Search Documents

"Pilot plants for pressure hydrometallurgy represent special design and project execution challenges. Over the past twenty years, Zeton has designed and fabricated a variety of world-class pressure hydrometallurgical pilot-plant facilities, and this paper discusses design considerations and strategies related to such projects. Project execution methods are also discussed, and guidance is given for the selection of materials of construction and for the selection of appropriate pressure and temperature design points for pressure hydrometallurgical pilot equipment. The paper concludes with a discussion of the need for process similarity with future commercial operations and the realities of pilot-scale equipment.INTRODUCTIONThe process technology developer or owner and the designer/fabricator of a new pilot-plant facility are faced with some difficult technical choices even after the decision to build a dedicated plant has been taken. A pilot-plant project is usually on the critical path of a large commercial project involving investments many multiples greater than the capital cost of the pilot plant. Schedule savings in the design, manufacture, and commissioning of the pilot plant or in a rapid completion of the experimental program can be disproportionately beneficial to the overall development project. However, inappropriate shortcuts resulting in major oversights can be disproportionately problematic.A number of considerations and suggestions for both the project execution approach and the process engineering design of pressure hydrometallurgical pilot-plant facilities are presented as a guide for potential owners and operators of new pilot-plant equipment and facilities."

Jan 1, 2012

By P. Tittes, M. Deal, M. Spicher, S. McDaniel, J. Wickens

"Haile Gold Mine is located near Kershaw, South Carolina, approximately 50 miles south of Charlotte, North Carolina. Gold was first discovered at the site in 1827, and the property has been through several operating periods since. The relatively low grade and refractory nature of the deposit has been a challenge for efficient processing since the start of mining on the property. Early processing techniques included gravity separation and barrel chlorination. The last operation employed heap leaching in 1985 through 1992. After being closed and reclaimed for over 20 years, the property is poised to re-open and produce once again. In this chapter of the Mine’s legacy, flotation and ultra-fine grinding will be employed to achieve economic extraction of gold and silver from the pyrite. This paper briefly reviews some of the mine’s history, the metallurgical testing, the flowsheet and discusses design considerations.INTRODUCTIONHaile Gold Mine is located near Kershaw, South Carolina, approximately 50 miles south of Charlotte, North Carolina. Gold was first discovered at the site in 1827, and the property has been through several operating periods since. The last operation employed heap leaching in 1985 through 1992. Since then, the property has been closed and fully reclaimed. Romarco Minerals acquired the property in 2007, and began an exploration program that has delineated over 62 tonnes (+2M ozs.) of gold in reserve at an overall grade of 2 ppm (0.06 opt). This paper provides a brief history of the property, a summary of metallurgical testing, description of the process flowsheet and discusses design considerations.HISTORY1827 – 1837Gold was discovered in creek beds on the Haile property in 1827. The property was owned by Benjamin Haile, and the first few years of production came from placer mining. After gold was discovered in schist beds to the sides of the streams, Haile expanded the operation by leasing 18 meter-square (50 ft.) plots to local planters. These planters used slaves to work the small excavations in the agricultural offseason. The gold ore was taken to arrastras where the free gold was liberated and recovered. The excavations were above the water table, generally less than 18 meters (60 ft.) down, and it was noted then that gold could be found embedded in sulfides and difficult to extract."

Jan 1, 2013

By A. McLean, A. Hue, K. Le, Y. D. Yang, P. Wu

While the treatment of relatively inexpensive ferrosilicon alloys is a potential refining route in order to generate solar grade silicon, phosphorus is one of the more difficult impurities to remove by conventional processing. In this project, the use of an electromagnetic levitation technique was used to investigate the dephosphorization of ferrosilicon alloy droplets exposed for various times and temperatures to a hydrogen-argon gas mixture. It was found that approximately 40% of the phosphorus was removed from an 85%Si-15%Fe alloy after 20 minutes exposure at approximately 1673K, to a gas mixture containing 48.5% hydrogen. Further dephosphorization is expected with longer reaction times. The effect of increasing temperature was found to be insignificant, although processing at lower temperatures is not only economically advantageous, it also decreases evaporative silicon losses, thus resulting in a more efficient process.

Jan 1, 2015

By H. C. Gunnings, C. O. Swanson

"The Sullivan mine; at Kimberley in southeastern British Columbia; is the largest silver-lead-zinc mine in the Empire and one of the largest in the world.The original discovery was made in 1892 by four prospectors. Until 1899, when the branch line of the Canadian Pacific railway from Cranbrook to Kimberley was completed, little work was done on the property. In 1900, systematic development was started, and during the next 3 years 5,000 tons of ore was shipped to the smelters at Nelson and Trail. By 1903, some 300,000 tons of ore was developed, and a smelter was started at Marysville, about 5 miles from the mine. However, this smelter closed down in 1907 because of metallurgical difficulties after treating 75,000 tons, and the property came under the control of the American Smelting and Refining Company. An option on the property was taken in 1909 by the Consolidated Mining and Smelting Company of Canada, who exercised their option in the following year. During the next 5 years by selective mining and sorting 188,000 tons of high-grade ore was produced and shipped to Trail. This tonnage came from the upper levels, about 4,600 to 4,800 feet in elevation. At the same time, deep drilling down to the 3,900-foot level showed the presence of an immense body of complex ore. In 1915, the main adit-the 3,900-foot level-was started, and by 1919 this had been driven a distance of 2 miles to develop the ore above this level. Meanwhile, progress was being made in overcoming the milling problems. An interesting account of this work was written by the staff ( 4). In 1923, the first unit of the present concentrator was erected, with a capacity of 2,500 tons a day, and thereafter the rate of production increased rapidly. In 1934 it was around 8,000 tons a day, and to date a total of about 30,000,000 tons of ore has been sent to the mill. In recent years, a considerable part of the production has come from levels between the 3,900-and 3,350-foot, which were opened by an internal incline shaft started in, 1930. In 1942, tin was added to the products separated at the concentrator."

Jan 1, 1954

By J. Mizera, J. Zdunek, K. J. Kurzydlowski, A. Dobkowska

This work concerns comparison of corrosion resistance of the aircraft aluminum alloy composed of Al - 2.3%Li - 0.1% Zr. The alloy was hot rolled (HR) from 13 mm to a thickness of 4 mm (e = 2.4) and 1 mm (e = 5.2). Corrosion resistance was investigated by Potentiodynamic Polarization Test. The investigation relied on exposure samples in two different corroding medium: 0.5 M NaCl solution and 0.01 M Na2SO4 solution with added 0.01% of Cl- at room temperature. Furthermore, the microstructure was analyzed using the optical microscope with polarized beam. The hardness was measured on lengthwise profile. It was stated that alloy after the largest deformation (equivalent total strain e = 5.2) is characterized by the best mechanical properties and the best corrosion resistance. The alloys in initial state and after deformation to 4 mm (e = 2.4) are characterized by worse corrosion resistance. It is associated with microstructure and density of dislocation in analyzing material.

Jan 1, 2015

By B. Haneman, J. A. Gorst, W. Slabbert

"The Bayer process involves the digestion of bauxite in caustic liquors at high temperature and pressure. Typically the digestion section of the plant involves the heating of liquors up to the digestion temperature followed by flashing of the digestion product to atmospheric pressure with the flashed steam used to pre-heat the incoming cold slurry. Despite the heat recovery, the digestion process is a high consumer of energy. The application of tube digestion technology in such plants has resulted in significant improvements in refinery energy efficiency with associated benefits of process simplification and refinery flow sheet capital cost reduction. This paper reviews the potential application of this technology to other metals within the non-ferrous industry.THE BAYER PROCESSA typical Bayer flow sheet is shown in Figure 1. The raw feed material bauxite (containing aluminium hydroxide as gibbsite Al(OH)3 and boehmite AlO(OH)) is digested in caustic liquors (caustic soda is the solvent) at high temperature and pressure. This process extracts the alumina and silica and any carbon present on the ore. The slurry is then flashed down to atmospheric condition allowing for heat recovery from the flashed vapour and producing slurry supersaturated in alumina.Following the digestion process the mud is removed via thickening and then pressure filtration to remove fine particulate and produce a clarified liquor with dissolved alumina in solution. The resulting pregnant liquor is then cooled allowing the alumina in solution to precipitate as aluminium trihydrate Al(OH)3. The precipitated hydrate is then filtered and washed and classified into fine and coarse fractions. The fine material is returned to the precipitation process as seed while the coarse fraction is calcined at high temperature to produce alumina. The filtrate from the filtration process (spent liquor) is then heated by the incoming pregnant liquor before being fed to an evaporation process which produced the strong caustic liquor required in the digestion process. Finally, the mud from the thickening process is washed to recover caustic and then fed to tailings ponds. The washer overflow is then mixed with the digester product to increase super-saturation."

Jan 1, 2012

By Matthew R. Ward

This paper aims to describe the reasons and methods to extend enterprise networks into underground mines. Currently mines use a number of communication networks for telephones, PLCs, two-way VHF radio and computer networking. Each system can have different wiring, protocols, converters and interfaces all which require expansion and maintenance. The convergence of voice, video and data using Ethernet and TCP/IP has the very real benefit of one ?wire? for underground networks. Now that the majority of underground equipment can communicate using TCP/IP, network convergence can offer reduced network expansion and maintenance costs. Cost savings are good, but the truly exciting aspect of network convergence using Ethernet is the low-cost, high speed wireless networking now available . These wireless networks offer an opportunity to facilitate mining automation even on a small budget. How would mine operators change they way they operate if they could gather vehicle location and data in real time? What about controlling equipment remotely? The list of applications is long and includes traffic control, dispatching, real-time ore blending, tele-operation, automated production reporting, vehicle health monitoring, elimination of paper forms and immediate network access for surveyors and geologists. An ideal converged network for underground mining would be robust, inexpensive, easy to expand, enable fast and secure connections while keeping voice communication performance equivalent or better than what is now provided by VHF radio

Apr 1, 2005

By A. Vien, A. J. Neale, B. C. Flintoff, R. P. Edwards

Froth flotation is one of the most widely used and effective processes for mineral beneficiation. First introduced in 1911, flotation technology has seen many developments over the past 80+ years. Innovations in reagent chemistry, equipment design, process analysis and process control have given design and plant engineers a powerful set of "tools" for process optimization. However, it does not follow that all flotation systems are optimized. As Klimpel observes: "The problem with the industrial flotation process is that it is relatively easy to get reasonable results, and relatively difficult to get excellent results" Klimpel (I 988). While reasonable was sufficient in the past, competitive forces will make excellent necessary in the future. Judging by the activities in many Canadian plants this transition is already underway. This paper examines the role of some of the optimization "tools" in effecting this change.

Jan 1, 1994

By P. Lostritto, G. E. Agar, G. Labonte, M. Cherevaty

"A locked cycle flotation test was done on a sample from the ovoid portion of the Voisey 's Bay copper-nickel sulphide ore. The chemical conditions for this test were generated by prior independent testing. In this test work the time in each of the five separation stages was optimized prior to executing the locked cycle test. A numerical simulation of the continuous circuit material balance was done prior to the locked cycle test. The test results were not fully satisfactory because the flotation of pyrrhotite in the bulk rougher and cleaner stages was not consistent. The preliminary indication was that the samples had oxidized to varying degrees during storage.INTRODUCTIONINCO has performed batch laboratory flotation testing on ore from Voisey's Bay which is a mixture of chalcopyrite, pentlandite and pyrrhotite. Earlier, Lakefield Research was contracted by Diamond Field Resources to test the ""flotability"" of the ore, which included a pilot plant trial. INCO's J. Roy Gordon Research Laboratory has repeated many of the batch tests that Lakefield did to verify their results. Based on their own work, INCO has modified the circuit proposed by Lakefield Research. The modified circuit is based on batch test work, but no locked cycle test (LCT) was done. It is believed that this circuit will produce a copper concentrate at 29-30% copper and a primary nickel concentrate at 15-20% with recoveries of 80% or above.For several years the University of Toronto has been working with INCO to provide ""hands on"" experience for undergraduate students as an Industrial Research Project (IRP). This year, the objective for IRP was to optimize the time for each of the five separation stages for the Voisey's Bay ore then to numerically and experimentally simulate the material balance for a continuous circuit."

Jan 1, 1998

By G. D. Markland

The Moose Mountain mine is located in a belt of Precambrian volcanic rocks situated 20 miles north of Sudbury, Ontario. It was the first iron mining operation in the Archean iron-formations of the Canadian Shield. The ore is believed to have been formed in an environment of active volcanism, being part of a pyroclastic and volcanic series where only the iron-formation and chert qualify as chemical sediments. The volcanic environment, subsequent regional tectonics and metamorphism produced orebodies which differ from the main sedimentary iron ranges of the world in such features as continuity, grade, structure and metallurgical characteristics. The orebodies occur as relatively small lenses which have been complexly folded, faulted and intruded by acidic and basic dykes.

Feb 1, 1966

By G. D. Markland

"The Moose Mountain mine is located in a belt of Precambrian volcanic rocks situated 20 miles north of Sudbury, Ontario. It was the first iron mining operation in the Archean iron-formations of the Canadian Shield.The ore is believed to have been formed in an environment of active volcanism, being part of a pyroclastic and volcanic series where only the iron-formation and chert qualify as chemical sediments. The volcanic environment, subsequent regional tectonics and metamorphism produced orebodies which differ from the main sedimentary iron ranges of the world in such features as continuity, grade, structure and metallurgical characteristics. The orebodies occur as relatively small lenses which have been complexly folded, faulted and intruded by acidic and basic dykesAlthough the basic mining and beneficiation methods are simple, detailed geological control in exploration, planning and operation has been necessary to apply detailed selective techniques to the large-scale open-pit methods necessary in profitable iron mining.The milling and pelletizing processes are sensitive to minor variations in ore grade, grain size, fabric and mineralogy. Although detailed correlations of geological information and mill performance are still not entirely satisfactory, general working relationships have been determined with simple testing procedures. These are of in-creasing use in forecasting production and in ore-blending processes.The application of geology to mining and milling operations at Moose Mountain represents a departure from general practice in iron ore operations."

Jan 1, 1966

By Y. Thibault, L. Morin, R. Cameron, D. Gould

"There are an estimated 50 to 100 million dry metric tonnes of low-grade nickeliferous pyrrhotite tailings in the Sudbury area alone, with an average nickel grade ~0.8% (plus cobalt). Pyrrhotite is a highly reactive sulphide mineral that has the potential to generate acidity; consequently, it is stored in large tailings ponds that require perpetual treatment to avoid the production of acidic drainage. Re-processing this material using bioleaching technologies has the potential to recover valuable metals, while reducing the toxicity, reactivity, and acid generating potential of the remaining residues. CanmetMINING is currently developing a stirred-tank bioleaching process to recovery nickel and cobalt from pyrrhotite-rich tailings. Stirred-tank experiments have been conducted with one tailings sample over a range of pH and temperature conditions, resulting in 80 to 90% and 70 to 80% leaching of nickel and cobalt respectively in 10 days.INTRODUCTION Sulphide tailings may represent a significant financial liability for mining companies as these wastes may produce acidic drainage under some disposal conditions. As a result, the companies must post financial bonds large enough to ensure there are sufficient funds for perpetual management of these wastes. At the same time, there are billions of dollars in metals incorporated into these mining wastes waiting to become valorized. Many sulphide tailings are amendable to bacterial oxidation for metal extraction. Re-processing of tailings using bacterial leaching has the potential to recover valuable metals from waste; and reduce the toxicity, the reactivity, and the acid generating potential of the remaining residue. By reprocessing these wastes there is an opportunity to significantly reduce liabilities and financial assurance bonds, while recovering metal values. There are an estimated 50 to 100 million dry metric tonnes of low-grade nickeliferous pyrrhotite-rich tailings in the Sudbury area alone with an average nickel grade ~0.8% (Peek et al., 2011) plus cobalt and copper. Pyrrhotite is separated from pentlandite concentrates by magnetic separation and flotation. It is already finely ground and has often been segregated from other tailings material, making „mining? relatively inexpensive. This represents roughly (> $100/ton) in contained value, with negligible mining costs. This paper reports on the development of a stirred-tank bioleaching process for recovering nickel and cobalt from pyrrhoitite-rich tailings, which is currently underway at Canmet MINING."

Jan 1, 2017

By F. H. Hueston, R. S. Barclay

"Depending on the application, zirconia, fused magnesia and graphite have been found to be the most suitable crucible materials for melting uranium metal and its alloys. Although graphite has been found to be satisfactory for uranium and uranium alloy castings with cross sections of 4 square inches or greater, ceramic-type molds are superior for small sections and those shaped castings which prohibit the economic use of machined graphite molds. Heating cycles, addition mechanisms and furnace conditions for melting are discussed."

Jan 1, 1967

By Sanjeeva Latchireddi

"Deteriorating ore grade and high demand of metals has tremendously influenced the unit capacity of SAG mills. Pebble circuits have been added to the existing SAG circuits to increase their unit capacity. To make the pebble circuits justifiable, the grate openings are increased almost to 4.5 inches to draw large quantity of pebbles. The inherent transportation problems associated with SAG mills in closed circuit with pebble fraction are more complicated than the single stage SAG mill operation, because the coarse pebbles behave significantly different to that of slurry in pulp lifters. In addition, operation of mills at higher speed, to take advantage of precise design of high release angled shell lifters significantly reduces the discharge efficiency of the conventional pulp dischargers. The presence of a sizable quantity of pebbles in the pulp lifter limits the space available and reduces the flow gradient through the grate thus increases the load inside the mill and hence the mill power-draw. This paper analyses all the problems associated in discharge of slurry and pebbles in SAG mills with pebble circuits. The Outokumpu patented Turbo Pulp Lifter (TPLTM) aims at eliminating the inherent material transport problems to ensure good grinding conditions. Recent installation of TPLTM in a 26-ft SAG mill has proven these claims by reducing the specific power consumption while increasing the mill capacity.INTRODUCTIONThe conventional wisdom is to look at the semi-autogenous grinding (SAG) mill as just another grinding mill in which ball charge, mill filling, and mill speed are varied to attain maximum throughput. Liner design for the SAG was also approached more from a wear perspective rather than a metallurgical and hydraulic-flow perspective. The extensive research work carried out by Latchireddi and Morrell (1997,2003a and 2003b) has demonstrated to think of the SAG as more of a pump in which the grates and pulp discharger end (“impeller”) were designed to efficiently discharge the product sized particles smaller than the grate size with minimal recirculation out of the mill.The rock load in the mill is essentially depends on ore characteristics and the discharge rate of broken particles. The discharge rate of the product material depends on how efficiently the discharge pump (grate and pulp lifters) is operating. Similar to the impeller design affecting the pump capacity, the pulp lifter design affects the discharge capacity (or mill throughput) of the SAG/AG grinding mills. The general arrangement of AG/SAG mills discharge system is shown in Figure 1."

Jan 1, 2007

By Loui Geoffroy, Philippe Gaultier, Martin Piotte, Claude Coache, André Drouin

"Automatic driving at high speed of an underground truck was tested at Brunswick mine in September 1995. Modifications to the truck included: a remote interface to control actuators, front and back video cameras to follow a roof mounted optical guide and proportional hydraulic controls on the steering.The mathematical model of the hydraulic system was adjusted using least square regression. The steering data, used in calculating the regression parameters, were acquired from the moving truck. The automatic steering control used three measured variables: lateral deviation, angular deviation and steering angle. Lateral deviations are obtained using the cameras, which are in continuous view of the guide, while steering angles are acquired from an extensiometer placed at the articulation point of the vehicle. Gain scheduling was used to compensate for vehicle speed and available hydraulic flow. Non-linear characteristics of the modeled hydraulic system were offset using open loop compensation.Speeds up to 23 km/h in forward direction and 13 km/h in reverse were achieved deviaduring continuous testing along one of the mine’s production drifts. Proportional steering was essential in achieving high speeds, as it enabled more precise positioning of the vehicle’s steering direction while reducing the abuses on cylinder and cylinder pins via diminished oscillations about the optical guide at high speeds."

Jan 1, 1997

By W. B. Morrey

This paper deals with the development of the new cap-sensitive slurry explosives. The history and special features of these explosives are outlined, and recent field trials are described.

Jan 1, 1973

By L. V. Bell

THE object in prospecting is to find ore. With the exception of certain discoveries of more or less accidental nature, intelligent prospecting as conducted today is, whether consciously or not, based upon a process of elimination. In the following discuss on it is proposed to evaluate those factors that enter into the eliminating of certain tracts of ground and, conyersely, the concentrating of attention upon others. The danger of generalizations as to the barrenness of cer.ain areas, without having due regard for all such factors, is emphasized. The fact that our conception as to what areas or rock formations are to be regarded as favourable or unfavourable is, in some measure at least, changing with new discoveries under diverse and unexpected circumstances, adds more point to the discussion. The criticism might be raised that the subject is treated largely from the standpoint of geology, but that may be met by stating that it is, and must continue to remain, precisely from this standpoint that the prospecror directs his activities. Briefly, the geologist may render the greatest service to the prospector in the early steps of selecting (a) the general territory in which to prospect; (b) the area to be intensively prospected; and, finally, (c) those parts of the claim or claims to be prospected in detail. Although certain phases of the discussion will be, in some measure, of general application, we shall here concern ourselves essentially with prospecting in the pre-Cambrian shield. Furthermore, the subject is so large that it has been decided to limit it to a consideration of that portion of the pre-Cambrian rocks in which is situated the mining district of western Quebec, of which the writer can speak with more personal knowledge. This limitation need not, however, seriously detract from whatever merit the discussion may possess, since the deposits concerned cover a fairly wide range of metallic ores, including gold, copper with associated zinc, and, lastly, molybdenum.

Jan 1, 1936

By Kiran B. Chaudhuri, Michael Koch, Jorg Lema Patino

"Stricter pollution regulations together with other factors have stimulated interest in the modernization of the traditional sinter - blast-furnace lead operation. In this context, direct smelting methods have again come into prominence. Consequently, the Kivcet Lead Smelting Process, which belongs to this group, has attracted the attention of the lead producers of the world. The Kivcet Process offers the advantage that lead and zinc can be simultaneously recovered in a single furnace unit. KHD Humboldt Wedag A G, Koln, Federal Republic of Germany, has signed a contract with the Sociedad Complejo Metalurgico de Karachipampa of Bolivia for the delivery of a turn-key Kivcet plant, which is expected to be the first plant of its kind in commercial operation. This paper describes the design and expected operating data of the plant."

Jan 1, 1980

By J. K. Shaw

The science of low temperature engineering is well entrenched in mining. Uses for common cryogens, including liquid oxygen (LOX), liquid nitrogen (LN2), and liquefied natural gas (LNG) in the gas and minerals industries are reviewed. Potential future applications are discussed within the scope of mining, particularly in refrigeration and ventilation. The second part of this paper focuses on the Linde cycle, which is at the heart of most liquefaction plants. Steady state equations describing the mass and energy flows are presented. The paper concludes by explaining the concept of a wind powered Linde- Hampson cryogenic cycle and assessing, with scoping calculations, the technological feasibility of producing cryogens with an intermittent source of (renewable) energy.

Aug 1, 2013

By J. Güntner

A significant portion of Outotec's business relates to the application of fluidized bed for processing a wide range of industrial materials, including gold ore and gold concentrate. As part of the former Lurgi and Boliden organization, our division constructed the first industrial reactor for roasting sulphur-bearing materials in 1950, based on the principles of fluidized bed technology. This process, when combined with efficient heat recovery and off-gas treatment and its conversion to sulphuric acid, became the standard for processing sulphur-bearing ores. In the last 60 years we have delivered more than 265 plants and developed (in addition to the standard fluidized bed solution) variants of the fluidization technology, such as the circulating fluidized bed and the bubbling fluidized bed. This paper describes the different options of the fluidized bed technology for gold roasting reflecting on main process design criteria.

Jan 1, 2011