolidation at the iep.

Jan 1, 2006

By ByongPil Lee, Changkyu Lee, Jin Gyun Park, Hyung Sub Eom, Sung-Koo Jo, Jae-Young Lee, Gilsoo Han

"A new hydrometallurgical process for nickel extraction from a low grade laterite ore such as limonite has been developed by RIST and POSCO. This POSCO Nickel Extraction Process (PosNEP) consists of five main processes: ore reduction using hydrogen as a reductant; acid leaching at atmospheric pressure and temperature; cementation by the use of reduced-ore seed; production of the main product such as ferronickel or a high purity nickel compound; and production of by-products such as cobalt and iron in the forms of cobalt sulfate and iron oxide. In addition, hydrogen produced in acid leaching and hydrochloric acid regenerated in pyrohydrolysis for iron oxide production can be reused in the process, which makes PosNEP more cost-effective. The performance of PosNEP has been proven through pilot tests, showing that this process is economically and technically viable. In this paper, basic concepts and detailed test results of PosNEP are shown.INTRODUCTIONNickel has been extracted from two types of ore, sulfide and oxide ore. Nickel and cobalt usually occur together in the ores. The principal ore mineral of the sulfide is pentlandite, (Ni,Fe)9S8, which is easily beneficiated to produce sulfide concentrates(Moats & Davenport, 2014). These concentrates are usually treated by smelting and converting to make a matte. The produced matte is then purified through either hydrometallurgical or pyrometallurgical processes to produce high-purity nickel. In general, this process for sulfide ore has been known as a more cost-effective process than that for oxide ore.The oxide ore is laterite comprised of two different ore types, saprolite and limonite. The main nickel-bearing mineral of saprolite is nickeliferrous garnierite,(Mg,Ni)6Si4O10(OH)8, and that of limonite is nickeliferrous goethite (Fe,Ni)O·OH ore (Moats & Davenport, 2014). Since the saprolite has high contents of nickel and slag formers (MgO and SiO2) and a low content of iron, it tends to be treated by a pyrometallurgical smelting process such as calcination and electric furnace techniques to produce ferronickel for use in stainless steel. In this process, the cobalt in the ferronickel does not have any economic value."

Jan 1, 2017

By G. Goodall, M. Muinonen, R. Pandher, R. Jabbar, S. J. Muinonen

"The implementation of a new and highly efficient converting practice at the Glencore Sudbury Integrated Nickel Operations Smelter has opened the possibility to further capacity increases by using larger ladles. To quantify the impact of increasing ladle sizes from 200 to 300 ft3, XPS constructed a detailed discrete event simulation using the commercial software package Rockwell Arena®. The challenges associated with implementing a model on an intricate and tightly scheduled process, and the solutions needed to derive meaningful results will be presented. The aisle capacity is predicted to increase by approximately 17 %, with a reduction in furnace tapping demand of 8 %. Arena modeling capabilities and the key factors contributing to the overall capacity increase at the Sudbury INO Smelter will be reviewed and presented.INTRODUCTION The Glencore Sudbury Integrated Nickel Operations (INO) comprises two Ni-Cu-PGM mines, Strathcona Mill, and the Sudbury Smelter. The Smelter has operated continuously since 1929 using different processes to produce nickel-copper Bessemer matte. Feeds to the Sudbury INO Smelter are a blend of concentrate from Strathcona Mill, Raglan concentrate produced at the mine-mill complex in Raglan, Quebec, as well as third party concentrate feeds shipped to Sudbury from around the world. In 2016, the Sudbury INO Smelter produced 75,900 tonnes of nickel and 20,000 tonnes of copper in Bessemer matte. The product matte is shipped to Glencore’s Nikkelverk refinery in Kristiansand, Norway where it is refined to produce nickel and copper cathode. A schematic of the Sudbury INO Smelter’s flowsheet is shown in Figure 1."

Jan 1, 2017

By D. Bouchard, J. Langlais, A. Lemieux, N. Andrade

A concerted effort between Akan International Limited and the National Research Council of Canada (NRC) has been initiated to develop a liquid-based slurrymaking process, dubbed SEED (Swirled Enthalpy Equilibration Device) for semi-solid forming. The technology is presently entering the industrial and commercial stages, and will be used by the first customers at the end of 2006. Semi-solid processing of aluminium alloys offers many advantages in fabricating economically near-net-shape parts of superior quality. The SEED process helps to overcome problems experienced with thixocasting and especially the high cost of feedstock. The SEED process involves two main steps: 1) heat extraction to achieve a desired liquid/solid mixture, and 2) drainage of an excess liquid to produce a self-supporting semi-solid slug that is formed under pressure. The heat transfer plays an important role (enthalpy equilibrium) during the manufacture of the semi-solid slurry and its analysis is briefly described. The semisolid material is obtained using different processing times and initial conditions. The impact on the solid fraction distribution and the morphological evolution of the microstructure is presented. The influence of the SEED processing parameters (slurry preparation) and the resulting mechanical properties for the alloy A356 are also reported.

Jan 1, 2006