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By Curtis Rempel, John Bartlett, Alex Holtzapple

METSIM is a powerful program capable of modelling and simulating every known metallurgical and inorganic chemical process. METSIM is used by companies throughout the world to design, simulate and control operations from mine to tailings and everything in between. At its absolute simplest, METSIM can be used to create a process flowsheet. METSIM modules and built-in unit operations cover mass and energy balances for either steady-state or dynamic simulations of mine, stockpile, heap leach, material handling, comminution, beneficiation, hydrometallurgy, pyrometallurgy, gas and steam handling, and tailings management processes. Data for the material being processed can include mineralogy, particle size analysis, grade by size or multicomponent size analysis, washability data, mechanical, physical and thermodynamic properties. METSIM is written in APL (A Programming Language). Unlike C++, APL is simple and easy to learn, allowing the user to program whatever they can imagine, without first obtaining a degree in computer science. METSIM can also interface with EXCEL and other software through dynamic data exchange (DDE), allowing data to be imported and exported for viewing, analyzing and controlling. METSIM can answer simple or complex metallurgical and process questions allowing the user to predict and engineer without the issues of clumsy and tortuous spreadsheets.

Jan 1, 2014

By G. Q. Liu

"The application of oxygen-enriched cyanidation to three Canadian gold ore samples has been investigated. The results showed that the use of oxygen can improve gold dissolution kinetics, reduce grinding time, and lower cyanide and lime consumptions. To obtain the same gold extraction, the required cyanide leaching time was reduced from 48 hours in slurry containing 8 ppm O2 to 12 - 24 hours in 20 ppm O2 slurry. Reagent consumptions were reduced by 23 - 37% for cyanide and by 35 - 54% for lime. There was little advantage to further increasing the dissolved oxygen to 32 ppm from 20 ppm. Gold extraction from the +200 mesh fraction improved 4 - 14% in oxygen-enriched slurry. A general kinetic model derived from the cyanidation of three ore samples can be described by the following equation: <equation>where E is the gold extraction (%) at time t (hours), EI is the ultimate gold extraction (%) , and &apos;P and k are constants depending on cyanide concentration, level of dissolved oxygen, and the characteristics of the ore samples. Comparative studies of conventional carbon adsorption and carbon adsorption in oxygen-enriched slurry have also demonstrated that oxygen enrichment resulted in more favourable conditions for gold adsorption."

Jan 1, 1995

By J. Koponen, M. van de Vijfeijken, L. Bos

"The availability and reliability of large grinding mills and their Gearless Mill Drives (GMDs) are of paramount importance for the grinding process. Although GMDs have been in service for decades, and are known for their operational efficiency (reliability and robustness with reduced operating cost per ton), compared to conventional drives, in the last decade due to certain reasons some failures led to serious unscheduled shutdowns and significant insurance events.The majority of these notable ""insured"" failures have happened on GMDs installed on relatively large mills, as the financial impact of a failure is proportional to the through-put of the mill. Despite the occurrences of these events, as mining operations are driven by lower ore grades and the ability to continue reducing operating costs per ton, the trend for having larger mills is still very present and there is no reason why this trend should not continue.It is obvious that if not handled correctly, the possibility of large value GMD loss events, coupled with the continuing increase in mill size or required availability and reliability targets, could potentially lead to major conflicts as it becomes difficult for the insurance companies to judge the risk and hence may result in hesitation to insure these grinding circuits. This paper will not only describe the conflicting situation from both an insurer&apos;s perspective and from an equipment supplier&apos;s perspective, but also how these conflicting challenges can be successfully mastered. It has to be noted that not only the mining companies themselves, but also their insurance companies and the involved equipment suppliers have a common interest: to reach the highest availability and reliability in order to avoid or at least minimize unscheduled shut down times, and most importantly prevent unplanned events that result in extended production stoppages or reductions in through-put of GMD driven mills.From the very beginning onwards, the complete service concept together with emergency plans must be integrated on every level in the design of the grinding circuit. This approach must be implemented continuously and without compromises by all involved parties during all following stages, such as basic design, detail design, manufacturing, quality inspection and testing, packing, transportation, storage, installation, commissioning, operation and maintenance. The concept of formal risk analysis related to mill operations, maintenance and spare parts strategies must be an integral part of mining companies’ decisions related to the selection for installation and continued use of large mills powered by GMDs. The service concept in place for operating mills shall also have a clear focus on very early detection of any abnormalities, so that the risk can be mitigated and unscheduled shutdown times avoided. However, if a major failure occurs, then procedures and tools shall already be available in order to ensure that production impact is minimized."

Jan 1, 2012

By T. Negeri, M. Boisclair, A. Bouajila

CanmetMINING has been working on process development for separation and concentration of rare earth bearing minerals from various ores. Among others, the flowsheet development for the Montviel Rare Earths/Nb deposit, located at the north end of the Abitibi region in Quebec and owned by GeoMegA Resources Inc. (GeoMegA) is now at an advanced stage. The concentrate produced by a flotation-only process at the early stage of the project accounted for higher than 90% TREO and Nb recovery in 40% mass. This concentrate was submitted to SGS Lakefield for hydrometallurgical processing. Lixiviation of the concentrate using hydrochloric acid yielded approximately 99 % REE. An overall (from ore in ground to final precipitate) REE recovery of 80% was obtained through a series of selective precipitation steps. Recently significant additional developments have been made. CanmetMINING is steadily improving the quality of concentrate produced through a simplified, more efficient flowsheet which consists of flotation, magnetic separation, and a thermal treatment procedure. The paper discusses aspects of the process that allowed obtaining 82% recovery of TREO and Nb in 16% of mass, the best result to-date.

Jan 1, 2014

By B. Dubreuil, J. -M. Lalancette, D. Lemieux

Arsenical bearing deposits are posing an increasing challenge for the mining industry. In particular, mineral processing of arsenical sulfidic ores for base and precious metals recovery tend to produce problematic arsenical tailings. This arsenic being present as sulphide or oxide, tends to dissolve, contaminating surface and underground waters. To meet the environmental regulations, it is often required to stabilize the arsenic in a more insoluble form. Dundee Sustainable Technologies has developed a new patented technology using vitrification of the arsenic oxide in an economical way, giving a stable solid, well below the environmental regulations upon leaching. This technology involves oxidation of As (III) to As (V), by using a low cost natural oxidizer and transformation of the produced arsenic oxide into calcium arsenate, which is not volatile at the melting temperature of the glass. This technology would be advantageously applied on most cases around the world where sulphide concentrates are oxidized in a fluidized bed or smelted.

Jan 1, 2014

By Lawrence Devon Smith

"The Management and Economics Society has undertaken a survey of industry practice in the evaluation of mineral projects. The survey addresses a number of issues relating to evaluation techniques, discounted cash flow methodology, and risk. Completed during the spring and summer of2005, the results provide a record of opinion at an active and vital time in our industry.The 2005 survey questionnaire was distributed by e-mail to groups and organizations around the world. There were 22 respondents out of several hundred questionnaires distributed (we gather this small proportion of respondents is typical for such surveys). The responses, although a small number, show a consistency that suggests that the survey has captured the views of the industry. The results of the survey are summarized below in series of tables and graphs.The reader is cautioned that the results are a snapshot of industry practice at a point in time as represented by a small sampling of the industry's practitioners. These results should be viewed as indicative values."

Jan 1, 2003

By D. T. Aikens, R. Gaudreault

"This paper summarizes structural repairs carried out on a marine wharf consisting of six 13.7 m by 13.7 m reinforced concrete cribs linked together by five 14.6 m long beam spans. As a result of problems during original construction and twenty years exposure to severe weather conditions, the deck support system between the cribs required major restoration work. In particular, some of the beam seats under the crane rail supports had marginal bearing area to support the structural loads. Faced with closure order for the wharf which is required to bring in raw materials to the plant and a long outage to make repairs as stipulated by Ports Canada (owners of the structure) alternate means of making the required repair were examined.The method chosen allowed the work to be done much more quickly, at lower cost, without taking the wharf completely out of service. The badly deteriorated seats were rebuilt using epoxy grout, tapered sole plates and a positioning jig."

Jan 1, 1988

By P. R. A. Andrews

"The sillimanite group minerals, kyanite, sillimanite and andalusite are identified as alumino-silicate minerals with the common chemical composition AIP3.Si02&apos; so that each possesses similar physical properties. Kyanite is the most abundant mineral and mainly occurs in Quebec, Ontario and British Columbia; sillimanite occurs in Ontario and Manitoba; and andalusite in Nova Scotia. The main use for the sillimanite-group minerals is in refractory applications for the production of refractory bricks and shapes. In refractory applications, the main performance criterion is the relative percentage of mullite formed within the material during firing. This phase gives a greater degree of resistance to creep deformation and slag attack, and improves the ability of the refractory to withstand high temperatures under load. The beneficiation of refractory silicate minerals has been the subject of many investigations at CANMET, and the former Mines Branch. Eighteen kyanite, two sillimanite, and three andalusite evaluation studies were conducted between 1933 and 1987. A review of some of the more important studies is presented, which includes information concerning mineralogy, beneficiation methods and flotation data."

Jan 1, 1995

By Donald Leroux, Robert Grant

"Flotation is a complex and highly multivariate process. Using the conventional OFf (one-factor-at-a-time) technique, the optimization of flotation circuits through laboratory or plant testwork is difficult, time-consuming and therefore, expensive and often results in marginal improvements. The optimal operating conditions can be more efficiently estimated when a systematic approach like SDE (Statistical Design of Experiments) is taken.The concentrator of Noranda's Brunswick Mining Division (near Bathurst, New-Brunswick) is well known for the complexity of its differential copper-lead-zinc flotation circuits. One of them, the chalcopyrite-galena separation (or CuSep) circuit, is impacted by more than 20 variables.Statistical Design of Experiments (SDE) techniques were applied at the laboratory scale to improve the performance of Brunswick's CuSep circuit. Screening tests were conducted using Fractional Factorial designs while optimization tests were carried out based on Response Surface Modelling techniques like the Central Composite design. Every series of tests, without exception, revealed new information and process insights which led to significant circuit performance improvements in the plant So far, the metallurgical gain may be as high as four percentage points of copper recovery (in the CuSep circuit). Potential cost savings of expensive consumables (steam, activated carbon) have also been identified but will require additional circuit modifications before being realized.IntroductionIn spite of its apparent simplicity, flotation is a complex three-phase (solid, liquid and gas) separation process. Fundamentally, it is a highly multivariate process. Industrial flotation circuits are commonly affected by 10 or more process variables."

Jan 1, 1997

By H. Henao, E. Kohnenkamp, L. Rojas

The slags generated in the copper conversion process are mainly composed of Cu2O-Fe2O3-SiO2 with the compounds CaO and Al2O3 in concentrations up to 10 wt%. The present work contributes to the knowledge of the conversion process, generating experimental data for the diagrams of phases Cu2O-Fe2O3- SiO2-Al2O3 and Cu2O-Fe2O3-SiO2-CaO. The experiments were carried out in a tubular furnace at temperatures of 1150°C and 1200°C under a condition of saturation with tridymite. Once the equilibrium was reached, the samples were fast quenched in water. The phases in the samples were observed in a Scanning Electron Microscope (SEM) and the elemental composition of the phases analyzed by means of Energy-dispersive X-ray spectroscopy (EDS) detectors. The addition of Al2O3 and CaO into the Cu2O-Fe2O3- SiO2 system resulted in an appreciable displacement of the liquidus lines, corresponding to an expansion of the liquid in the tridymite primary phase field. INTRODUCTION The conversion process of copper consists of oxidizing Fe and S present in mattes with 60 to 65wt% Cu (up to 16wt% Fe). This process is separated into two stages: 1- Slag blowing: Fe is oxidized, the addition of a flux such as SiO2 (silica) forms a second liquid phase called slag, this phase is removed from the furnace; 2-Copper blowing: in this stage, the matte with low concentration of Fe (<1% w/w) is again oxidized to remove S as SO2 in the exhaust gases. The product of these two processes is the formation of Copper Blister (> 98wt% Cu) (Schlesinger et al., 2011). Unlike the aforementioned conventional processes, in most Chilean smelters, conversion Peirce- Smith Furnaces are loaded with high copper matte (70–75wt% Cu) (Henao & Moyano, 2016). Due to the low concentration of iron in these matte (up to 5wt%), it is considered that separating the conversion process in two stages is neither operational nor environmentally convenient. Therefore, the process is carried out in a single stage (Pradena et al., 2006), generating a slag phase with a high percentage of Cu2O (wt%Cu>40).

Jan 1, 2019

By M. Timberlake, A. J. Jonaitis

"The DENVER Tube Press is a simple, high pressure (1500 PSI (100 bar)) filtration unit, developed for processing difficult-to-dewater materials and to produce a handleable filter cake and clear filtrate product.Lab and Pilot testwork conducted in Australia on coal fines (55-70% -35 micron (400 mesh)) have shown that total moisture contents of less than 20% are consistently achieved in the final cake products from the Tube Press.currently, these coal super fines are sent to waste due to uneconomical mechanical dewatering methods, which were only able to reduce total moisture levels in excess of 30%. Calculated, throughput rates for the 500 series Tube Press exceeded 1700 kg/hr (3750 lbs/hr). Feed solids concentration requirements are between 45 and 50% to achieve these results.INTRODUCTIONThe DENVER Tube Press is an automatic membrane high pressure filter press, which operates at hydraulic water pressures up to 1500 PSI (100 bar). The Tube Press was developed in the late 1960's by Charlestown Engineering, st. Austell, Cornwall, England, formerly a division of English China Clays, Ltd., to address more effective methods of moisture reduction of micron-size china clays. The Tube Press reduced moisture sufficiently to produce a hard surface-dry, handleable cake and clear filtrate discharge, which was recycled into the process. This development work was conducted using a 200 Series Tube Press (200 mm diameter x 2500 mm long filter surface)."

Jan 1, 1993

By H. Clare Horwood

"Three types of structures, the main shear zone, the north shear zone, and a series of hanging-wall fractures, contain all the orebodies so far discovered at the McKenzie Red Lake mine. Lenses and veins of quartz in these zones and fractures are the sources of the ore. The ore-bearing structures are unusual in that they are in a complex intrusive mass known as the McKenzie-Gold Eagle stock. They are believed to have been produced by compressive stresses from the south andsouthwest.The mine is on the northeast side of McKenzie island, in Dome township in the central part of the Red Lake area. The original discovery, the main shear zone, was made in 1928, about 3 years after the property was staked, by M. L. Bouzan who was in charge of prospecting and development work on the property. Subsequent diamond drilling and underground exploration led to the installation of a mill, which came into production early in 1935. The hanging-wall fractures were found branching out from the main shear zone during development work on the 350-foot level. The north shear zone was discovered in 1940.From 1935 when the mill began operation until the end of 1946 total production from the mine was approximately 269,349 oz. gold and 69,317 oz. silver, having a value of $9,679,739, recovered from 823,527 tons of ore.GENERAL GEOLOGYThe McKenzie-Gold Eagle stock has a total length of approximately 1 ½ miles and a width of about ½ mile. It was intruded into a complex synclinal fold in Timiskaming sediments. The sediments, which have been cut in only one place in the underground workings, are principally wellbedded greywackes. The stock is composed of large masses of diorite and granodiorite, a small mass of hornblende pyroxenite, and basic dykes of two ages. The diorite occurs as irregular masses in large measure surrounded by the granodiorite that it intrudes. It contains tabular crystals of andesine, having a maximum length of3/4 inch. The hornblende pyroxenite is an elongated lens or dyke in the diorite. The granodiorite masses occupy about two-thirds of the stock. Along its eastern side the main mass tends to become darker and more dioritic toward the diorite contact.Basic dykes of pre-vein and post-vein age are the youngest intrusive rocks at the mine."

Jan 1, 1954

By Jeffrey D. Eisenman

FRP is a proven material for the solvent extraction processes of copper production. There is a history of successful applications of FRP piping and equipment in hydrometallurgical processing. The performance of FRP equipment has not always been consistent, but at no fault of the material. Its non-metal attributes and behavior vary from those of more typical materials of construction, such as steel and alloys. FRP is a mainstay material in many areas of solvent extraction and electrowinning and yet not well understood by all. We will discuss the critical concerns, which are key to reliable performance of FRP systems. This paper will include discussion of key elements, which are fundamental to reliable FRP piping design and considered best practices. Essential design and construction considerations to maximize reliable service life of FRP equipment, such as thickeners and process vessels, used in copper extraction and processing, will be discussed. Additionally, we will expose potential pitfalls and share lessons learned from previous copper processing plant projects, which can aid and impact other copper processing projects to ensure best system performance and reliability. INTRODUCTION The corrosion resistant attributes of fiberglass reinforced plastics (FRP) make it an attractive and cost effective material of construction in corrosive service applications that are found in copper processing. FRP is used all over the processing plant in seawater, brine and sulfuric acid services where the corrosive nature of these services would challenge most ferrous materials and coatings. FRP is a fully customizable material to meet the specific needs of each service and process. FRP piping and equipment can be found throughout the hydrometallurgical process, in the acid plant, desalination, leaching processes, solvent extraction and electrowinning to name a few. Beyond its superior corrosion resistant characteristics, FRP can be made abrasion resistant by introducing particulate additives into the resin, such as silicon carbide and alumina oxide. Because many of these services have combustible organic elements in the flow streams with accompanying safety concerns, the linings can be made conductive with carbon fibers to dissipate static charges that might collect on the surface of the equipment otherwise. Further, FRP can be made flame retardant as well, where flammability may be of concern.

Jan 1, 2019

By S. Kaushik

The control room in a mineral processing plant has become increasingly complicated with complex unit operations coupled with rapidly evolving systems of sensors and control. Even with significant automation, human intervention is required to counter various scenarios that play out every day. A typical control room operator must monitor over 300 individual points of data in order to ensure the safe and efficient operation of the plant. At the same time, the experience of the workforce is decreasing as operators retire and the new generation enters the concentrators. Global competition for skilled operators continues to be strong and the opportunity to apprentice has diminished. The challenge is to provide a skill foundation for the operators so that they can be effective in the concentrator in a timely and safe manner. Progressively, the industry is turning to dynamic simulation tied into the control system. The simulator environment operates behind the control system to emulate the plant operation, reacting as the plant would when a change is made. The operator drives the process, with realistic feedback, which enables learning in a safe environment. This paper will take the reader through a green-field case study and discuss the effectiveness of integrating an operator training simulator (OTS) on the operator’s learning curve.

Jan 1, 2014

By Sarah Bélair, Denis Beltrami, Deka Moussa Ragueh, Valérie Weigel

"Scandium is a highly valuable element belonging to the rare earth elements (REE) but it has different chemical and physical properties from those of lanthanides. This metal is generally used in aluminum-scandium alloys and in fuel cells but the development of its market is slowed down by its high price (more than 1000 US$/kg for a 99.0% grade product). Indeed, the low scandium content in the continental crust (an average of 22 ppm) and the difficulties to extract it selectively from solutions containing high impurity concentrations increase the cost of the recovery processes. Nowadays, scandium is primarily recovered as a byproduct.ERAMET is developing a hydrometallurgical process in Gabon (Mabounié) in which the scandium content in the deposit reaches 10 to 100 ppm. The Maboumine project consists in the extraction and purification of uranium, niobium, tantalum and REE from Mabounié ore. In the frame of this hydrometallurgical project, ERAMET had also studied the feasibility to recover scandium as a byproduct. During the ore leaching, uranium and rare earth elements including scandium are solubilized into the pregnant leach solution (PLS). Among the various methods investigated to recover scandium from the PLS, liquid-liquid extraction using Primene JM-T as extractant was chosen and tested first at laboratory scale and then at pilot scale. Selective stripping of the loaded organic was carried out by using phosphoric acid solution, allowing the selective recovery of scandium from thorium and zirconium partially extracted from the PLS by Primene JM-T under the process conditions."

Jan 1, 2016

By S. A. Kenzap

This paper provides an overview and discussion of key aspects of operating risk valuation in underground metal mining systems, with impact on project economics, using stochastic computer modelling in Discounted Cash Flow (DCF) analysis. Mine operating risk classification and assessment for ground, equipment and scheduling aspects are presented with an overview of available risk valuation tools that have been developed in engineering disciplines. The classification is organized by keeping in perspective the mine design needs and constraints, as well as the potential economic impact that operating problems can have on an underground development and production system. These sources of cost, revenue and time delays are tabulated to enable the hierarchization of potentially hazardous unplanned events occurring during the mining project life cycle. In complex technological systems, like the underground mining systems, the decision-making process involve a wide range of uncertainties, and often this is based on subjective and qualitative expert evaluations. Whether a qualitative or quantitative analysis is conducted, it is often the case that the probability of a certain project parameter value needs to be estimated. This requires use of methods and techniques to handle subjective, qualitative measures and to combine them with quantitative stochastic modelling in order to evaluate mine operations-related issues on DCF economic performance measure parameters. Links are established between decision making and the risk-based mine planning process for evaluation of design alternatives, with emphasis on the need of introducing flexibility in mine design. Finally, challenges of risk-based mine planning and design implementations are discussed and the call for an integrated risk-based real options systems valuation (ROV) ?in? projects analysis is made.

Aug 1, 2013

By M. Feinendegen, Ph. Siebert, C. Clauser, K. Willbrand, M. Ziegler

"Three institutes of RWTH Aachen University collaborate on laboratory tests and numerical simulations of hydraulically driven fractures in igneous rocks. The project´s target is to enhance the understanding of hydraulic induced fractures for deep geothermal energy exploration. Based on the idea of creating new discrete fractures in hot dry rock (HDR) reservoirs, the current project stage deals with this process on a laboratory scale. Especially for this purpose, a new testing facility has been developed and laboratory tests are performed to verify a hydraulic fracture propagation code based on the extended finite element method (XFEM). The testing facility enables us to initiate and propagate fractures in large samples of dense rock under triaxial confining pressures and to monitor the fracture propagation by extensive measurements. This contribution gives a short introduction to the project‘s background and mainly focusses on the test facility, the experimental procedure and exemplary results.INTRODUCTIONThe most efficient technique to increase the permeability of subsurface rock is to initiate and open fractures by applying hydraulic pressure from a packed borehole-section and to inject fluid into these fractures to propagate them. Since its first use in petro industries to enhance the production of wells in natural gas and oil reservoirs, the interest in targeted creation of hydraulic fractures has increased exponentially. As the key technology to the extraction of unconventional gas from shale, hydraulic fracturing (HF) became a major topic in a heated public debate. Based on the fact that a fracture tends to propagate in a direction perpendicular to the minimal principal stress, hydraulic fracturing has become an established tool for estimating geological stress states in almost any depth. Enhanced geothermal systems (EGS) in HDR reservoirs use engineered fractures as a heat exchanging system for a cycling fluid driving a power plant."

Jan 1, 2015

By Paul Johnston

or is it? Mining Automated Loader Technology Application ? Intelligent software mounted in hardware on a remotely controlled scoop. ? Led by INCO, Sudbury, with ? C-CORE, St. John?s ? Automated Mining Systems, Aurora ? Bell Canada, Sudbury ? Laurentian University, Sudbury ? University of Western Ontario, London Completed: March 2000

May 1, 2008

By M. Pawlik, E. Arinaitwe, V. Ferrera

A series of flocculation tests were performed on dilute quartz suspensions with the use of five polyacrylamide-based flocculants of similar molecular weights but of different degrees of anionicity. The tests were performed as a function of ionic strength and pH. The macromolecular conformation of flocculants in solution was assessed through intrinsic viscosity measurements under the same physicochemical conditions as those of the flocculation tests. It was generally found that the flocculating efficiency of the polyacrylamides correlated with their ability to coil or stretch in solution. Polyacrylamides with the degrees of anionicity on the order of 10-18% showed the highest flocculating efficiency in terms of the settling rates of the flocculated solids and the residual turbidity of the resulting supernatant. At the same time, these most effective flocculants were also found to exhibit the greatest tendency to coil and stretch in solution. This result suggests that the flocculating power of a flocculant is determined not only by its ability to adsorb onto (and bridge) fine particles but also on its ability to conform to the size of the resulting floes.

Jan 1, 2009

By Avi Nanda, Robert Brandt, Alex Piatkiewicz, David M. Jones

In 2010 the United States Environmental Protection Agency (UESPA) revised the National Ambient Air Quality Standards (NAAQS) by lowering the permissible value to a 1-hour average SO2 concentration of 75 ppb. In 2012, the USEPA designated the Miami area as non-attaining for the new SO2 NAAQS. A number of options were studied to assist in bringing the Miami smelter into attainment with the new standard. The chosen solution included: Installation of a large tertiary hooding system over the converter aisle; Hooding of the anode vessels and treatment of the anode gas in a baghouse; Installation of a large 2,325,212 Nm3/hr caustic scrubber to treat the captured converter fugitives and anode off-gases; Installation of a secondary ESP for the tapping fugitive off-gas treatment system; and the continuous scrubbing of all acid plant tail stack gases. The modifications have reduced smelter SO2 emissions by 85%, achieving a world class SO2 stack emissions rate of 0.45 kg of SO2/tonne Cu. INTRODUCTION The Freeport McMoRan Miami smelter has been previously described in literature (Steinborn, Pasca, Sallee, Binegar, Bhappu). For the sake of brevity a brief description is given here. The Miami smelter is located 129 km east of Phoenix, Arizona near the town of Miami, Arizona. The smelter was established in 1915 and has undergone a number of process upgrades and modernizations over the years. The present smelter consists of an Isasmelt furnace, an electric settling furnace, four Hoboken converters, two anode refining vessels & one casting wheel; and one double contact sulfuric acid plant. Concentrates are railed & trucked to Miami from four Freeport McMoRan mines located in Arizona & New Mexico. The wet concentrates, typically containing 10% H2O with a Cu/S ratio of 0.85, are smelted in an Isasmelt furnace to a matte grade of 58%. The entire output from the Isasmelt is laundered into an Elkem electric furnace (originally installed in 1972 as the primary smelting furnace) for separation into matte and slag. Slag containing 0.85% Cu is skimmed from the electric furnace and discarded. Molten matte, containing 60% Cu, is tapped from the electric furnace and processed in one of four Hoboken converters to produce blister copper. Two anode refining vessels further refine the blister copper before the final product is cast on a single, 30 mold, casting wheel. All of the anodes produced at Miami are shipped to the Freeport McMoRan electrolytic refinery in El Paso Texas for refining into cathode copper. Smelter off-gases from the Isasmelt, electric furnace and Hoboken converters are combined and treated in a double contact acid plant to produce sulfuric acid. Acid produced at Miami is internally consumed at Freeport McMoRan mines in the region.

Jan 1, 2019