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By Daniel Hodouin, Bruno Girard, Claude Bazin

"Mineral processing and smelting operations have the reputation of being complex processes. Process operators of these unit operations have acquired from experience and basic training a superficial understanding of the relationships between process output and manipulated variables. This understanding, which is a very valuable know-how for process control and optimization as well as for operator training, is however difficult to extract. This paper describes a time series based approach that can be used to extract this know-how, which can subsequently be used for operator training. The method is illustrated with an example taken from a smelting process.IntroductionThe emergence of Total Quality Management and Statistical Process Control philosophies in the North American industry (Brown, 1991 ), as well as the increasing popularity of the IS0- 900x standard accreditation, provide a strong incentive to review the training procedures for plant operators. The importance of employees training is acknowledged in two of the 14 points of Deming's road to quality (Deming, 1982) as well as by control engineering consultants (Hendricks et al., 1994). However guidelines for the operation of industrial processes are often transferred from an operator to another one with allowance for flexible interpretation of many operating rules. Such transfer is typical of complex industrial processes to which particulate processes of ore dressing and extractive metallurgy belong.Capturing the knowledge of experienced operators is often a difficult task. Cognition engineers are able to extract this knowledge and transfer it into rules that ultimately are implemented into expert systems. Cognition engineers are however not always available and plant supervisors may prefer to keep training as an internal liability. Another difficulty through interviewing of the process operator is its lack of willingness to transfer what he has learned by hard working to other people, whose ultimate goals are to develop computerized applications that may replace him in a near future, or reduce its importance in the production line.This paper shows that time series can be advantageously used to capture the average process understanding of plant operators and to help reviewing training procedures. The method s illustrated with data collected during normal operation of electric arc furnaces and it is shown how the approach has led to a fruitful discussion between process engineers and operators that ultimately provided savings of more that $200,000 per year per furnace. There are 9 furnaces in the studied foundry. Such savings are not the results of application of advanced control strategies nor of ""miracle press button software», but of an improve awareness by engineers and operators of the importance of properly defining the operating procedures to control a process."

Jan 1, 1996

By R. S. Nichols

"During 1973 to 1978, Canadaka Mines Limited, a subsidiary of St. Joseph Explorations Ltd., undertook an extensive exploration and development program in the Cobalt area. This program resulted in the delineation of previously unknown stratigraphic units in the Archean volcanic sequence. During this time period, significant are controls related to area silver deposits were also identified.The Archean geology is comprised of a volcanic pile conformably overlain by sediments. The volcanics contain at least two felsic volcanic centres near the stratigraphic top of the pile. The bulk of the pile consists of mafic flows and interflow sediments. lnterflow sediments around silver are shoots contain mineralized halos of base metal sulphides. The halos exhibit lateral and vertical metal zoning with Cu, Pb and Zn mineralization decreasing away from an are shoot.Silver mineralization controls determined during the Canadaka program agree with the historically well established importance of Coleman sediments as well as Archean contacts for hosting silver deposits. The vertical extent of are shoots is typically 150to 250ft. A strong correlation was found to exist in the Cobalt area between Archean strike and the strike of are veins. Finally, al/ Cobalt area are deposits appear to be associated with a distinct volcanic pile at the top of a sequence of Archean flows."

Jan 1, 1988

By Derek J. Barratt

This paper compares a number of operating conventional and semi-autogenous grinding circuits and analyzes them in regard to operating and capital costs, specifically as applied to porphyry copper ores.

Jan 1, 1979

By Lorne Roberts

"This paper describes: how Falconbridge's fire protection system meets the needs of the Lockerby Mine; why the system was chosen over other alternatives; how it is unique, but can be applied to any underground situation; details of the system; how it was installed; the role of a fire protection company; and general considerations when choosing afire-suppresant system.IntroductionIn May 1981, after about three years of searching for the best fire protection system for the re-opened Lockerby nickel mine at Whitefish, near Sudbury, Ontario, Falconbridge Nickel Mines Ltd. installed an AFFF type of fire suppression system. It was designed and supplied by the Fire Protection Systems Division of Levitt -Safety Ltd.The system protects against loss of life, equipment and/or production, and it complies with legislation should fire occur in a fuel storage area and/or scooptram garage and service bay at any or all of the three levels near Shaft No.2.About 18 months after Levitt-Safety began working with Falconbridge, the system was designed and installed at a cost considerably less than that which would be incurred if fire damage caused the loss of two days of production.The fire protection system, which overcomes a limited water supply, is a self-contained balanced pressure proportioning system. It senses the flow and automatically determines the correct concentration of foam to water. It is triggered by a release mechanism which operates a bank of nitrogen cylinders, which in turn pressurize a pressure vessel to expel the foam concentrate and water from the tanks. This solution is piped to sprinkler heads in the specific area."

Jan 1, 1982

By Robert White

?Introduction of BMS?Paste fill generalities?Development through paste?Development through rock fill?Conclusion ?Brunswick mine is operated by Xstrata. The mine has been in operation since 1964 and produces around 10 000 tons per day of ore containing (in order) zinc, lead and silver? The ore body consists of close to ten sub-parallel massive sulfide lenses. The length of the ore body is 1200 m with a width of up to 200 m. From the surface, the ore body extends to a depth to 1200m ?There is 100 km of active drifts for a total 400 km ?The mine is divided by 7 levels and 23 actives sub levels

Feb 1, 2008

By C. E. McCoy

This paper will discuss briefly loader shovel requirements and then present a detailed survey of electrical drive systems to meet these requirements. The survey in general will deal with the various electrical provisions for shovel drives, along with the advantages and disadvantages, and in particular will discuss the MG set and static D. C. drive systems. Also included will be some insight into the requirements for optimum electrical power at the shovels.

Jan 1, 1979

By J. E. Dutrizac

A pyritic Zn-Pb-Cu ore waspercolation leached with acidified ferric sulphate solutions; zinc and copper were leached, lead was oxidized, but not dissolved, and pyrtte was essentially unattacked. High zinc extractions were achieved after a few months leaching, and substantial zinc solution concentrations could be produced by recycle of the oxidized solution. The leaching rate was generally controlled by the transport of the ferric sulphate oxidant. Zinc extractions increased with increasingferric ion concentration or flow rate, but were essentially independent of the concentrations of sulphuric acid, ferrous sulphate, cupric sulphate or chloride ion. The leaching rates were insensitive to the height of the ore column once a minimum height had been exceeded (0.8-1.0 m). Elemental sulphur was the principal sulphidic reaction product, but variations in the ratio of sulphur to sulphate produced anomalous temperature effects.

Jan 1, 1979

By J. Kalejta

Ever increasing depth of mineral extraction presents a challenging environment for hard rock underground mines. High in-situ stresses and associated seismicity with potential rockburst hazards are the major decisive factors contributing to the choice of a ground support regime. Conventional ground support systems, designed primarily for static loads, are not always capable of providing safe working conditions for underground personnel in seismically active mines. Systems specifically developed to resist dynamic loading and allowing for larger deformations are therefore preferred alternatives. High-tensile chain-link mesh has a proven record of successful use in open cut operations in various rockfall barrier installations due to its high energy absorption capacity. It has also been used in underground operations in various parts of the world. This paper describes a method of mechanized installation of a chain-link mesh evaluated at the Kiruna mine in Sweden and South Deep Mine in South Africa. A purpose-built mechanized roll mesh handler was used in this evaluation. The handler is compatible with all standard multi-boom underground drill rigs and is operated utilizing the hydraulic circuit normally used for the feed arrangement. A number of key performance indicators have been identified as success criteria: ??A 30-50% faster installation compared to the conventional methodology ??The mesh should sustain any blast damage when applied to the blasting face ??No unraveling of the mesh when cut ??No failure of mesh under normal conditions Although the energy-absorbing mesh combined with yielding rock bolts is a ground support system of choice for rockburst prone conditions, the operational upsides recognized during the evaluation imply that this product can also be competitively used in less demanding ground conditions where customarily weld mesh or shotcrete are used as a primary surface support. The main conclusion: a fast, safe and fully mechanized installation.

Aug 1, 2013

By H. Utsunomiya, Mehdi Sanjari, Abu Kabir, Steve Yue, Jing Su, L. Kestens, In-ho Jung

The microstructure and texture evolution of low temperature rolled AZ31 magnesium alloy during annealing were investigated. The specimens were rolled at the temperature of 100? at a high rolling speed of 1000m/min with a reduction of 30% in one pass. Annealing was conducted at various temperatures ranging from 200? to 500? for different time. To study the effect of fast speed rolling, the same annealing procedures have been applied for the specimens rolled at a significantly lower speed of 15m/min. The microstructure was characterized by optical microscopy and scanning electron microscopy, while the texture was analyzed by X-ray diffraction analysis and electron backscattered diffraction analysis. Texture weakening occurred during annealing at both fast and slow rolling speeds. However, at the same annealing condition, fast rolled specimens always had weaker intensity of basal texture than slow rolled ones.

Jan 1, 2014

By Dallas W. Davis

"Since May 1980, New Brunswick has called separate tenders for the right to explore and develop several potash prospects, as well as areas underlain by Alberta oil shale. These tender calls had in common the provision for a basic ad-valorem royalty, combined with sharing of cash flow after exceeding a 15-20% discontinued cash flow rate-of-return threshold. In the case of potash, the bidding variable was a share of cash flow, but for oil shale it was exploration expenditures committed, with the cash flow sharing to be negotiated at the time of application for a production lease. The Millstream potash occurrence, previously discovered by government drilling, received five bids (21.1% highest), the Dorchester ""grassroots area"" with four surmised drill targets apparently received no bids, and in the case of oil shale there were only two bids on the one block previously subjected to the most exploration.It is concluded that New Brunswick will not be successful in awarding the potash or oil shale rights in return for a comparable level of basic royalty and cash flow share as in the case of Millstream, unless it spends money in discovering prospects or sharing the exploration risk with companies. The approach is likely to work for oil shales only if current exploration proves the existence of much high-quality material or a definite trend of real increases in the price of oil is again established. Undoubtedly, it continues to be desirable to assure an on-going stable investment climate through award of potash and oil shale rights under terms which provide for a return that the public and future governments will consider fair. This could mean that some form or risk sharing with companies would be advisable."

Jan 1, 1983

By D. A. Trotter

"Low-pressure sodium light sources have been available for several years, but have not received wide acceptance in underground mining. This is because they are difficult to operate using DC power, they are not an intrinsically safe light where explosive gases may be encountered and they give poor colour rendition.With the need for energy conservation, several Canadian hard-rock metal mines are now changing their lighting to low pressure sodium, as it has the highest efficacy of any light source in terms of lumens per watt. Studies have pointed out several other advantages as well. Glare can be controlled, they penetrate fog well, they are easily maintained, they have a long life and they give the highest visual acuity when compared to other types of lighting. As well, in an underground mine, contrast is much more important than colour for task identification. For close work, the colour problem is alleviated with the use of cap lamps.Case studies are presented from Canadian practice. These show how the lights are modified for underground use, calculations preceding light installation, and how and where the lights are installed in the underground environment. Mention is made of worker reaction to the lights and possible physiological effects.IntroductionThe importance of good underground lighting to the total environment of mining cannot be overemphasized. In addition to the obvious benefits of improved worker morale, available studies show that good lighting practices reduce accident severity and frequency as well as increase production."

Jan 1, 1982

By C. Chongo, L. Little, Q. Mclennan

Since commissioning in 2005, First Quantum Minerals’ Kansanshi Mine in Zambia has produced over three million tons of copper and 1.8 million ounces of gold from a deposit with highly varied copper mineralization. The processing plant is complex with three independent flotation circuits, gold gravity concentration, atmospheric and high pressure leaching, solvent extraction, and electro-winning. For the first ten years of operating the plant, copper mineralogy was inferred from total copper and acid soluble copper assays, and various misconceptions developed about the mineralogy which impacted operational strategy and project decisions. In 2015, an on-site mineralogy section was set up with an Automated Scanning Electron Microscope, the Zeiss MinScan. This instrument has provided detailed mineralogical data that have debunked some of the mineralogy myths that had developed, highlighting the key underlying issues affecting processing performance. This has enabled the development of projects targeting losses of specific copper minerals in defined size classes, unlocking significant value. This paper describes some of the early misconceptions around mineralogy at Kansanshi processing plant, outlining projects that have benefitted from understanding copper mineral distribution. Learnings from Kansanshi are to be applied at other FQM sites, with a similar mineralogy program being set up at the Cobre Panama project. INTRODUCTION The deposit Kansanshi Mine is located in the North Western Province of Zambia, and it has been the largest copper producer in Africa for over a decade. The deposit occurs within a broad northwest trending antiform that can be traced for 12 km, hosted in a zone of complicated faulting, abundant vein injection, breccia development and down-dropped rock units that lies within Kansanshi’s mining license. The copper mineralization within the deposit is predominantly vein-hosted, although some is strata-bound, occurring in thin bands and veinlets parallel to foliation, and some is disseminated associated with albite-carbonate alteration (Gray, 2015). Supergene enrichment has led to significant variety in the copper mineral speciation. This alteration is complex, and has not followed the text-book principles with a neat layer of supergene mineralization overlying fresh hypogene ore. Rather, the occurrence and extent of oxidation and supergene enrichment is highly irregular throughout the deposit, sometimes occurring at significant depth in localized pockets and along fault lines. Gold mineralization tends to follow the copper within the deposit, but it is dominated by coarse-grained, free-milling native gold. The extent of copper oxidation – measured as the fraction of total copper that assays as acid soluble – is used to classify ore into three main ore types, named Sulphide, Mixed, and Oxide, which are then fed to three different primary crushers for processing in independent circuits.

Jan 1, 2019

By V. Panayotov, M. Panayotova

"Finding a reliable relationship between fundamental properties of minerals of non-ferrous metals and their ability to float is extremely important. The approach presented in this work allows us to draw predictive models for an effective flotation, suitable choice of reagents regime and expected technological results before the minerals enter the flotation process. Attempts to adjust the technological regime in already begun flotation are often unsuccessful because the basic physicochemical processes have already taken place. Mineral processing can be optimized on the basis of objective and basic parameters, decisive for the efficiency of the process - the state of the surface of the mineral; assessment of: minerals flotation ability, the need to apply and the type of needed pretreatment, and expected technological results. The theoretical foundations of such an approach are presented in the work, as well as supporting them experimental results, and information on practical implementation in lead-zinc and copper-pyrite ores selection.INTRODUCTIONIncreasing impoverishment of ores of nonferrous metals incoming to the flotation and rising costs for obtaining the final product lead to the inevitable question - will the mineral processing process be beneficial economically, technologically feasible and environmentally safe and what is the way to improve its efficiency. Some of the possible solutions are already in practice - new more efficient and less energy consuming flotation machines and equipment, new - more efficient and selective reagents, new combinations of flotation regimens, and so on.Finding a reliable relationship between fundamental properties of minerals of non-ferrous metals (sulphides and oxides - most of them with semiconductor properties) and their ability to float is extremely important. This is the subject of research, started in the 60s of the previous century and continuing to the present day. Such dependence would enable a realistic assessment of flotation ability (flotability) of minerals before their flotation processing. The basic dependence, displayed by the researchers as Hoberg (1975), Chanturia and Shafeev (1977), Chanturia and Lunin (1983), etc., represents a relationship between bulk properties of minerals and their flotability, considering especially the concentration of the main charge carriers, namely electrons or holes. The bulk properties are practically constant for minerals from a given field. But the 'main arena' of the flotation process is actually the mineral surface (Carta, 1970; Rao, Labonte, & Finch, 1992; Panayotov, 1999; Rao, 2003; Hu, Sun & Wang, 2010). Therefore, we introduce a methodology for studying the surface of minerals, which methodology gives the degree of semiconductor bands bending on the surface and respectively - the charge of the mineral surface and its ability to interact with reagent-collector. The latter can be used to select the most optimal reagent for the corresponding mineral."

Jan 1, 2016

By Andrew J. Neale, Brian C. Flintoff

"In most mineral processing operations the term ""audit"" is usually reserved for the exercise of checking financial records and/or safety practices. While these activities are time-consuming, no one disputes their necessity or value. If these areas are subjected to such careful scrutiny, why is it that the same principles are not normally applied to critically examine process operation. After all, the operating efficiency of the plant impacts directly on the measures of profitability.A mineral processing plant is a complex system that has a number of distinct, but mutually dependent elements: process equipment, instrumentation, operating policies, maintenance policies, control strategies and people. To ensure maximum economic performance in the dynamic environment that characterizes a concentrator, requires a periodic review of each of these areas. However, to be useful, the study must be based on sound metallurgical principles and be conducted in a highly focussed manner. Experience has shown that the exercise is very revealing and rewarding.This paper will discuss the plant audit process and illustrate its potential value through examples taken from plant studies."

Jan 1, 1992

By M. Beech-Jones

The increased emphasis on the efficient utilization of capital and mineral resources has led to several new advances in the science of mineral separation. One example of a recent development is the application of high-capacity high-intensity wet magnetic separators to fine hematit e recovery by a leading Canadian iron ore producer. The iron ore recovery feasibilit , flow-sheet development, circuit operation and metallurgical performance are reviewed.

Jan 1, 1979

Presentation Overview Corporate Overview Kutcho Project History Exploration Development Permitting Capstone -Pursuit of Value Building a mid-tier copper producer focused in the Americas Two operating copper mines; Cozamin& Mintomines High grade and low cost 2010 forecast: 80-85 million pounds of copper in concentrates Total Cash Costs* of ~US$1.10/lb to US$1.20/lb of payable copper produced Significant by-products of gold, silver, lead & zinc Growth potential Further expansions at existing Cozamin& Mintomines High grade copper development: Kutcho project, BC Investments in Nevada Copper & Silver Wheaton 100% North American assets Low risk ?Canada & Mexico ?Conventional operations

Oct 1, 2010

By T. Crivits, I. Bellemans, V. Cnockaert, K. Verbeken

It is well known that slag foaming can significantly complicate copper smelting processes. This is especially true for unpredictable events that generate large amounts of slag foam during a small period of time. These events are here referred to as eruptions and are typical for certain types of liquid bath furnaces such as modern top submerged lance (TSL) furnaces. A few authors already made the link between over- oxidation of the slag phase and slag foaming. In this work, the mechanism is studied in more detail and explained using the smelter chemistry and the behaviour of dynamic foam formation. Finally, the most influential parameters on the foaming behaviour of the process are presented. INTRODUCTION Copper remains one of the most important metals used in our modern society. In 2017, the annual amount of copper produced worldwide was about 23.5 million metric tons. This makes copper the third most produced metal in the world after steel and aluminium. The majority of this copper was produced by copper smelting, about 19 million metric tons, both from primary concentrate and secondary feed material as reported in ICSG’s World Copper Factbook 2018. In the past, copper smelting was mainly performed using Flash smelting, a technology developed before 1949 (Kojo, Jokilaakso & Hanniala, 2000). Nowadays, this type of smelter is being complemented by other smelter types such as ISASMELT and Ausmelt technologies. These are two types op smelter furnaces, based on the concept of a top submerged lance (TSL) furnace. These two technologies were both commercialized around 1990 (Arthur & Hunt, 2005). It is estimated by Wang et al. (2016) that at this time, both flash and TSL smelters contribute equally to the total amount of annually smelted copper. Flash smelting stays the most important technology for extracting copper from primary sources. TSL furnaces, on the other hand, are more suited than Flash smelters for the recovery of copper from secondary materials. This is because of the different ways that the feed material is inserted in both furnaces. In Flash smelters, the ore and fluxes needs to be fine and completely dry in order to be able to blow the mixture inside the burner area of the furnace. The feed material for TSL smelters show less constrains concerning humidity and particle size. The material is dropped from the top inside the molten bath. As a result, a more complex and flexible feed stream can be processed using TSL smelting (Wood, Hoang & Hughes, 2017). This feature will become more important in the future as primary copper sources gets more scarce and the need for a fully sustainable material cycle increases.

Jan 1, 2019

"In conjunction with Banick Mercur , Wright Engineers Limited designed the first multi-stage aqueous pressure oxidation system in an alkaline environment in North America. A three-stage slurry heating and slurry pressure let-down with heat recovery was an innovative approach to the problem of high energy cost with the low sulphur content of the ore. The design of this system required solving a number of problems associated with heating and pumping of slurries at pressures up to 3230 kPa and temperatures in excess of 220°C. Wright received an Award of Merit in October 1989, from the Canadian Consulting Engineering Awards Committee in the Process Category for its design of the Mercur pressure oxidation system.The Mercur Mine is located at the south end of the Oquirrh Mountains in Tooele County about 65 miles by road from Salt Lake City, Utah, U.S.A. The original mill was designed to process 5000 tpd of oxidized gold ore in a carbon-in-leach (CIL) circuit. A new ore treatment system was required to treat the substantial quantities of refractory ore reserves which could not be treated economically in the existing mill. The new pressure oxidation circuit makes the refractory ore amenable to gold recovery by oxidation of the sulphides contained in the ore .Wright Engineers Limited was commissioned by Barrick Mercur Gold Mine Ltd ., a wholly-owned subsidiary of American Barrick Resources, to design the pressure oxidation facility. This followed completion of a feasibility study by Wright which showed that the project was technically and economically viable.Work on the feasibility study began in 1986, detail design commenced in February 1987, and was completed in December 1987. Mechanical installation was completed in January 1988, and slurry feed began in February 1988. The plant has operated since June 1988 without major interruption . Wright was responsible for engineering, procurement and construction management for the addition of the 750 tpd pressure oxidation circuit to the existing mill and also had commissioning responsibility.Major unit processes involved in the pressure oxidation facility are ore thickening, three-stage slurry preheating, pressure oxidation and three-stage slurry cooling with heat recovery, stearn generation, propane and oxygen storage and a video graphic display process control system were included in the scope as process anciliaries.The pressure oxidation increases gold recovery from the refractory ore by conventional CIL from as low as 35% to more than 86070. A patent has been granted for the process."

Jan 1, 1989

By Arsalan Talebzadeh

Construction -Surface ?First two intake fans constructed in 2007; third fan added in 2008 to reduce resistance in the system. 450 HP fans. ?Excavation for exhaust fans started in 2008. ?In parallel with underground construction in preparation for the changeover. ?Bulkhead in place prior to completion/ commissioning of

Oct 1, 2010

By G. K. Rutherford, G. W. Van Loon

"Tailings in the mining and smelting industry are reject products of the refining process which are deemed too deficient in native are to warrant smelting. They are essentially finely ground rock materials which have been moved by alluvial suspension from the site of crushing to a deposit site. It is realized that components of flotation chemicals used in specific gravity separation may become part of the tailings and also that sewage sludge or other materials may be added at some stage to the tailing deposits.It would seem, then, that as tailings have a similar parent material to soils, namely rocks, and that they have also been comminuted to similar size fractions, they would react in similar ways to soils. There is an increasing body of evidence and experience which both supports and negates this supposition. It is the object of this paper to point out similarities and contrasts between these two materials which may influence the vegetation and rehabilitation of tailings.Soil-Formlnq FactorsThere are considered to be six soil-forming factors which impart the particular and unique properties harboured by a soil at any site. It is .relevant to consider each of these in turn, as each provides an historically based parameter with which to judge tailing properties.Parent MaterialsAlthough all mineral soils have originally come from rocks, for most soils the route has been rather circuitous. Soils may be formed directly from underlying rocks, as in some parts of tropical and semitropical regions today; these are sedentary soils. However, most soils of the world have been formed by materials which were transported to their present site by ice, water or wind, or as volcanic ash. Virtually all soils in Canada have been transported by ice or water and deposited on an extraneous rock surface during the last glacial retreat. Ice-deposited materials are extraordinarily heterogeneous in their size components and may range from very bouldery and gravelly to predominantly clay-sized materials. Water deposited sediments are usually homogeneous, but nevertheless these also show considerable level variations. In many parts of Canada, clay-sized materials deposited in ephemeral post-glacial lakes form the parent material for soils."

Jan 1, 1982