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By J. D. Wilkins

"Ore outcrops were first discovered in the area in 1911. Following various periods of exploration by private interests and Cominco Limited, the Coast Copper Company, Limited property was brought into production in August 1962. Subsequently, Cominco explored the adjacent Quatsino Gold Mines property and is currently developing, and producing from, what is now known as the Benson Lake Mine.The Benson Lake Mine was developed using a conveyor-equipped decline and trackless LHD equipment. The operation produces 800 tons per day of copper-iron ore, copper being the main product. Copper and iron concentrates are trucked 25 miles to storage and shiploading facilities near Port McNeill to await shipment to Japan."

Jan 1, 1971

By Seshadri Seetharaman, Nurni N. Viswanathan, Haijuan Wang

The present work aims at some process modifications in specified metallurgical processes, wherein CO2 can be used successfully as an oxidant for decarburization in steelmaking and applied in some non-ferrous metals production processes. During the decarburization of Cr-containing high alloyed steels, the present researchers investigated the possible use of CO2 instead of Ar-O2 mixture and could successfully decarburize the steel melt without significant loss of alloyed Cr to the slag phase. A mathematical model was developed based on the bubble formation accompanying the chemical reaction: C(molten steel)+ CO2(gas)= 2 CO(gas). The model predictions were tested by laboratory scale (1 kg) experiments carried out in an induction furnace and very good agreement between the model predictions and experimental results were observed. A national project has been sanctioned in China for the implementation of CO2 in decarburization of ferroalloys as well enable the addition of pig iron in the electric arc furnace process when the scrap supply is limited. New processes have been developed for the utilization of CO2 in the case of non-ferrous processes. A novel method of treatment of Al dross by leaching with water and capturing the evolved NH3(formed by the hydrolysis of AlN) has shown very promising results.

Jan 1, 2015

By A. Manouchehrian, M. Cai

"Rockburst, which often occurs around underground openings in highly stressed hard rocks, is a sudden and violent unstable rock failure and is associated with energy release. Rockburst is very dangerous to workers and mining equipment, and it has been a major concern for deep underground construction and mining. Before excavation, rocks are loaded under a true-triaxial condition. Upon excavation, the rocks at the excavation boundaries are loaded in the maximum principal stress direction and unloaded in the minimum principal stress direction and this provides a necessary condition for unstable rock failure to occur. Understanding rock behavior under true-triaxial unloading condition is critical for developing measures to control unstable rock failure in underground construction.In this article, an explicit FEM tool is used to simulate rock behavior under true-triaxial unloading condition, with a focus on analyzing stable and unstable failure and the released energy during failure. Firstly, a uniaxial compression test was simulated. The results indicated that the adopted numerical tool was able to simulate stable and unstable failure by varying the Loading System Stiffness (LSS). In this research, Loading System Reaction Intensity (LSRI) was proposed as an indicator to identify stable and unstable failure. Secondly, unstable rock failure under true-triaxial unloading condition was simulated. A rock specimen was loaded in three directions; the lateral pressures (s3 and s2) were kept constant and the vertical stress (s1) was increased to a pre-defined stress. The specimen was suddenly unloaded in the minimum principal stress direction (s3) and loading in the s1 direction was continued until failure occurred. Different LSS values were considered and the results showed that the LSS influenced the failure mode; a soft loading system resulted in more violent failure and released more energy than that in a stiff loading system. The influence of specimen height to width ratio on rock failure was also investigated. It was found that failure in taller specimens was more violent than that in shorter specimens. Insights gained from the simulation are useful for better understanding of the influencing factors on the released kinetic energy during unstable rock failure and to find means to control rockburst damage in engineering practice."

Jan 1, 2015

The comminution circuit at Tarkwa Gold Mine was commissioned as a Single Stage SAG mill operated in closed circuit with hydrocyclones designed to process 4Mtpa. The circuit was later expanded by adding a secondary ball mill in closed circuit with hydrocyclones with a view to treat 12Mtpa. The change in the circuit configuration and assigning the low aspect ratio SAG mill for primary grinding application makes the Tarkwa experience unique in terms the optimisation strategy and operating philosophy. This paper reports the findings from a series of surveys performed on this plant. The surveys reported include data obtained when the SAG mill was operated as a single stage mill in closed circuit with hydrocyclones and also SABC mode under two different feed conditions. The differences in operating philosophy between the initial single stage SAG circuit and the current SAG/Ball mill circuit are discussed.

Jan 1, 2012

By A. Aaltonen, S. Paloranta, H. Myllykangas

A property based dynamic model of flotation was built and validated for training purposes. The model is based on the work of the AMIRA P9 project. The recovery of each particle with composition and size is calculated in a given simulation step. The model takes into account machine and operational parameters such as air flowrate and froth height. The model was created using fullscale test data on Pyhlisalmi Cu-Zn-pyrite ore with flotation kinetics of multiphase particles determined. Simulation and validation shows that model can predict the dynamic behavior of the process accurately enough for training purposes.

Jan 1, 2009

By A. Romero

"Most underground mines require heating or cooling systems to meet health and safety standards in the working areas. In regions where daily or seasonal fluctuations of environmental conditions exist, these systems tend to be over-sized and operate at low average load factors, which increase both investment and operating costs. One possible approach to reduce the temperature variations of the fresh air supplied to the mine, and so reducing the investment in large heating or cooling systems, is to use rock as a thermal regenerator or thermal storage system. Packed rock beds act as thermal inertial units, damping the atmospheric temperature oscillations to provide a more constant fresh air temperature. However, although regenerators exist in some mines, and packed bed rocks have been studied in detail in solar thermal power applications, there is a lack of tools to design new and sufficiently large storage systems of this kind. This work fills the existing gap by presenting a methodology to design and evaluate the impact on the ventilation systems of these regenerators. The method is validated using existing rock bed systems found in the literature and illustrates possible designs for small and large size regenerators in both hot and cold climates.1 INTRODUCTION “ It is quite amazing how often answers to extremely complicated problems can be obtained in this way, by using greatly simplified models of the real situation for the purpose of calculation.” Whiller, A. in private communication to J. S. Stachulak (1989). Motivation Most underground mines located in regions with extreme climatic conditions require the thermal pre-treatment of the fresh ventilation airflows, whether for heating or cooling. Heating commonly is needed in sites with sub-zero temperatures and is usually effected by direct or indirect burning of natural gas or propane. Alternatively, cooling is required in areas with hot temperatures, or in mines with high underground thermal loads where the fresh air at ambient temperature cannot provide enough refrigeration. Thus, when the ambient air conditions cannot provide by itself enough thermal power to ensure safe underground working conditions, a heating or cooling plant is required, which involves a considerable equipment and operation cost."

Jan 1, 2019

By T. Crivits

"Freeze lining technologies are used industrially to protect the integrity of furnace walls in pyrometallurgical reactors. This is achieved by solidifying a protective layer of slag on the inner furnace wall. In the current study, laboratory experiments have been undertaken to produce freeze linings in ‘Cu2232 O’-‘FeO’-MgO-SiO slags under controlled conditions using an air-cooled probe technique. Whilst most thermal models of freeze linings have assumed the freeze lining-bath interface to be at the liquidus temperature of the bulk bath and to be planar in geometry, the current research has demonstrated that this is not the case. Experiments undertaken using this high-temperature slag system have shown the interface at steady state conditions to be at subliquidus temperatures. The solid phases present at the interface do not include the primary phase and the interface is non-planar. The study indicates the need for improved understanding of the fundamentals of freeze lining formation, and of the influence of system properties and process parameters"

Jan 1, 2015

By M. L. Jeremic

The design of the long-hole sublevel mining method was originally based on the traditional assumption that the principal load was due to the weight of the overlying rock, and that the horizontal stresses are equal to one-third of the vertical stress. However, as mining progressed, the virgin lateral stress was found to be equal to or greater than the vertical stress. The virgin stress in the rock mass is not uniform throughout the folded orebody and adjacent strata. From detailed investigations, three basic patterns of virgin stress in ore panels have been inferred: uniform, bent and twisted. Stresses induced by stoping are up to three times greater than original stresses in the rock mass; they cause heavy ground conditions and make extraction of ore difficult. In the last ten years, the original mining system has been modified several times in order to destress the ground and improve the extraction of ore.

Jan 1, 1978

By C. Samuelsson, H. Ahmed, B Björkman, A. Andersson

The cost of raw material and energy is a continuing driving force towards working with increasing the recycling of ore based steelmaking residues. In Sweden no on-site sinter plants are operated at the integrated steelworks. Instead, selected residues from the plant are incorporated in a cold bonded briquette product which is recycled to the process via the blast furnace (BF). Since the BF sludge is the major bleed of zinc out of the furnace it is required to be de-zinced prior to recycling in the briquette product. In the present work landfilled BF sludge has been characterized with respect to chemical composition, particle size distribution, X-ray diffraction (XRD), and scanning electron microscopy (SEM). The sludge was also subjected to laboratory scale hydrocyclone trials aiming at reducing the zinc content making the sludge viable for recycling. The results suggested that the sludge had been agglomerated prior to the characterization and hydrocyclone treatment. The zinc removal using the hydrocyclone was discussed.

Jan 1, 2015

By E. Swartzman

"DURING 1951, experimental cleaning studies on both fines and larger sizes of certain Canadian coals were conducted on a relatively large scale in two pilot plants in the United States, large enough to be considered as small commercial units, and in one commercial plant in Canada.One of the pilot plants was a wet washer of a type which apparently has never been .used in Canada, nor has any Canadian coal been tested in it before. In the other pilot plant and in the commercial plant, dry cleaning equipment was used. The commercial plant is the first of its kind to be employed in Canada, and this type is used only to a limited extent in the United States.Fine-Coal Cleaning ExperimentsTest PlantsHydrotator and Hydrotator-Classifier combination pilot-plant with a capacity of about twenty tons per hour. This is a classifier type washer adapted for cleaning fine coal as well as certain intermediate sizes. The Hydrotator deals with that portion of a coal retained on approximately a 24-mesh Tyler sieve, whereas the Hydrotator-Classifier deals with the minus 24-mesh fines."

Jan 1, 1952

By F. M. Doyle, G. Sidhu, A. J. Dussault, A. Raygani

There is a growing demand for rare earth metals for use in high strength permanent magnets, most notably Nd2Fe14B. Rare earth metals are extremely reactive, with reduction potentials around -2.5V SHE, and are conventionally produced by molten salt electrolysis. The current work was done to investigate an earlier report of electrodeposition of a neodymium ferroalloy from aqueous solution, to determine whether this approach could be an environmentally and economically competitive commercial approach for producing feedstock for permanent magnets. Such a process would be analogous thermodynamically to the Castner- Kellner process, in which aqueous sodium chloride brine is electrolyzed in cells with mercury cathodes. Metallic sodium forms an alloy (amalgam) at the cathode, thereby lowering the activity of the metallic sodium significantly below unity and making the reduction potential of sodium significantly less negative than the standard reduction potential. Here we report the effects of Nd/Fe ratio in the electrolyte, current density, temperature and two different complexing agents, glycine and cysteine, on the composition and morphology of the electrodeposits, along with current efficiency. The energy needed to produce neodymium as Nd:Fe alloys by aqueous electrodeposition was compared with values estimated for production by molten salt electrolysis and the thermodynamic energy requirement.

Jan 1, 2014

By M. Mbonimpa

Field experimental cells were constructed in 2007 to assess the performance of different cover scenarios for the reclamation of the Parc 1 tailings disposal facility at the Westwood-Doyon Mine site (Abitibi, Quebec). Three configurations of cover with capillary barrier effects (CCBEs) with different thicknesses and material types for the moisture retention layer (MRL) were studied. MRL with 80 cm till, 40 cm till, and 40 cm clayey silt were used for cell nos. 2, 3, and 5, respectively. The capillary barrier layer (CBL) and drainage and protection layer (DPL) of the CCBE consisted of 30 cm gravel. A reference cell without cover was also constructed to compare the geochemical performance of the CCBEs. Due to an unexpected flooding in the leachate exit area of the cells in spring 2008, the cell instrumentation for hydrogeotechnical monitoring was postponed to spring 2009. Changes with time in volumetric water content, suction, soil oxygen concentration, and temperature were measured at different depths. This paper presents and discusses preliminary results obtained from spring 2009 to autumn 2010. In all cases, the degree of saturation Sr is lower in the CBL than in the MRL, indicating the presence of capillary barrier effects at the interface of these layers. Cell nos. 2 and 5 showed hydrogeotechnical behavior typical of an effective CCBE, with Sr maintained above 85% in the MRL and lower than 30?50% in the DPL and CBL. Based on the obtained results, and as expected, MRL thickness and the type of construction material used appear to affect the hydrogeotechnical behavior of the CCBE. Oxygen concentration profiles through the CCBEs were used to estimate the oxygen flux, and results indicate that cell nos. 2 and 3 performed better than cell no. 3. CCBE performance is currently being investigated using the geochemical monitoring data.

Aug 1, 2013

By G. W. MacLeod

The iron ore question in this country has been widely discussed for many years, but only recently has its real significance becoming generally understood. The exhaustion of the old Helen mine, in 1918, marked the last phase of hematite production in Ontario, and with the closing of the Magpie mine in 1921 , Canada ceased to be a producer of iron ore. For the past three years every ton of ore used in Canadian blast furnaces has been imported. In a recent issue of the Engineering and Mining Journal-Press, Arthur B. Pearsons, Assistant Editor, makes the following statement : Iron dominates the world. Some contend that coal is more vital. be-cause heat is needed to make iron and steel. But there are other sources of energy, more convenient and less costly and it is only a question of time when progress in hydro-electric development will have reached the point where coal will be but an incidental source of power and heat. Even more direct means than the generation of electricity by hydro-power eventu-ally will be developed by making available the latent energy of the sun. But iron; Science gives not the vaguest suggestion that anything will dis-place iron and steel as the most essential material tool of modem civiliza-tion. ? Hardness, tenacity, malleability-it possesses all these in unique de-gree. These are some of the qualities that make steel and iron indispensable in modern industry. The domestic consumption per inhabitant of the United States has climbed uniformly from 0.18 tons in 1900, to 0.36 tons in 1922. New kinds of machines and new types of structures are being devised every year; and steel or iron is the basis of most of them." It is unlikely that the Ontario Government were actuated by this motive when they appointed the Iron Ore Committee to investigate and report on the iron ore situation, nevertheless, these facts must have influenced them in some degree.

Jan 1, 1924

By J. Dong

"A “green” collector project has been initiated at Vale Base Metals Technology Development to replace xanthate. Bench and miniplant testwork showed comparable metallurgical results between xanthate and DTC (sodium dibutyl dithiocarbamate), a “greener” collector. During the first DTC plant trial, a strong interaction between the process water and DTC negatively impacted the metallurgy. The subsequent investigation showed that the quality of process water including suspended solids and dissolved metal ions had a significant impact on the performance with DTC, while less so with PAX. This paper explains these differences using UV spectrophotometry and batch flotation tests. INTRODUCTIONVale Base Metals is dedicated to sustainable mining and mineral processing. One of the key activities is to find a “greener” collector to replace xanthate (PAX: potassium amyl xanthate), which decomposes during storage and flotation causing CS2 emissions in the work place. As the most promising candidate, DTC (sodium dibutyl dithiocarbamate) was evaluated in the lab and miniplant (Dong & Xu, 2011). Consequently, a plant trial was conducted in the winter of 2010. However, the results were not as good as expected. The subsequent investigation showed that the quality of process water played a significant role in the metallurgical performance with DTC but less so with xanthate.From test work in 1996 and 1997, a series of batch tests were performed at Clarabelle Mill to investigate the winter/summer metallurgical shift with xanthate. As shown in Figure 1, the winter metallurgy was considerably worse than the summer metallurgy (Xu & Wilson, 2000). At 80% pentlandite recovery, the concentrate (Cu+Ni) grade was 21% in the winter and 26% in the summer. At 23% (Cu+Ni) concentrate grade, pentlandite recovery was 85% in the summer and 70% in the winter. In the summer, the process water is much cleaner, with very low concentrations of dissolved metals ions and suspended solids; while in the winter, the water is yellow and cloudy, with much higher suspended solids. Based on these results, it was concluded that the process water in winter has a detrimental impact on metallurgy."

Jan 1, 2012

By Boyd Davis, Brook Zaback

"Among the first published papers from Prof. Torstein Utigard was work on imaging the aluminum electrolysis process and in-situ measurements of aluminum in cryolite melts. He and Prof. Jim Toguri used an x-ray radiographic technique to measure interfacial tension of aluminum drops. Publications using this equipment for aluminum electrolysis spanned from 1985 to 2006. As well, other methods were used to better understand electrolysis in molten salts, including hot-stage microscopy, direct observations from above the bath and water modeling techniques. For chloride systems (for magnesium and lithium), it is possible to see side-on the electrolysis using a quartz cell. In honour of Prof. Utigard’s contribution to this field, this paper presents a summary of work on visualization of molten salt electrolysis, including work done at the authors’ labs and others around the world. The paper will summarize key findings and their possible impact on molten salt electrolysis."

Jan 1, 2015

By L. Vinnett, I. Panire, J. Yianatos, F. Ruiz

"The effect of operating variables on the flotation performance at steady-state has been extensively used for modelling and simulation of separation processes. However, the dynamic characterization of key variables such as gas dispersion (Sauter mean diameter of bubbles, D32, and bubble surface area flux, SB) and froth discharge rate is rather scarce. In this paper, an experimental design allowed identifying the dynamic response of the flotation process in a laboratory scale flotation cell, using a two-phase system, airwater. The installation included automatic control for the superficial gas rate, JG, and the pulp level. Gas dispersion was evaluated in terms of the Sauter mean diameter of a bubble population and the bubble surface area flux, SB = 6·JG/D32. The D32 was measured using the McGill Bubble Size Analyzer (MBSA) along with a semiautomated algorithm. In addition, the froth discharge velocity was measured in real-time using a Visiofroth system. The control variables were the superficial gas rate and the frother concentration (Teefroth). The dynamic characterization of the flotation process is useful to design algorithms that allow the direct or indirect control of metallurgical variables such as flotation rate, concentrate grade and mineral recovery.INTRODUCTIONGas dispersion indicates the way the gas entering a flotation machine is dispersed throughout the volume of the equipment (Schwarz & Alexander, 2006). The gas dispersion is typically characterized in terms of the bubble size (dB), gas holdup (eG), superficial gas rate (JG), and bubble surface area flux (SB =6·JG/dB) (Finch et al., 2000). All these variables have significant impact on the metallurgical performance of flotation machines. For example, Perez-Garibay et al. (2014) investigated the effect of the particle size, bubble size distribution, superficial gas rate and collector dosage on the flotation performance, for the separation of a sphalerite mineral. The authors observed that recovery increased with the superficial gas rate ranging from JG = 0.04 to JG = 0.08 cm/s and also a maximum recovery was obtained for bubble size close to 300 µm. Gorain et al. (1998) reported a strong correlation between the flotation rate constant and the bubble surface area flux in a zinc cleaner circuit. Both variables were directly proportional at three froth depths in the range of hF =7 - 45 cm. Dobby & Finch (1986) incorporated the effect of the superficial gas rate and the bubble size on the flotation efficiency by means of a kinetic model for the rate constants. Yianatos & Contreras (2010) developed a model to estimate the carrying capacity in large flotation cells by including the bubble surface area flux."

Jan 1, 2016

By A. Ducastel, S. Connemann, A. Stark, F. Bouillot, C. Fricke-Begemann, LSA, H. Knapp, L. Horckmans

"Refractory materials are essential for all high-temperature applications in industry. Depending on the position in the furnace and specific process requirements, refractories are produced from several raw materials, such as dolomite, magnesite, bauxite, graphite or chromite. Most of these raw materials are not rare but strict quality requirements limit the producers of refractories to only a few deposits in the world. Thus, raw material supply is a critical factor for the production of refractories and accounts for 40-50 % of the total costs of refractories.A possible way to lower dependency on raw material supply is recycling of spent refractories. Main challenge in recycling is the separation of different brick types from each other and the removal of impurities, such as steel or slag. The European FP7 project REFRASORT aims to apply sensor-based sorting for separation of spent refractories. Sensor-based sorting is known from food industry, recycling and mineral processing and has proven its reliability. Nevertheless, some adjustments are necessary compared to applications in mineral processing because of other sensor-types and a higher number of products in one sorting step. This paper presents the results of feasibility tests for sensor-based sorting of refractories with near infrared spectroscopy and laser-induced breakdown spectroscopy (LIBS). Both sensors showed the potential to identify different brick types but the most promising results were obtained using LIBS technology. INTRODUCTIONRefractories are solid, ceramic products, which can sustain temperatures of more than 1500°C, without losing their stability or shape. Bricks of refractories have to withstand corrosion in contact with liquid steel or slag. Various high temperature applications, such as the production of glass, steel, copper or cement, require high quality refractories. The quality requirements of refractory bricks are strict, because small impurities can lower the thermal strength significantly."

Jan 1, 2016

By J. F. Adams, V. G. Papangelakis

Chemical modelling is becoming increasingly useful in the development, analysis, design, and control of hydrometallurgical processes. The paper presents the development of reliable databases for chemical modelling of selected hydrometallurgical systems using state-of-the-art software, such as OLI. The modelling strategies are also demonstrated. The high pressure acid leaching (HP AL) of laterites, oxygen solubility in the oxidative leaching process of zinc sulfide, gypsum solubility and lead chemistry in mixed sulfate-chloride solutions are presented as case studies. This on-going work attempts to bridge the gap between theoretical research and industry needs. Computational Analysis in Hydrometallurgy 35th Annual Hydrometallurgy Meeting held in conjunction with the 44th Annual Conference of Metallurgists ofCIM Calgary, Alberta, Canada Edited by

Jan 1, 2005

By Alessandro Navarra, Roberto Parra, Boyd Davis, Frank Mucciardi

A smelter scheduling algorithm has been developed, which allocates the oxygen production between the smelting furnace and the converter aisle, so as to maximize copper throughput. The algorithm is intended for daily operation planning, controlling the sequencing of the converter cycles, and the oxygen drawn by these cycles. In some cases, it may be worthwhile to decrease converter oxygen allocation in favour of the smelting furnaces. Thus, a better utilization of the oxygen plant can increase primary copper throughput by several percentage points. This principle is demonstrated through sample computations. The approach presented in this paper can be incorporated into smelter management software.

Jan 1, 2015

By L. E. Puddington, A. L. Mular

"Since the inception of spherical agglomeration, few investigations to exploit commercially the technique in the metallurgical field have been conducted. Of these, none appear to have been carried sufficiently far to demonstrate commercial feasibility.This paper describes a continuous agglomeration-separation process that can rapidly handle large tonnages of ore material. A small pilot plant de-signed from information obtained with the semi-batch unit described herein is currently in operation.In the absence of a reagent recovery system or cheap reagents, the process is probably not economically attractive for many common ores. However, for iron ores, the fuel content of the agglomerates can be used in a subsequent step such as direct reduction."

Jan 1, 1968