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By K. Mirkhani, P. Gebski, W. Ying

The campaign life of an industrial metallurgical vessels strongly relies on the quality and quantity of the refractory lining. An operating furnace or converter refractory lining can be assessed either by thermal modeling or by acousto ultrasonic-echo (AU-E) technique or a combination. AU-E is a Non-Destructive Testing (NDT) stress wave propagation technique that has been utilized on a wide variety of smelting vessels for over 12 years with good success. AU-E can determine the thickness of remaining refractory lining, estimate the thickness of build-up or accretion, detect and locate metal penetration and impregnation into the lining, and identify hydrated or cracked areas of refractory. This paper details the AU-E principles, equipment and recent improvements to the data analysis to further improve speed and accuracy. In addition, the paper discusses the AU-E accuracy and limitations through a diverse and vast array of practical examples including a comparison with thermal modeling and physical measurements.

Jan 1, 2011

By D. Jean Hutchinson, Mark Diederichs

"Cable bolts are an important support component in modern underground mines. If an optimized cable bolt system is to be achieved, it is insufficient to focus on cable bolt layout design or on cable bolt installation in isolation. Cable bolt support, like all engineered systems, requires a holistic approach, encompassing integrated elements of design, implementation and verification. The “Cable bolting Cycle” described in this paper incorporates these components along with related tools and procedures which should be used together to ensure effective and efficient cable bolt support.Design involves the consideration of demand, capacity and constraints as outlined in this paper. The demands imposed on the sup-port system by the rock mass response to excavation under the combined action of stress and gravity must be matched to the capacity of the cable bolt array. The cable bolt system capacity is a function of the component strengths of the steel strand and the bond (load transfer) and by the deformation response and retention characteristics of the system. The design is bounded by operational and economic constraints.Implementation of the cable bolt array can then proceed and must include appropriate protocols of communication, training and quality control, in addition to both general and site specific installation procedures. Implementation will be discussed as the sum of these components.Implementation of the cable bolt array can then proceed and must include appropriate protocols of communication, training and quality control, in addition to both general and site specific installation procedures. Implementation will be discussed as the sum of these components.The information presented in this paper represents a very abbreviated version of much broader concepts, procedures and design charts, presented in a practical cable bolting handbook by Hutchinson and Diederichs (1996)."

Jan 1, 1996

By N. K. Jaber

The "Pidgeon Process" for the extraction of magnesium from dolomite ore utilizing ferrosilicon as the reducing agent has been studied extensively by active metallurgists such Mr L,M, Pidgeon the father of this process, Most of the work sited so far has focused on heating the (FeSi/MgO,CaO) briquette mix under vacuum in stainless steel retorts by external fuel hydrocarbon heating, In this work Electrical Induction Heating was employed as the heating method whereby the briquette mix was placed in a steel crucible around which an Induction Heating copper coil was wound and placed inside in a stainless steel vacuum tank, It was observed that by virtue of the fast Induction Heating method utilized in the silicothermic extraction process higher reduction temperatures were reached in shorter periods of time due to fast heat transport into the ore charge mix, This facilitated shorter metal reduction times as compared to the conventional fuel heating methods.

Jan 1, 2006

By R. F. Neider, W. R. Bain

"Expanding upon one aspect of a recent paper on ""Fluid Column Roasting at Sherbrooke Metallurgical Co. Ltd.,"" the present paper deals with the operation of the fluid column process to achieve substantial elimination of cadmium and lead during the roasting of pelletized zinc concentrates. Designed to meet the need for additional feed for Matthiessen and Regeler Zinc Company's vertical retort zinc smelter in West Virginia, without recourse to a sintering operation, the plant is capable of simultaneously attaining very low lead and cadmium levels on demand, through operation in the manner described. Fluidizing air admitted via the wind box is supplemented by natural gas admitted via a tuyere bank 15 ins. above the hearth, in quantities adjusted to maintain a reducing atmosphere within the interstices of the bed. In addition, careful attention is paid to bed temperatures, which run from 1,080° to 1,100°C. Under these reducing conditions, 90 per cent of the cadmium and 92 per cent of the lead in the feed are eliminated, the sulphate sulphur content is decreased by 0.5 per cent, sulphide sulphur is held at 0.6 to 0.08 per cent, and the zinc content correspondingly in-creases. The fuel value of the natural gas is recovered as extra steam, which carries a credit. There are some added difficulties with fume accretions, gas conditioning and gas -cleaning, some of which have yet to be overcome."

Jan 1, 1967

By T. C. Holmes

"Dome mine, in the Porcupine mining camp of northern Ontario, is one of the important gold mines of Canada, its production of gold from the commencement in 1910 to the end of 1946 having a value of $149,000,000.GENERAL GEOLOGYThe oldest rocks in the mine are greenstones of Keewatin age(l). Those to the south are known as the southern greenstones, but little is known of their structure. Those in the northwest part of Fig. 1 and the north part of Fig. 2 are known as the northern greenstones or greenstone 'nose'. They face north, dip steeply north, and end to the east against an unconformity which pitches northeast about 20°. The volcanics are overlain unconformably by Timiskaming .conglomerate and slate. All these rocks are cut by porphyry. Closely associated with the porphyry is a group of rocks that have suffered extreme alteration. Diabase dykes intrude all the other rocks and the ore. The principal massive rocks in the mine are two adjacent flows known asthe andesite (south) and dacite (Fig. 1). They are composed chiefly ofmassive, medium-grained lava. Pillows, flow lines, and other typically volcanicfeatures are found along the tops of both flows and at other places in theandesite. These parts nearly everywhere show a slight schistosity panllelwith the flows except in the orebodies, where they are massive."

Jan 1, 1954

By A. Pearson, F. A. Auld, S. O. Colbeck

"""The theory of buckling of shafts and Steel tunnel-linings"" was published by E. Amstutz in 1970 and commented on by S. Jacobsen in 1974. The authors have revised and enhanced Amstutz’s work to address Jacobsen's comments on its limitations and to extend its validity over a wider range of pipe/shaft geometries, including those commonly found in deep mine access shafts. The author has looked at Amstutz’s assessment of strengthening with flexible shear anchorages and adapted the theory of non-linear shear deformation response of bolts to develop a method of assessing increased buckling capacity utilising the full plastic shear capacity of studs. INTRODUCTION “Amstutz Buckling” refers to the buckling of pipe embedded in concrete under external uniform pressure. In terms of a mining environment, this relates directly to the design of a watertight shaft. This load case will commonly occur where a main shaft is cast against a geostatically stable primary liner and the only load applied to the final shaft is that of a uniform ground water load. Ernst Amstutz wrote his first paper on buckling of pressure-shaft steel linings in 1950 and subsequently improved his theory (Amstutz, 1970), which was then widely adopted for use within the industry. Years later, an alternative approach (Jacobsen, 1974) was proposed. Within his paper Jacobsen critiques Amstutz work, identifying some mathematical inconsistencies and highlighting limitations of the theory imposed by approximations adopted by Amstutz. Despite these limitations Amstutz work has still been used as the favoured design theory for use in the mining industry. In reviewing this body of work the author realised that with the advent of readily available computing software it was possible to adopt an iterative approach using Amstutz approximate formulae to find a solution to the original precise formulae, thus eliminating the limitations highlighted by Jacobsen The shear deformation to load characteristics of bolts has long been established (Crawford & Kulak 1968) and used for the plastic design of bolted connections in shear. This relationship is directly transferable to the design of shear studs, typical properties are well known, and actual values easily established in simple lab tests. The author has taken this relationship and modified Amstutz theory (Amstutz, 1970) for shear anchored strengthened liner buckling, to give a more efficient solution, using readily available material properties."

Jan 1, 2019

By M. Jahazi, J. Gholipour

Design and manufacturing of parts using hydroforming process require knowledge about material behaviour and tribological effects during hydroforming. Lubrication is one of the key issues in successfully hydroform the tubes. A Ni-based super alloy tube with 50.8 mm (2 inches) outer diameter and 0.9 mm (0.035 inches) thickness is considered for this research to study the effect of lubricants on the formability of the tubes. Hydroforming of a hollow compressor blade is considered for this project. A combination of press forming and hydroforming is employed to produce the part. LS-DYNA, an explicit dynamic finite element code, is used to model the experiments. Different lubricants are modeled using different coefficient of friction in the model. Predicted results for strain distribution at a critical section of the tube are extracted for each case to evaluate the effect of different lubricants on the process.

Jan 1, 2006

By Unknown

With the present-day trend of rising labour costs and a lowering of production efficiency of workmen, it has become imperative that every effort be made to use manpower to the greatest advantage and to mechanize mining as much as possible. During the past few years this trend has gained much prominence in the Porcupine camp. In view of this, the executive of the Porcupine Branch considered that the Mechanical Movement of Muck would be a very timely subject for a Symposium. Accordingly a Committee was formed, with A. K. Douglass, Mine Superintendent for Delnite Mines, Ltd., as Chairman, and the Symposium was held in the Auditorium of the McIntyre Community Building, Schumacher, on March 25th last. Papers dealing with shovel loader and mechanical scraper operation at six of the larger mines of the camp were presented and discussed, and a tabulation was prepared giving data on the machines in operation at a total of eleven mines. The papers and tabulation, reproduced below, will doubtless be of considerable interest to operators of mines in all parts of Canada.

Jan 1, 1948

By M. Girard, C. Farsangi, N. Singh

"Canadian Royalties Inc. owns and exploits the Nunavik Nickel Project: a copper and nickel deposit in Nunavik, Québec. The nickel and copper concentrates are filtered by plate and frame filter presses, and are transported 100km north to Deception Bay by truck. As the site is situated in the far north, extreme weather can be detrimental to production: roads can close for significant periods of time, resulting in the concentrator using all its storage capacity. During the winter of 2017, this accounted for over 100 hours of unplanned mill downtime. Different solutions to this problem were evaluated and the most economically viable combination of solutions was determined to be the use of concentrate storage containers and upgrading the plate size of the existing nickel filter press. By satisfying new, increased utility requirements, the cycle times would not change, but produce 30% more filter cake. Simulations were developed to determine the number of concentrate containers needed in conjunction with the upgraded press to eliminate unplanned downtime due to road closures and secure production through the winter. This paper summarises these simulations, the commissioning and start-up of the upgraded filter press, container loading procedures, and how this was put together to achieve a record 2018 winter season with a 90 percent reduction in downtime. The payback period of the project was 4 months. A specialised side-tipping trailer emptied the containers during the fall of 2018.INTRODUCTION The Nunavik Nickel Project is a nickel/copper mining project located in Nunavik, Québec. The nickel and copper concentrates are stored in stock tanks after thickening and are then filtered by plate and frame filter presses at the concentrator before being transported 100km to the shipping port at Deception Bay by trucks. The region is prone to periods of extreme weather during the winter, with winds that can reach +100km/hr and blizzards that severely limit visibility. The roads to Deception Bay are often affected by this weather, causing closures that last an average of 18hrs and as long as 72hrs. Additionally, there is a 15% chance that road closures occur within 24hrs of the last event. This has been an issue for the concentrator team since start-up in 2013, causing unplanned mill downtime every winter (Table 1) due to filling concentrate storage capacity during prolonged closures of the roads to Deception Bay."

Jan 1, 2019

By H. A. ?ye

The ISO TC 226 (Materials for the production of primary aluminium) has presently issued more than one hundred standards on the materials: alumina, pitch, petroleum coke, carbon anodes, carbon cathodes, ramming paste, fluorides and refractory). The object of the standardization work is to find methods that both material producers and smelters will accept. Methods that are specific for the operational conditions have been developed in addition to more traditional room temperature methods. Examples of important properties under operational conditions are: Air and C02 reactivity of anodes, Equivalent temperature for baked anodes, Sodium expansion of cathode blocks, Shrinkage and Rammability of paste, Penetration of electrolyte into refractories.

Jan 1, 2006

By T. Banerjee, R. deS. Almeida, D. Gudgeon, F. C. F. Batista, L. deÁ. Silva

"Yamana Chapada’s mine is one of the larger copper-gold mines in Brazil. The mine is located in Goiás state, in the central part of Brazil. The mine has estimated Mineral Reserves of 4.1 million ounces of gold and 3.2 billion pounds of copper as of December 31, 2016. While gold and silver are significant, Chapada’s process flowsheet is configured closer to that of copper facilities. This includes a SAG/Ball configuration for grinding followed by flotation. In the case of Chapada, the mineralogy results in higher-than-normal complexity, notably a significant circulating load both in the grinding and flotation circuits. From an operating perspective, the complexities are controllable, but require careful attention to ensure that circulating loads are effectively managed and gold is not lost to tailings. Chapada created an automation roadmap in 2016 designed to increase plant performance (tonnage, recovery and efficiency). Based on strong potential, the project was fast tracked and within 4 months instruments were installed, control algorithms implemented, and training sessions took place to ensure sustainability at site. This paper will follow the Chapada journey from identifying the opportunities through to implementation and testing.IntroductionYamana Chapada mine is a Copper-Gold mine located in Goiás State, Brazil. Although the mine contains large quantities in Mineral Reserve of gold (4.1 million contained oz as of December 31, 2016), Chapada is primarily a copper mine with copper principally found as chalcopyrite. Accordingly, the processing flowsheet at Chapada is comparable to that of other copper mines with a SAG and Ball mill each partnered with a cyclopack, followed by a flotation circuit. While the overall design is conventional, the mineralogy at Chapada results in significant circulating loads both in the grinding and flotation circuits. This does introduce certain complexities for operating strategies and practices, but, importantly, favourable recoveries and elevated processing rates can be maintained, albeit they need to be closely managed. Plant automation helps in this regard."

Jan 1, 2018

By B. Rivard, D. Francis

A layered Archean magma chamber is exposed at the base of the Yasinski segment of the La Grande greenstone belt. This intrusive complex lies beneath a sequence of mafic volcanics and is underlain by granitoid basement which is crosscut by a swarm of gabbroic dykes. The gabbros of both this complex and the dyke swarm of gabbroic dykes. The gabbros of both this complex and the dyke swarm define a pronounced Fe-enrichment trend. The volcanic patterns of the La Grande and Eas tmain greens tone belts, however, define a series of iron depletion trends which originate in the iron enrichment trend of the gabbroic intrusives. These patterns suggest that the gabbros produced in the intrusive complex may serve as parental liquids for some of the lava suites of the James Bay greens tone belts.

Jan 1, 1984

"THE CONCEPT of energy as a commodity, while not entirely new, is not as widespread as the importance of the idea to this modern world would lead one to expect. The growth in the supply and use of energy over the past years has been tremendous, but our very closeness and familiarity have somewhat distorted the viewpoint, particularly of the younger generation. To many of us who remember the wonderful satisfaction of our first responsibility for directing two horsepower hitched to a farm cart or hay wagon, there still arises a feeling of some awe at the casual flick of the switch with which our sons and daughters summon to their convenience the service of some one hundred or more horsepower.Energy is the vital component of our existence and, no matter what contempt our day-to-day familiarity may •breed, it is wise to .pause from time to time and consider our national energy standing. Have we still capital in the bank? Are our expenditures wisely •conceived and well directed? Is provision being made for the years •ahead for the needs of our children and our children's children?"

Jan 1, 1953

By J. Jin, J. D. Miller

"Bubble attachment at hydrophobic surfaces is of critical importance in the flotation recovery of mineral resources and fundamental experimental results have been reported in the literature describing the details of film thinning, rupture, and displacement. Now, for the first time, bubble attachment phenomena are examined using Molecular Dynamics Simulations (MDS). The simulation involves a nitrogen bubble containing 906 nitrogen molecules in a water phase with 74,000 water molecules at the hydrophobic molybdenite (001) surface. During the simulation period of 1 ns, film rupture occurs and the nitrogen bubble attaches to the molybdenite (001) surface, resulting in a contact angle of about 90o. In contrast, the film is stable at the hydrophilic quartz (001) surface and the bubble does not attach. Contact angles, determined from MD simulation after stabilization of the three phase line of contact, are reported and these results agree well with experimental and MDS sessile drop results. In this way, film stability and bubble attachment are described with respect to interfacial water structure for surfaces of different polarity. For example, the interfacial water molecules for the hydrophobic molybdenite (001) surface have relatively weak interactions with the surface when compared to the hydrophilic quartz (001) surface, as revealed bythe presence of a 3 A water exclusion zone at the molybdenite/water interface. INTRODUCTIONAttachment of air bubbles to mineral particles is of fundamental importance in understanding flotation separation phenomena. It is well known that attachment of an air bubble at a hydrophobic surface includes film thinning, film rupture, and film displacement (Somasundaran, 2006; Wilson, Adlard, Cooke, & Poole, 2000). Experimental techniques, such as high speed video, can catch the process of bubble attachment at a mineral surface (Drelich & Miller, 2012; Niecikowska, Krasowska, Ralston, & Malysa, 2012). However, molecular scale information to examine the phenomena has not yet been reported."

Jan 1, 2016

By Brian Flintoff

"When I was first asked to prepare this paper and presentation in late June, I thought it might be fun to ""step back and paint the bigger picture."" Having attempted to do this, fun is not the first descriptor that now comes to mind, and speaking dyslexically, I've had 'nuf.'Unlike Nostradamus, or even Orwell, I've discovered that I'm ""clairvoyantly challenged"" and not even the psychic hot-line was of much help, at least with respect to process control! I am somewhat comfortable speculating on evolutionary change, but the radical developments that will arise from revolutionary changes are well beyond my mortal capabilities. Even with evolutionary change, I'm reminded of the lessons of time series analysis which show the prediction error to grow exponentially as the horizon moves into the future. As Macluhan is reported to have said: ""Predicting the future based on the past is a little like driving your car while looking in the rearview mirror!""Having honestly presented my qualifications, allow me to try to look at process control and to offer some conjecture on where we're probably headed. In the end, it is said that: ""The plant of the future will have only two employees, a man and a dog. The dog will be there to keep the man from touching the equipment.1""IntroductionA little less than a decade ago Andy Mular and I co-edited a monograph entitled ""A Practical Guide to Process Control in the Minerals Industry."" The work was commissioned by the senior management of a consortium of Canadian mining companies, since it was widely perceived that control was an area of great economic potential, but one that had not been effectively tapped. The concern was that if the industry could not soon deliver on the ""potential"", the term may well have appeared in the epitaph of what was, to these men, a very attractive investment opportunity. I think it is fair to say that over the past few years process control has clearly established itself as an essential technology in plant operation and optimization. That isn't to say that we get it all-right, all-the-time, but, the circumstances are much different than they were. In the eyes of many, process control has attained the distinction of being considered a mature technology, even though there are still countless avenues for exploration."

Jan 1, 1998

By S. Hunt, D. de Vries

Kansanshi Copper Smelter began operation in March 2015. The smelter features a single Isasmelt furnace for smelting, one 6-in-line electric furnace for matte-settling and slag-cleaning duties, four Peirce- Smith converters and two rotary anode furnaces. A 1,450 t/day oxygen plant and a 4,085 t/day sulphuric acid plant are included in the smelter operations. This paper gives an overview of the operational performance to date with summary data for each smelter section. Challenges such as an unforeseen refractory failure in the Isasmelt furnace in 2016 are discussed. Design improvements around the electric furnace are mentioned. Plans for potential future improvements are put into context. A consistent focus on operations, maintenance and continuous improvement has seen the smelter easily achieve its nameplate capacity of 1.2 million tonnes per annum of copper concentrate throughput. The smelter now operates consistently at a concentrate throughput rate of 1.38 million tonnes per annum of copper concentrate. INTRODUCTION The smelter was commissioned in March 2015. Design and commissioning of the smelter have been discussed by de Vries, Hunt, Hanschar and Louie (2016). The smelter rapidly ramped up to achieve nameplate production (1.2 million tonnes per year concentrate) and in 2018 operated consistently at the rate of 1.38 million tonnes per year concentrate. This paper presents major operational data for each section of the plant and describes significant events and improvements during the first four years of operation. The smelter flowsheet is shown in Figure 1.

Jan 1, 2019

By D. Simon

This paper studies the effect of binder type and content on the early age development of cemented paste backfill (CPB). The early age development of the mixtures is analyzed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDX). These tests show that the early age development of CPB is sensitive to changes in the paste composition. The properties of the CPB depend on the cement content and hydration time. The quantity of hydration products increases with hydration time for all of the mixtures containing cement. However, the high cement content pastes (at least 50% PC) exhibit complete coverage of the PC grains and mine tailings by C-S-H, while the low cement content paste shows scattered coverage of the PC grains and mine tailings and a higher void ratio.

May 1, 2007

By O. Matwijenko

"1. IntroductionThe Falconbridge Owl Creek open pit gold mine is located 17 km northeast of Timmins and 2.5 km west of the Kidd Creek metallurgical site. Diamond drilling first commenced in 1964 with open pit production commencing in 1982. Other operations within close proximity are the Canamax-Pamour Bell Creek Mine and the Falconbridge Hoyle Pond Mine.Since 1982, 1,216,000 tonnes assaying 4.5 g/t have been processed in six concentrators. This paper summarizes the metallurgy achieved with special emphasis on some of the unique problems encountered in the processing of this refractory ore.2. GeologyThe Owl Creek deposit, located 3 km north of the Porcupine-Destor fault is in easterly trending carbonaceously altered volcanic and sedimentary rocks. The deposit strikes east and dips steeply north.The ore body can be best described as a wedge shaped sandwich of volcanic basalt between the surrounding sedimentary greywacke. The north and south volcanic-sedimentary interfaces are marked by graphitic zones. The south graphitic contact is more continuous with its thickness varying from 5 m to 20 m as compared to 0.5 m to 3 m to the north. Quartz veins occur throughout the deposit with a predominant vein running along the south contact where it is characterized by numerous graphitic inclusions. Some veins carrying gold values intrude into the sediments in the north. With depth the sedimentary and volcanic zones taper while the quartz-graphitic zones appear to become more dominant."

Jan 1, 1988

By J. E. Nesset, L. S. Urbanoski, J. R. Goode

"The benefits and advantages of pre-competitive, collaborative industry/university research are not always well appreciated. This paper presents the case study of a current collaborative project between CAMIRO-Metallurgical Processing Division and McGill University that is investigating the understanding and prevention of sphalerite activation in lead and copper-lead flotation circuits. The benefits of the research findings to the sponsors can be maximized by an approach which links the researchers themselves with the sponsors at frequent, interactive project review sessions. Some examples of the findings and their application to industry are also presented along with a general update on CAMIRO-MPD.INTRODUCTIONThe history of Canadian efforts in the area of collaborative pre-competitive research is not long when compared to Australia (AMIRA) and Britain (MIRO). AMIRA (Australian Mineral Industry Research Association) began over 40 years ago and has had a well recognized role in bringing together industrial sponsors and researchers to fund a large variety of very significant development projects in that country, The total AMIRA funding effort for mineral processing work currently exceeds some $Aus 40 million with new projects valued at about $Aus 12 million initiated each year. This high level of commitment by industry has contributed to establishing Australian researchers and their facilities as among the best in the world.Canadian companies have traditionally funded much of their R & D in-house with extensive facilities and large funding commitments. The past 2 decades have seen most of these facilities disappear. The current situation is one in which only the largest integrated metal and mining companies have retained their own R & D groups (e.g. INCO, Falconbridge, Noranda). Industry-funded research at universities was primarily through individual efforts by the mining companies and rarely included collaboration with other mining companies, equipment or chemical suppliers, or engineering firms."

Jan 1, 2001

By Nicholas C. Williams

This paper presents the development of a demand reduction and responsive strategy capable of reducing the electrical power demand, particularly during peak conditions. The work presented includes a case study of a UK colliery. Areas explained are the equipment installation at the mine; the development of the demand reduction strategy including the load profile database and prediction optimisation model. Some live production data from the power meter installation at the mine is also presented.

Aug 1, 2013