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By G. Lucas

"Material substitution occurs continuously in response to competitive and economic pressures. Technical development can accelerate or slow substitution by improving the performance of the invading or defending material. The choices are seldom simple and have to be made in the context of continuous commercial change.The development and commercialization of a new aluminum material is examined. The material has been introduced into· several different markets, so it is possible to compare and contrast the degree of success obtained in each.IntroductionAluminum-based materials have been in use for over one hundred years and , therefore, the development of a new family of alloys is rare. In the early 1970s, Dr. L.R. Morris and his coworkers at Alcan' s Kingston Research Centre started work on what was, at the time, something of a scientific curiosity-a family of alloys strengthened by an unusual mechanism.This paper deals with the development and commercialization of what became known as the Alcan 255 alloys"". These alloys have found uses in several markets, usually as improved substitutes for existing materials. Forecasting the usefulness of a substitute material in an existing marketplace is difficult, in part, because even material users are seldom able to specify precisely their requirements. This uncertainty can cause the failure of some substitutions but can also lead to opportunities which were not initially obvious.Technical BackgroundPure aluminum is a soft, weak material. It can be strengthened by the addition of various alloying elements and by work hardening. Alloying elements usually act by forming solid solutions which are stronger than the pure metal or by precipitating during heat treating or aging and so preventing the easy movement of dislocations during deformation. Elements which can perform either role had been investigated for decades and were thought to offer little chance of technical breakthrough in 1970. An outgrowth of the then new and exciting research on directional solidification seemed, however, to offer such promise.Some aluminum-iran-manganese alloys will solidify under certain conditions as 'coupled growth' eutectics (Figs. I and 2). The microstructure shows one phase growing as long rods through the other. This is an uncommon structure and it was investigated to see if it had equally unusual properties. On deformation by rolling the rods were broken up into small equiaxed , evenly-spaced particles (Fig. 3). Materials with this structure were found to be stronger than other alloys with similar amounts of alloying addition, and to resist thermal softening remarkably well. This combination of properties was thought initially to be due directly to the particles by a dispersion strengthening mechanism, but later this was found not to be strictly true."

Jan 1, 1987

By P. F. Berry

X-ray fluorescence analytical techniques are fairly well established in the mining and metallurgical industries. In recent years, instruments utilizing radioactive isotopes have been developed which, owing to their more compact size, greater reliability and independence of substantial power supplies, are often preferred to X-ray tube installations. Analyses can now readily be carried out in the field, on the factory floor and in otherwise difficult locations. This paper describes many examples of radioisotope X-ray fluorescence for the analysis of metallic minerals, finished metals and alloys and also for the continuous measurement of metallic coatings, such as tin and zinc, on steel. Radiation scatter techniques are also described for certain analyses and for thickness and density measurements.

Jan 1, 1967

Strengthening a mine with the Power of their Employees: ?Imagine if the global economy collapses, your head office calls, and tells you to shut down for 3 months... now what do you do? ? HVC Business Improvement Initiative Why did we need help ? External Events ? How we responded ? How we worked with Westwind ? Alignment ? Priorities ? Coaching ? Focus Groups ? Innovation ? What worked / Opportunities ? Questions

Nov 1, 2011

By Veronique Falmagne

"In 1987 the only knowledge available of the Ansil orebody was that it was high grade, deep and relatively small . High stresses were also anticipated because there had been rockbursts during shaft sinking and destress blasting had been necessary (Fig. 1). From the design, through the development and now in the mining stage, rock mechanics and microseismic monitoring have been used to maximize recovery and safety and minimize dilution. Examples are given of the use of a microseismic monitoring system in the early stages o f mining. This paper also presents a review of the mine's in situ stress measurement campaign, cable bolting practice and backfill procedure.The Design PhaseAfter the initial mapping and classification work, preIiminary numerical modelling was performed using assumed stresses of ov = oH and oH = 3ov• The empirical Mathew's analysis was then used to optimize stope dimensions based on geomechanics data available at the time (Bawden et 01., 1988; Falmagne, 1987; Potvin et 01., 1988). Because of high stresses predicted by numerical modelling and a brittle, strong and relatively unfractured host rock which was believed to be rockburst prone, it was decided to mine without temporary or permanent pillars. However, in order to satisfy production rates, the orebody had to be broken up into two horiwns separated by a triangular pillar (Fig. 2). The final mining sequence is shown in Figure 3.The Development PhaseAt this point, based on work accomplished to date, including mapping and observations from drifting and modelling, the following problems were identified: (1) flat backs in the hangingwall andesite were thought to be highly stressed; (2) flat backs in weak massive sulphide ore would also be subjected to high stress and be difficult to support; (3) the felsic dyke was noted as a "" stress raiser"" , because activity increased as drifts approached it; and (4) chlorite coating of joints in the hangingwall was thought to be an important factor in reducing their stability."

Jan 1, 1991

By R. C. Beard

"Heap leaching, currently being applied in the treatment of low-grade ores in the south western United States, is shown to have potential for use in north western Ontario. The history and operation of the process are described, and cost comparisons are given.IntroductionHeap leaching is a simple, low-cost method of recovering gold from low-grade ore. Although it is not currently being used in Canada on a production scale, it is being used extensively, and successfully, in the southwestern United States as well as elsewhere in the world. Especially suited for large deposits of very low -grade ore, it also appears to be practical for use on small, high-grade deposits because it avoids the high capital costs of mills. Eveleth (1980) and others suggest that the capital and operating costs required for heap leaching are approximately 20% and 40% respectively of conventional milling methods.Northwestern Ontario is noted for its large number of undeveloped, small, high-grade gold deposits. Although there are a number o f larger and higher-grade deposits in the area as well, it is the relatively small undeveloped deposits which would benefit most from heap leaching, if it could be demonstrated to be a viable extraction method.To assess the significance of these small deposits, the Ontario Ministry of Natural Resources recently commissioned a consultants' study of the gold reserves in certain parts of northwestern Ontario. This report, titled ""Feasibility of Small-Scale Gold Mining in Northwestern Ontario"", by J.N. Neilson and R.C.E. Bray (1981, OGS Open File Report 5332), documents 106 known gold deposits having sufficient information to calculate gold reserves. A total of over 7.8 million tons having a weighted average grade of 0.19 oz of gold per ton were compiled in the proven, probable and possible categories, with an additional 8.2 million tons in the speculative category. Many of these deposits could be mined by open-pit methods."

Jan 1, 1983

By C. Blawert

In spite of various corrosion studies on HPDC AZ91, there is no clear indication which microstructure gives the best corrosion performance. The skin with its fine microstructure is sometimes reported to have the best corrosion resistance, but there is no clear definition of the skin. If the skin is the outermost part of the casting and nothing is removed from it, then it is contaminated and the corrosion resistance is low. If the outermost skin is removed (about 25 µm) then a better corrosion resistance can be obtained. However this does not automatically mean that there is no other region in the bulk of the casting which could have a similar or even better corrosion resistance. Indeed, the corrosion measurements including potentiodynamic polarization and long term electrochemical impedance spectroscopy (EIS) revealed a lower corrosion resistance of the original as-cast skin about 100 pm thick. The thickness of this region is more or less independent from the thickness of the casting section. The surface region is free from any dendritic grain growth which influences the amount and distribution of the 13-phase and therefore the distribution of the most important alloying element Al. This could explain the different corrosion behavior. Further reason can be found in the enrichment of some impurities such as Fe in the near surface.

Jan 1, 2006

By Wayne N. McKee, Scott A. Lewis

"Introduction to the Syncrude OperationSyncrude Canada Ltd., located 42 km north of the city of Fort McMurray, Alberta, (Fig. I) is an integrated operation that has produced synthetic crude oil from the Athabasca oil sand deposit since 1978.The operation, consisting of a surface mine, an extraction plant, a bitumen upgrader, and a utilities plant, is currently capable of producing over 60 million barrels of crude oil per year. Production is expected to increase to 70 million barrels of crude oil per year over the next five-year period with no major changes to equipment or process planned.The Syncrude surface mine, producing a total of 675 000 tonnes of ore and waste per day, rates as one of the largest mines in the world. A strip mining method is utilized, with two or three operating benches necessary to excavate a total depth varying between 60 m and 70 m. The 20 m to 30 m of overburden is removed by electric and hydraulic shovels and 200-ton haul trucks, and dumped in the mined-out pit for final storage. The overburden operation creates a flat bench near the top of the ore zone on which the four 60 m3 draglines operate. The draglines excavate interbanded ore and waste in the highwall, with ore placed on the operating bench in windrows, and waste returned to the mined-out pit. The windrowed ore is reclaimed by four bucketwheel reclaimers, and discharged onto a conveyor system for transfer to the extraction plant."

Jan 1, 1993

By Gilles Bonin

Structures and serpentinization patterns in the Thetford Mines peridotites are important characteristics indicating the necessary geological conditions which led to the development of chrysotile orebodies in Early Ordovician limes. These structures and serpentinization patterns are reviewed in this paper using the geology of LAB Chrysotile orebodies as a model. Structural aspects include parallel and transverse faults, parallel and transverse granite slabs, and orebodies, some of which trend clearly north-westward parallel to the accretionarymovement. Serpentinization patterns in the peridotite belt, particularly in the harzburgite, include primary pervasive mass serpentinization and secondary complete serpentinization. Listwaenites layers appeared along some faults and along some granite slabs as a result of hydrothermal alteration of the serpentine, following the emplacement of the devonian plutons to the south. These plutons as we/1 as other important lineaments, align with the structural pattern of Thetford Mines ophiolites. It is believed that these plutons are part of a heavy magma tic corridor resembling the Pilote-Mont-Louis corridor in the Gaspe (Doyon and Berger, 1997), and the Buchans' structure in Newfoundland (Hutchinson, 1984), both intersecting the Brompton-Baie Verte line.

Jan 1, 2001

By Thomas S. Falk, Nils G. Lindberg

The first industrial COBO (Cold Bound) pelletizing plant began operation in May 1975 at Trollhiittan, Swede n. A technical description of the process, together with operational experience with the plant, forms the basis of this paper.

Jan 1, 1976

By Alan Reed

"Afton Mines Ltd. (N.P.L.) operates an 8500-tpd open-pit copper-gold mine near Kamloops, R.C. The pit is currently 480 feet deep and will reach an ultimate depth of 800 feet. The east, south and west walls of the pit are composed of Triassic andesites (Nicola Volcanic Formation) and contemporaneous sub-volcanic intrusions of micro-syenite, microdiorite, diorite and picrite-basalt (Iron Mask Pluton). The north wall of the pit consists of Tertiary sandstones, shales and mudstones (Tranquille formation) and dacitic dykes, sills, flows and tuff s (Kamloops Volcanic Formation).The Afton copper-gold orebody (30 million tons of open-pit ore with a grade of 1.0 per cent copper, 0.016 oz/ton gold and 0.12 oz/ton silver) occurs within the Triassic Iron Mask Pluton adjacent to its faulted contact with Tertiary rocks. The Triassic-Tertiary contact is a complex fault system dipping 65 degrees southward and causing the Triassic rocks to overlie the Tertiary rocks. The detailed trace of this contact is very intricate due to the mutual interference of three principal fault systems.The dominant geological structures in both Triassic and Tertiary rocks are faults striking WNW and dipping 65 degrees southward, i.e. sub-parallel to the orebody (strike faults). Cross faults and oblique faults are abundant and highly significant in some sectors of the pit. The Tertiary sedimentary rocks show an early series of northwesterly plunging folds deformed by a later series of northeasterly striking folds. Major lithological and structural boundaries divide the pit into 8 structural domain s within which the pitwall slope stability is controlled by the local geological structures and lithology.Assay data from production blasthole samples and exploration diamond drillhole samples show a log-normal frequency distribution, with a fairly low relative variance. Variograms computed from production blasthole samples show good continuity with elliptical horizontal zones of influence which are truncated by the major faults that bound the ore zone."

Jan 1, 1983

By Ellie Condolios

Hydraulic hoisting offers a number ~f attractive features over conventional hoisting methods: small shaft space requirements; great flexibility of layout, including pick-up or delivery of the material at points distant from the mine shaft; low investment and operating costs. However, limited practical experience with this type of hoisting dictates that careful design and, frequently, extensive testing be done by competent engineers before large-scale installations are built. This paper covers the following: basic laws and design criteria for hydraulic hoisting installations; a description of a coal hoisting installation which has been in industrial operation since 1960, with a vertical lift of 600 feet and an annual capacity of 500,000 tons of -3 ~-in. coal; and a tentative appraisal of the process, including cost estimates. THE transportation of solids in water flowing through a pipe-line has, for a number of years, been common practice in dredging, public

Jan 1, 1963

By J. G. Thomson

Development of the Canadian North, a subject of growing national interest, must in part await the development of better forms of trans-port. The estimated 500,000 square miles of muskeg terrain in the north combined with the" scarcity of roads make essential the early development of special purpose muskeg vehicles. Good progress has been made in the last eleven years in classifying muskeg and some progress has been made in determining its mechanical properties. Limited travel is now possible through the use of special purpose tracked vehicles which have been built without adequate design data. A program to provide data which can be used to optimize muskeg vehicle designs began in 1957. The results of the second phase of this pro-gram are presented in this report. It is shown that vehicle performance in muskeg is directly related to the mechanical properties of the muskeg. Further, it is shown that good de-sign practice for tracked vehicles expected to operate in snow, sand, soft clays and loams is also good practice for muskeg vehicles. All indications are that muskeg mechanics is properly a part of conventional soil mechanics.

Jan 1, 1961

By S. S. Dimov, B. R. Hare

This paper describes two micro-beam analytical techniques(Dynamic SIMS and TOF-SIMS) which have become an intricate part of a comprehensive analytical approach for precious metal (PM) ore characterization and process mineralogy or deportment studies. The value of the D-SIMS technique is its capacity for accurate analysis in the sub ppm range along with the ability to produce high resolution elemental maps. The TOF-SIMS is significant for speciating and quantifying preg-robbed Au on the surface of carbonaceous material. In combination with traditional assays, the two techniques can provide invaluable information regarding the distribution of PMs within an ore along with providing insight into potential sources of PM loss in processing or where losses have occurred in process streams.

Jan 1, 2011

By J. J. Ferreira, M. L. Thurston, I. L. Chinn, D. M. Rose

"Concerns about using microdiamonds for resource estimation have been raised by workers because multiple diamond populations exist in many parts of the mantle source region, small diamonds in kimberlite could be exposed to proportionately greater levels of resorption and modification, and euhedral microdiamonds could crystallize immediately prior to kimberlite eruption. This paper addresses these concerns; discusses the geology of the mantle, the principal diamond host rocks, and the impact of mantle processes; compares micro- and macrodiamond properties and features; and outlines steps to identify and mitigate the risk of diamond resorption and its impact on the diamond grade-size relationship.RÉSUMÉ Des travailleurs se sont interrogés sur l’utilisation de microdiamants pour estimer la ressource; en effet, de multiples populations de diamants existent dans plusieurs secteurs de la région source dans le manteau. Des petits diamants dans la kimberlite pourraient être exposés à des niveaux proportionnellement supérieurs de résorption et de modification; de plus, des diamants idiomorphes pourraient cristalliser immédiatement avant l’éruption de la kimberlite. Le présent article traite de ces questions, discute de la géologie du manteau, des principales roches-mères des diamants et de l’impact des processus dans le manteau, compare les propriétés et les caractéristiques des micro- et des macrodiamants et définit les étapes pour identifier et mitiger le risque de résorption des diamants et son impact sur la relation entre la taille et la qualité des diamants."

Jan 1, 2016

By M. Kim, M. Ha

"The effect of red mud on the melting behavior of ferronickel slag was investigated by a laboratory-scale horizontal tube furnace. Melting and softening of slag samples fluxed with different amount of red mud was examined by in-situ visualization technique at temperature range from 1400 to 1550°C. FactSageTM 7.0 was used for the thermodynamic calculation of multi component system of ferronickel slag and red mud. Liquid phase area was extended to lower temperature by adding red mud indicating its suitability as a flux material. X-ray diffraction analysis confirmed the dependency of the phase changes on the red mud content. Microscopic observation by scanning electron microscope (SEM / EDX) clarified the phase transformations from olivine to spinel along with red mud additions.INTRODUCTION Ferronickel smelting by submerged arc furnace (SAF) is an energy intensive process performed at high temperature range 1500–1600°C. During the smelting process of saprolitic nickel laterite ore with a nickel content of 2.2–2.3 pct, a large quantity of ferronickel slag is being produced that account for 97 pct of ore charged. To achieve ferronickel grade of 15–20 pct Ni, electrical energy of 80 to 85 MW is used for the melting and reduction of nickel oxide (NiO) and iron oxide (FeO) in the ore (Rodd et al., 2010). Unreduced components, mostly MgO, SiO2 and partly FeO are removed from the furnace in a liquid slag form by a tapping operation. Due to the high melting temperature, forsterite (Mg2SiO4) based slag containing approximately 10 pct FeO requires typical process temperature of 1600°C. Flux in metallurgical process is a medium that decreases melting and operating temperatures while it increases fluidity of the liquid slags. Calcite and fluorite are examples of flux materials used for the ironmaking, steel refining and continuous casting process. Oxide systems based on CaO - CaF2 - SiO2 - Al2O3 - MgO cover most of the slag composition in ferrous metallurgy accordingly. Crucial operating factors for ironmaking and steelmaking slags are basicity (typically CaO/SiO2 ratio), viscosity and impurity levels. These are extensively controlled by the fluxes. General metallurgical fluxes such as limestone, dolomite and calcium fluoride are abundant in nature and supplied to steel mills at low prices. Meanwhile, in copper flash smelting process, silica is supplied with copper concentrate to remove iron oxide (FeO) generated from sulfide oxidation. FeO - SiO2 binary system formulates eutectic area at 25–38 pct of silica that has low melting temperature below 1205°C. Fayalitic system (Fe2SiO4) that has low viscosity (0.1 Pa·s) (Park et al., 2011) facilitates easy separation of slags from molten sulfide mattes. Recently, copper plants actively utilize recycled raw materials as a flux. Various recycled glasses are ground and fed to copper smelting process as a partial replacement of silica ore. Applying industrial wastes to smelting processes is advantageous since the operators can reduce the production cost remarkably. Not to mention the consumption of recycled materials can ultimately minimize the environmental risks and the waste management costs. The authors, therefore, investigated the reasonable waste materials that can be effectively used for ferronickel smelting process. Prerequisites for potential fluxing materials are non-recyclable property, low transportation cost and excellent performance as a flux."

Jan 1, 2017

By R. Pressacco

"IntroductionAgrium’s history in fertilizer production and marketing goes back to 1931. Today, Agrium Inc. is a world leader in the production, distribution, and marketing of fertilizers and related products to the agricultural industry. Agrium is the largest North American producer of nitrogen fertilizers, a major producer of phosphate and potash fertilizers, and a world leader in fertilizer wholesale distribution and retail marketing. The mine at Kapuskasing is located some 40 km southwest of Kapuskasing, Ontario (Fig. 1). It has been developed to supply high-quality, low-cost phosphate rock to the company’s Redwater, Alberta facility, where it is an ingredient in ammonium phosphate fertilizer production. The Kapuskasing mine is the only phosphate mine in Canada and will rank as one of the highest-grade phosphate mines in the world (Clark and Duncan, 1999). Apatite is the principal ore mineral mined at the Kapuskasing Phosphate Operations.GeologyThe first record of exploration in the area was from a program executed by Continental Copper Mines in 1955 which evaluated the magnetic anomaly located in the Cargill and Cumming townships for its base metal potential. Intermittent exploration of the base metal potential of this magnetic anomaly continued in the following years, until the phosphate potential of the area was first examined in 1974 by International Minerals Corporation which recognized the presence of a layer of apatite sands overlying the carbonatite host rocks.The local geology consists of a core complex of multi-phased carbonatite rocks which are surrounded by a ring of pyroxenite, and have provided a U-Pb age date of 1907 Ma ± 4 (Sage, 1988). These two rock types are in turn situated within quartz diorite gneisses that form a large portion of the Kapuskasing Structural Zone (Fig. 2). The carbonatite host rock is sub-divided into two sub-types: sovite and rauhaugite. The sovite is a medium- to coarse-grained, white, banded rock in which calcite is the dominant carbonate species and it includes accessory minerals such as phlogopite, magnetite, clinohumite, apatite, olivine, pyrrhotite, and amphibole. Apatite can reach 15% abundance in this rock type (Sage, 1988). In sharp contrast to the sovite, the rauhaugite appears as a massive, fine-grained, dense, beige to tan-coloured rock in which dolomite is the dominant carbonate species. Phosphate values can range to 14% P2O5 in the rauhaugite."

Jan 1, 2001

By J. A. C. Ross

Introduction To enlighten those who may be wondering where anyone could find sufficient data to write a paper on underground concrete work, the author would like to explain that, at Copper Mountain, we have found it necessary to line numerous headings with a layer of concrete in order to keep them in a safe and serviceable condition. The majority of these headings are scram drifts and ore-pass raises. This paper will therefore deal, in the main, with the methods of and reasons for placing concrete in these headings. During recent years, radical changes have been made in the methods of mining ore at the Copper Mountain mine. After considerable experimenting, a mining system has been developed making use of diamond drills for primary breaking and transfering such broken ore through scram drifts with slusher hoists. With the advent of scram drifts, it soon became apparent that some substantial means of reinforcement and protection for the scram drifts themselves would be necessary. Since the orebodies in this mine are cut by numerous dykes or faults, and often both, it was anticipated that some means of support would be required where headings necessarily passed through these incompetent zones. Further, as experience was gained, scram drifts were driven into pillars and in close proximity to old workings so as to recover the maximum amount of ore. In such places, the ground is often severely fractured, either as a result of previous mining or from the effect of excessive rock pressures.

Jan 1, 1950

By Jos. Kalbhenn

MR. G. G. BOWSER: Mr. Kalbhenn's paper is an excellent one and is a concise description of a very interesting piece of work. It is well known that a great deal of preliminary study was given to this job before the final plans were made. It is due to this thorough preparation .chat the work progressed so satisfactorily, smoothly, and safely. The ideas carried out in the construction of the hardwood pack, timbered compartment, inclined raise, loading chute, and steel-boomed room, all contributed to a successful conclusion of the work. The extra care in being certain that the compartment shafts were well timbered was especially necessary on account of the difficult blasting conditions. In other words, the foundations .of this job were well and truly laid. The blasting in this work was very difficult due to the nature of the Strata. Working under an ever precarious roof condition and completing .this job with only two lost-time accidents is a record of which to be proud. The shaft men engaged on this work are also due for praise. I regret I did not visit this work while it was in progress. It was not in lack of interest. This, however, more or less proves that the blasting end .of this job went along with practically no trouble. I have seen the nature of the rock, as I made several visits to the tunnels while they were being put through from the Phalen to the Harbour seam. According to figures in Mr. Kalbhenn's paper, the explosives consumption works out to 1.61 pounds per cubic yard of rock in the solid, or 0.8 pounds per ton. The explosives consumption in the tunnels ran from 2.86 to 3.46 pounds per cubic yard or an average of 1.58 pounds per ton of rock. Of course, the rock in the shaft was blasted in the most economical way possible, as far as powder costs are concerned, as the face advanced at close -wright angles to the strata and gravity was acting with the explosive. The tunnels were driven nearly 'end on' the strata and bottom holes had to be lifted, and I believe there was some re-drilling of ribs left in the floor. I would like to congratulate Mr. Kalbhenn on his very fine paper.

Jan 1, 1944

By George C. Coupland

"THE PRELIMINARY EVALUATION of the orebodies was computerized for tonnages and grades on a 20- by 20-ft grid. The evaluation was based on drill-core intersections over 40-ft vertical projections coinciding with the proposed bench intervals, taking the deviations of the drill holes into account. The computer print-outs gave an ore distribution and evaluation bench by bench and indicated the areas of varying mineralization. The two orebodies have a combined length of 2,200 ft. and a maximum width of 600 ft. They strike almost due north, dip about 85 degrees east and rake to the north. The computer print-outs were used to design an open pit with an over-all waste to ore ratio of 2.58:1. At the outset, the waste to ore ratio was 4:1. The pit is tear-drop shaped, with the narrow end to the south, and at the surface is 2,600 ft long by 1,800 ft wide. Ramps are 100 ft wide, with a 10% grade. The south ramp is left-handed, starts at the southeast and will continue to the bottom of the pit. A second ramp on the west and north walls runs from surface to join the south ramp at 7 bench. This ramp will handle the total pit production when part of the south ramp, from 4 bench to surface, is lost due to the underground operation. Over-all wall slopes are 53 degrees, and are laid out to avoid prominent protuberances which could relax and become unstable and potentially dangerous (Fig. 1) ."

Jan 1, 1974

By G. A. Bezuidenhout, J. Davis, S. M. Bradshaw, J. P. T. Kapusta, D. K. Chibwe

"This research work forms part of an assessment to complement the feasibility of implementing high pressure sonic injection into relatively small (2.25 m I.D by 3.66 m I.L) Peirce-Smith converters (PSC) used at Lonmin Plc. Work has been carried out to characterize the fluid dynamics of three-phase (air, matte and slag) fluid flow in these converters using Computational Fluid Dynamics (CFD) simulations. The investigation has been done to study the flow pattern of the three phase system at high air pressure injection achieving sonic velocity at the tuyere exit into the converter. The 2-D and 3-D simulations of the three phase system were carried out using the volume of fluid (VOF) and realizable k -e turbulence models to account for the multiphase and turbulence nature of the flow, respectively. These models were implemented using the commercial CFD numerical code FLUENT. A detailed study of the flow pattern has been presented in the form of contour plots and the results obtained are useful for understanding plume extension and velocity distribution, shear wall stress distribution, and phase distribution characteristics in the system. The results provide a basis for further development of sonic injection technology into relatively small industrial Peirce-Smith converters with the ultimate objective of achieving lower energy consumption, improved process efficiency and increased throughput of the converting process. INTRODUCTIONPeirce-Smith converters (PSC) have been used in copper (Cu) and nickel (Ni) making smelters for more than a century for the purpose of removing iron (Fe) and sulphur (S) chemically associated with copper-nickel mattes through exothermic oxidation reactions. This process is commonly referred to as conversion. In principle, conversion is a submerged injection process, where typically air (or oxygen enriched air), at subsonic velocity (typically < 150 m/s), is laterally blown into liquid matte (Cu-Ni-Fe-S system). Oxygen preferentially reacts with Fe and S to produce iron oxide (FeO), which is slagged off, and sulphur dioxide (SO2), which reports to the process off gas."

Jan 1, 2012