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By Pablo González, Rodolfo Espinosa, Jose-Luis Noyola, Sergio Cossio

"Minera Penmont, at La Herradura, is a joint venture between Industrias Peñoles, S.A. de C.V., and Newmont Mining Corporation. The mine is located in the northern Mexican state of Sonora. La Herradura consists of an open pit mine with two-stage crushing and heap leaching facility, the gold is recovered from the pregnant solution using the Merrill-Crowe process; production began in July 1998. La Herradura produces about 130,000 gold ounces per year, and treatment capacity is 22,000 tonnes/day. Ore mineralization occurs in a shear zone with quartz and native gold. Gold distribution is quite heterogeneous due to the coarse visible gold, in some coarser particles ranging from 100 to 600 microns.Sampling and assaying protocols where established during exploration and prior to starting up operations, based on nomographs developed from early heterogeneity tests. But, as the coarse gold problem became noticeable, it was necessary to develop new sampling protocols to have an acceptable relative standard deviation to control the fundamental error within ± 15%.An experimental program was developed and conducted on a selected ore block made of 195 blastholes; regular ore grade control procedures were applied to both sets of data to evaluate the difference in results between the protocol established prior to starting up operations (“existing”) and the new protocol (“leaching”). In the “existing” protocol, subsampling is done through riffle splitters, and coning and quartering. Fire assaying is used to estimate the gold content, on a 50 g sample. In the “leaching” protocol a 12,000 g sample was bottle rolled cyanide leached, and the leach residue was assayed on a 50 g sample using fire assaying, and a weighted average total gold content was calculated. Currently, a new alternative method is being evaluated, where sub-sampling is done using rotary splitters, and fire assay on a 50 g sample; in this “rotary sampling” protocol and for comparison purposes, gold assays were also repeated using the “leaching” protocol.Test results were compared in three groups < 0.30 g/t (below cut-off), 0.30 to 0.8 g/t, and >0.8 g/t. Overall. Results show that the protocol established prior to starting up operations underestimates the gold assays. Detailed technical results, alternative options, and their implications are discussed in the paper."

Jan 1, 2003

By Richard F. Lynch, Frank E. Goodwin

"The development of Galfan, a new generation 95% zinc-5% aluminum-mischmetal alloy coating for steel, offers opportunities for greater fabrication flexibility and upgraded corrosion performance in automotive applications. The formability of Galfan is equivalent to that of electrogalvanized steel, based on laboratory tests and automotive component fabrication. Corrosion resistance of Galfan exceeds that of hot dip and electrogalvanized, including performance in automotive industry tests. Automotive production applications for deep drawn and stamped components in France and Germany are based on the ability to meet dual performance requirements for upgraded formability and corrosion resistance. The first U.S. Galfan application was on 1985 model Ford cars and light trucks for transmission oil cooler lines which has now expanded into a number of power steering tubing uses. IntroductionContinuing requirements for improved vehicle performance coupled with the ever present need for reduced cost have spawned the development of a number of new coated steel products. Among this new generation of coated steels is Gaifan™, a 95070 zinc-Solo aluminum-mischmetal hot dip alloy coating. Galfan exhibits particular promise for automotive use based on broad fabrication advantages and upgraded product performance(I ),The unique characteristic of Galfan is the key combination of greatly improved formability with much longer corrosion life. Galfan provides significantly better formability than any other hot dip coating. Testing shows that formability is limited primarily by the steel substrate to which the Galfan coating is applied. Galfan exhibits excellent resistance to flaking and microcracking during commercial forming operations. The result is the elimination of unnoticed damage to the coating which would show up later as premature rusting on the finished product."

Jan 1, 1987

By Tim Edwards, Richard Triglavcanin, Ian Arbuthnot, Darren Colwell, Brad Garraway, Ken Roberts

"In the mineral processing industries, there is an increasing need to design thickeners which are able to produce high density underflows usually referred to as “paste”.The behaviour of a flocculated suspension in compression needs to be well understood in order to arrive at a reliable thickener tank configuration (i.e. diameter, cone angle and depth) for a required paste result.As a suspension approaches paste consistency, it’s fluid characteristics change markedly. It develops a high yield stress, and may have an increased tendency to form agglomerates, which lead to a phenomenon known as “rotating beds”, “donuts”, or “islands”. These characteristics present challenges to the designer of the rake mechanism.The subject paper addresses the requirements for designing a paste thickener, covering the following topics:o Testwork for thickener sizingo Design of rake mechanismso Suspension rheology and effect on designo Case studiesTESTWORK AND SIZING FOR PASTE THICKENERSThickening slurries to the maximum possible density (paste) is becoming increasingly common. Applications such as Autoclave feed thickeners, paste backfill and some counter current washing (CCD) circuits are all examples of potential paste thickening applications. The principle of paste thickeners is that the compression zone is much deeper than on either high rate (HRT) or high compression (HCT) units; generally 3 metres or more. As the compression zone gets deeper, theunderflow density for a given flux rate (tph/m2) increases, as a result of two factors:1. Longer bed settling time. Settling flocs move relative to one another and release interstitial fluid when they are in compression. Increasing bed residence time achieves higher density underflow as more fluid is removed.2. The nett weight of the bed creates a compressive force on the settling flocs. This force increases with depth, so that the flocs at the bottom of the bed experience the highest compressive force. This represents the driving force to expel interstitial fluid and hence increase bed density."

Jan 1, 2005

By Tad S. Golosinski

The paper describes Online Master of Engineering Program at the University of Missouri-Rolla and discusses the experience gained during the first three years of its offering. This innovative educational program is designed primarily for mature students with an engineering or science background who want to acquire or upgrade their knowledge of mining engineering. Students can specialize in several different areas of mining, such as surface mining, underground mining, mine environment and the like. All courses constituting the program are taken online, through the Internet, without the need to attend the UMR campus in person.

May 1, 2004

By Eric Konigsmann

"Omai Gold Mines is a large scale open pit gold mining operation located in central Guyana, South America with a 12,000 tonne per day milling facility. Mill operations were initiated in December 1992 with commercial production beginning in January 1993. The entire operation employs approximately 120 expatriates and some 800 Guyanese nationals and is expected to produce in excess of 250,000 ounces of gold per year. The total mineable reserves contain 2.5 million ounces of gold with a projected mine life of twelve years.The milling circuits feature an SABC grinding circuit, gravity concentration and a conventional CIP gold recovery circuit. This paper will review the mill start up and ""run-in"" phase during the first year of operation. Emphasis will be placed on descriptions of start up problems and circuit modifications, mill performance trends in 1993, and personnel training and development. An outlook for 1994 is also given.IntroductionOmai Gold Mines is a large scale, open pit gold mining operation located in the Potaro district of Guyana, South America, some 160 kilometers south of the capital city Georgetown. Although there are numerous small scale gold mining ventures in Guyana, particularly with the dredging operations on the rivers, Omai is the first hard rock, open pit mine to be developed in the country. At present, this mining operation is one of the largest gold mines in South America.The Omai gold deposit has been exploited for over one hundred years. In the late 1800's, a German syndicate used hydraulicing with subsequent gravimetric separators such as sluice boxes and trommel screens to recover gold from saprolite, a soft, oxidized, claylike mineral which covers much of the claim area. Through the early 1900's and up until the 1950's, numerous mining companies including Anaconda Mining Co. Ltd. explored and drilled the Omai deposit but the technology and low gold price of the day made the reserve uneconomic to develop."

Jan 1, 1994

By Yaw Boadi, Andrew McCallum, Sandy Gray, Yavuz Atasoy, Peter Wemyss

"Various full-scale test programs and installations of the InLine Pressure Jig (IPJ) have provided evidence that pre-concentration of the difficult to leach sulphide mineral through gravity can provide significant increases in economic recoveries. The continuous gravity concentrates are intensively treated either by re-grinding or Intensive Cyanidation. Data from various mine sites worldwide is presented. Treatment of complex ore bodies with this low cost methodology may render previously uneconomic ore bodies financially viable and assist in the recovery profile of transitional ore.INTRODUCTIONThe use of gravity is made extremely attractive in complex ore situations due to the low cost of operation, typically a few cents per ton operating cost and lack of chemicals.Gold mines which suffer from poor recovery due to complex mineralogy such as Stibnite, Arsenic, Carbon, Telluride, Silver and other pacifying agents such as Iron, which can form coatings, can all benefit from the process proposed in this paper. The key issue is not overall recovery as much as one of economic recovery. The key to this is maximised recovery at the lowest possible capital and operating cost. Other options such as flotation are reviewed but are not seen in many instances to be the panacea due to issues discussed in the paper. The use of the InLine Pressure Jig in the re-circulating load of the milling circuit is a cost effective means of recovering a sulphide/gold concentrate containing the complex mineral assemblages which require re-grinding and intensive leaching for optimised gold recovery.The benefits of Jig Assisted Grinding (JAG) are many and the challenge over the past years has been developing, understanding, implementing and evaluating the benefits of various flowsheet models. This has involved the reconciliation of results in plant scale trials back to the original laboratory test program. The following paper outlines the insights gained in this area through extensive work carried out by many people across both laboratories and plant sites in Australia and overseas. The examples in this paper are some of the work carried out on a few selected sites but similar work has been carried out on other sites such as Penjom, Granny Smith and Agnew. This work has eventuated in several installations which we believe have great importance in the future of the gold processing industry. They will lead the way forward to the modern all-gravity plants of the future.Compared to flotation, for the recovery of sulphides, gravity is a simple option. The simplicity generally translates to low capital and operating cost."

Jan 1, 2004

By F. Barriga-Ordonez, J. A. Finch, L. Calzado, S. R. (Ram) Rao

Sludge, formed by lime treatment of acidic drainage and stored in tailing ponds of the Sudbury region, contains 5-7% Ni, mostly in a mix of hydroxides with Fe (~ 10%), Mg (~ 10%) and Cu (-0.5%), and Ca (-3.5%) as sulphate. Investigations were conducted to recover nickel by a 2-stage process. In the first stage, the sludge was leached with sulphuric acid at pH 3.2. About 90% of the nickel was extracted, producing a solution, which contained mainly nickel (2 g/L) and magnesium (3.7 g/L). In the second stage, nickel was separated by treating with ozone which recovered 99% of the nickel in the Ni(III) oxidation state as -85% pure nickel oxide-hydroxide (NiOOH) precipitate. The oxide settled and filtered readily. A potential use of the product in battery making is suggested. The leach residue contained 0.5% Ni making it less toxic for disposal. Some physical properties of nickel oxy-hydroxide and process parameters including ozone consumption will be discussed.

Jan 1, 2005

By P. Lefebvre, J. Sargent, K. Major, B. Darnton

"Stillwater Mining commenced mining operations at Nye, Montana in 1987 for the recovery of platinum and palladium. Exploration identified that the J-M Reef extended for 43 km. In 1998 Stillwater Mining made the decision to develop the East Boulder mine complex, located approximately 13 miles from the Stillwater mine complex at Nye, to increase production. This paper describes the design, construction, and start-up of the East Boulder process plant.INTRODUCTIONStillwater Mining Company have been producing Platinum and Palladium from their Nye, Montana operations since 1987. The mine production from Nye had been increased in stages with mine production being delivered through several portals and one vertical shaft.The deposit is narrow veined which prevents the application of bulk mining methods and thus limits the production capabilities.In order to increase the production of platinum (Pt) and palladium (Pd) Stillwater made the decision to access the ore from the J-M Reef from the East Boulder site. The East Boulder mine site is located about 21 km (13 miles) from Nye, however as shown in Figure 1, the travel distance is closer to 188 km (114 miles). Distance, on strike, and space availability at Nye precluded the expansion of the Nye concentrator to handle the increased mining rate and supported the decision to install a new concentrator at East Boulder."

Jan 1, 2003

By K. Barr, F. Grenier, J. Hettinger

"To reach the Hemlo Gold Inc. objective of becoming the lowest cost, safest Canadian gold producer while causing no environmental damage, management embarked from its inception on a strategy to build an organization which would foster employee involvement wherever possible. This paper describes the organizational structure and how various innovative concepts have been implemented.BACKGROUNDThe Golden Giant Mine in the Hemlo area of North Western Ontario is owned by Hemlo Gold Mines Inc. 50.1% is controlled by Noranda. The mine commenced operations in March 1985 at a modest production rate. After it reaches full production by the end of 1988, with completion of underground development work, the mine is expected to operate at 3000 t/d and produce in excess of 300,000 ounces of gold per annum. This makes it one of the three largest producing gold mines in North America.Two other companies, Lac Minerals and Teck-Corona, operate mines on either side of the Golden Giant Mine. Noranda Geco Division is located 55 kilometers to the north at Manitouwadge. The majority of Hemlo Gold's 270 employees live in Manitouwadge where a mix of accommodation was constructed and made available for purchase by employees. Bus transportation is provided to and from the workplace with modern coaches. The housing and transportation policies were implemented prior to start-up and designed to help attract and maintain good employees.As shown in Figure 1, the operation is divided into five operating and support departments with each reflecting a high degree of departmental control and responsibility. For example, the mill department is responsible for all aspects directly relating to the milling complex including safety, operation, mechanical maintenance, assaying, instrumentation, and environmental control. Similarly, the mine department is responsible for all phases of operation, mine engineering, geology, and maintenance of underground mobile equipment. The plant department is responsible for maintenance of hoisting plants and conveyances, underground stationary equipment, all site electrical services, surface buildings, housing and yard maintenance. Efforts are made at every level of the organization, from departmental organization to individual job assignments, to ensure responsibilities are clear and that they encompass complete functions."

Jan 1, 1988

By L. Flett, S. Woods, C. Deredin

"Following a significant reduction in world Imperial Smelting Furnace (ISF) capacity from 2003 to 2008, a major optimization initiative was successfully carried out on the lead upgrading and bulk (zinclead) flotation circuits in the Brunswick Concentrator.This paper describes the process improvements that have taken place in order to reduce the quantity of bulk concentrate:•,Increase in lead upgrading rougher flotation circuit capacity•,Installation of a closed-circuit bulk regrind utilizing MillPebs and 150 mm Cavex hydrocyclones•,Installation of two additional cleaner flotation stages on the bulk circuit•,Optimization of the manipulated variables in the lead upgrading and bulk circuitsINTRODUCTIONThe Brunswick Mine (Xstrata Zinc Canada) is located near Bathurst, New Brunswick and is one of the world’s largest lead/zinc mines. Milling of ore commenced in 1964 from the No. 12 orebody, with an expansion in 1966 to accommodate ore from the No. 6 open pit mine. The planned closure of the mine will take place at the end of the first quarter in 2013. The ore is a complex massive sulphide, consisting of approximately 20% valuable minerals, 60% pyrite and 20% silicates.A simplified flowsheet for the concentrator is given in Figure 1. The overall flowsheet involves SAG milling, secondary ball milling, selective flotation, and dewatering by thickening, filtering and drying. The complexity of the flowsheet evolves from the requirements for fine grinding and the production of four concentrates: zinc (sphalerite), lead (galena), copper (chalcopyrite) and bulk (sphalerite plus galena).Primary hydrocyclone overflow feeds the copper-lead aerator-roughers for flotation at pH 9.0 with soda ash. Plant xanthate (80-20 sodium isopropyl and potassium amyl) and AP407 are used as collectors in the copper-lead circuit. The rougher concentrate is directed to the copper-lead regrind circuit and the tailings are fed to the secondary grinding circuit. The secondary hydrocyclone overflow from the secondary grinding circuit feeds the copper-lead rougher-scavenger banks. Rougher concentrates are reground to a P80 of 28 µm prior to three stages of copper-lead cleaning. The first stage of cleaning is done in an open circuit with the tail reporting to the cleaner scavenger. The cleaner scavenger concentrate reports to the regrind circuit and the cleaner scavenger tail combines with the rougher/scavenger tail to feed the zinc circuit. The second and third stages of cleaning are performed in closed circuit with the cleaner tail being recycled to the copper-lead regrind circuit. The average final concentrate grades 23% Pb, 3% Cu and 704 g/t Ag, and is fed to the copper separation circuit."

Jan 1, 2013

By R. J. Mitchell

"High narrow backfills of significant strike length approach the stress conditions associated with a free standing wall but this lower bound design approach is not considered efficient for earth structures. This paper considers the design of high narrow backfills using upper bound limit analysis, retaining wall theory with backfill arching and centrifuge model tests. Complex toe support situations pertaining to operational factors at Falconbridge&apos;s Lockerby Mine are investigated. It is shown that the susceptibility of high narrow fills to toppling is much lower than anticipated from the retaining wall analysis and that toppling can be avoided by a suitable toe support. It is also concluded that adhesion between the fill and an adjacent pillar can markedly increase the stability of the fill. INTRODUCTIONFalconbridge&apos;s Lockerby Mine pillar projects will expose cemented tailings backfills to heights (H) up to 55 m. The exposed backfills may have strike lengths (L) greater than the heights but are relatively narrow, having widths (w) of up to 12 m. The bulk cement content of the fills varies from 8.3% (12.1 T:C) to 3.0% (33.1 T:C). Exposed faces may have up to a metre of overhang due to stope overblasting, as shown in Figure 1. These fills have a solids specific gravity of close to 3.0 and were placed at a pulp density of about 68%. The tailings have a fairly uniform grain size with 32% less than 0.075 mm (200 sieve) and about 12% slimes (less than 0.02 mm sizes). The fill exposed by early pillar removal will be backed by adjacent, near vertical, ore pillars. Future pillar removal may expose similar fills which are not supported by an adjacent ore pillar but which will be backed by either an open void or by uncemented backfill. Furthermore, these fills may be undercut when the pillar slot is driven, further reducing stability (case 3, Fig. I) or a wedge could be left to help support the fill (case 2, Fig . 1). This paper presents limit equilibrium analyses for these various backfill conditions in a 22: 1 T:C fill and com- pares the results to data from centrifuge model studies at a scale factor of A= 157 as indicated in Figure I. Prototype fills have a 6 m deep cone plug of 16:1 T:C which is accounted for in the comparison of centrifuge model test with analytical results."

Jan 1, 1989

By S. Nikolic, G. M. Stieper, D. P. Mallah, B. J. Hogg, P. B. Voigt

Copper feed materials processing is becoming more challenging, due to an incremental increase in the mineralogical and compositional complexity of these feeds. These complex and polymetallic feeds are now becoming more common and many sites have been forced to re-evaluate their operating strategies to process these materials at cost competitive rates, whilst meeting ever more stringent environmental regulations. Most operations must first evaluate the merits of pyrometallurgical and hydrometallurgical treatment routes. Although there are multiple copper smelting technologies available, only top-submerged lance (TSL) technology, supplied by Glencore Technology as ISASMELT™, has been applied in the real world to consistently and successfully smelt complex materials in integrated metallurgical facilities such as Glencore’s Kazzinc Ltd. operation in Kazakhstan, Umicore Precious Metals Refining in Belgium and Aurubis AG in Germany. Glencore Technology also offers hydrometallurgical processing, through the Albion Process™ technology, opening up viable flowsheet options previously not possible for these complex feeds. This paper describes a number of real world process flowsheets at global operations and Glencore’s own operations at Mount Isa and Kazzinc Ltd., which process complex feeds. These flowsheets integrate the ISASMELT™, Albion Process™, ISACONVERT™, ISAKIDD™ Tank house, and bottom blown oxygen cupel (BBOC™) technologies to provide an effective process solution for the treatment of complex polymetallic feeds to produce metallic copper and associated by-products. INTRODUCTION Traditional smelters and those built in recent times within the bulk smelting hubs of the world have been designed to treat standard/clean concentrates. In recent years the processing of complex polymetallic sulfide concentrates and the recycling of secondary copper and derivatives of waste electrical and electronic equipment, such as e-scrap, have become a focus for numerous companies (Alvear & Nikolic, 2013). Processing of these complex feeds, characterized by relatively high levels of minor elements (over 5% of elements such as arsenic, antimony, bismuth, lead and zinc) is more challenging. Facilities not designed for these types of materials may require significant modifications or a change in smelting technology to treat them. Often operations find themselves re-evaluating the merits of pyrometallurgical and hydrometallurgical treatment routes for their sites through a number of factors:

Jan 1, 2019

By Marc C. Bétournay

A mine production locomotive, the world?s first applied industrial fuelcell vehicle, has been designed and tested in the context of a number of proof-of-concept projects supported by the Fuelcell Propulsion Institute, an international consortium of stakeholders dedicated to facilitate the commercialization of fuelcell vehicles. The locomotive?s simple electric-powered motor and controller system was ideal to study a number of requirements related to fuelcell power application: hydrogen power plant operation, underground hydrogen use, risk and regulatory requirements, production performance versus the conventional battery-powered locomotive version under measured duty cycles and production requirements, power plant design improvements for other fuelcell vehicles, and cost-benefit aspects. This article will focus on the design and testing aspects of this project which has led to successful performance demonstrations of the vehicle under surface and underground conditions at two mines. It will also present information on the creation of a safe, reliable and efficient power plant which fulfilled its design objectives, including longer productivity time for a given vehicle fill-up.

May 1, 2003

By Neri Roux, Chris Budgell, Allan Cramm, Leo Cheung

"Anaconda Mining Inc. is investigating potential improvements and expansions to their operating plant located on the Baie Verte Peninsula in Newfoundland. An extensive batch and continuous bench scale testing program was launched to investigate the efficiency of cyanide destruction under different conditions in order to improve tailings handling. The primary objective of the cyanide destruction study was to apply new technologies to develop a novel cyanide destruction system.Effluent and slurry from Anaconda Mining Inc.’s Point Rousse Project was received at RPC where test work was conducted. Various sodium metabisulfite (MBS) dosages were evaluated and the use of utilizing ozone and ultra violet (UV) light to oxidize cyanide was investigated. All the data was evaluated and mass balances were compiled to develop several flowsheets. Overall encouraging results were found using a combination of ozone and MBS.IntroductionAnaconda Mining Inc.’s Point Rousse project includes an operating gold processing plant located on the Baie Verte Peninsula in Newfoundland which is in the process of improving and expanding. This plant comprises of milling and flotation followed by cyanide leaching in order to extract the gold. The residue from cyanide leaching is filtered by drum filters prior to being clarified for the Merrill-Crowe process. Once the gold has been recovered by the Merrill-Crowe process the effluent is filtered by filter presses and the resulting filtrate as well as the solids from the drum filters are detoxified prior to being pumped to the tailings pond along with the flotation tailings.The entire process is very dependent upon the efficient destruction of cyanide in the effluents and successful tailings handling. Substantial amounts of effluent are delivered to tailings ponds after gold extraction which could create environmental problems if the regulations are not met. Environmental regulations stipulate that final effluents contain no more than 1 mg/L Total CN.The detoxified tailings of the Point Rousse project are produced by the INCO SO2-Air circuit depicted in Figure 1. These detox tailings contain 10 mg/L Total CN at that point of the circuit and this was selected as the target to be matched while reducing overall MBS consumption rates from 3.2 g/L per minute. Prior to detoxification, the filter press tailings contain 520 mg/L Total CN while the drum tailings contain 29 mg/L Total CN."

Jan 1, 2017

By S. Spigarelli

The creep response of the AE44 magnesium alloy was studied by means of constant load creep tests carried out at 125 and 150°C, obtaining that at the latter temperature the minimum creep rate observed under an applied stress of 100 MPa was two orders of magnitude lower in the investigated alloy than in AM50. The minimum creep rate dependence on applied stress was described by a conventional power-law, e = Aon , where A was a temperature dependent parameter and n was the stress exponent, resulting in a n value close to 30, i.e. by far larger than those observed in commercial alloys with similar Al content. This large difference in creep response was attributed to the precipitation of rare earths (RE) intermetallic phases distributed in the grain boundary zone in form of an almost continuous network of dispersoids that were observed by means of scanning electron microscopy.

Jan 1, 2006

By R. Ramírez, N. Aslin, G. Ríos, T. Bravo, A. R. Almansa

Lacy copper has been an on-going concern at Atlantic Copper for at least 10 years and was first reported to Glencore Technology in mid-2010. Over the past 12 years, many of the plates were replaced due to age and general deterioration however; plate passivation and lacy copper issues have persisted. After analyzing all the possible causes of this phenomena, it was found that the problem is caused by a degradation of stainless steel as a consequence of the deposition of Sb oxides. These deposits act as passivating agents of stainless steel, which reduces the density of copper nuclei, causing defective copper deposit, with low thickness and ductility. After doing several tests for reducing/removing the phenomena, the over-riding factor was found to be the anode-cathode overlap. An adequate overlap eliminates the problem of "lacy copper". This was verified during an eight month trial with anodes extended 2.5cm in length. Longer anode not only avoids the appearance of lacy copper, but also recovers cathodes that already have lacy copper. On the other hand polishing of plates only gives rise to a temporary solution that requires on-going polishing, to avoid the re-appearance of lacy copper. INTRODUCTION The electrolytic copper refinery of Atlantic Copper in Huelva (Spain) was commissioned in 1970 with an initial capacity of 40,000 t of cathodes per year. In 1975 the copper refinery was expanded to 108,000 t/year. From 1994 to 1996, a new expansion together with the implementation of ISA permanent cathode technology led to a capacity of 215,000 t/y. Since 1995, a progressive increase in the current density up to 350 A/m2 has been accomplished, which together with an increase in the number of cells from 1,120 to 1,204, has led to the present cathode production capacity of 290,000 t/y A lack of copper deposition in the lower part of the steel permanent cathodes was first reported in 2010. This phenomenon is known as “Lacy copper” because of the appearance of the copper deposit as it can be seen in Figure 1. The occurrence of this phenomena was relatively low and was assumed to be originated by an excessive anode scrapping. Nevertheless, in December 2015 Lacy Copper was observed in a significant amount of copper cathodes giving rise to the following issues: Increased tramp copper – housekeeping and maintenance problems Poor appearance of cathode deposit and untidy looking bundles

Jan 1, 2019

By M. P. Amsden

"Ecstall Mining Limited, a subsidiary of Texas Gulf Incorporated operates the Kidd Creek Mine, a 10,000 tons per day base metal producer, near Timmins, Ontario. Two different ore types are mined and milled: copper-zinc and silver-lead-zinc. At the highly automated Ecstall Concentrator the ores are processed by selective flotation in threes individual circuits. One of the most important metallurgical tools for process control is a sample system incorporating continuous on-stream x-ray analysis. Recently this system was further automated by adding computer control of reagents for two copper-zinc flotation circuits. The computer programs, utilizing optimum seeking methods and smelter contract terms, have increased copper recovery 0.8%, zinc recovery 1.6%, and reduced reagent costs by 12%. Although not anticipated, copper and zinc concentrate grades were improved modestly as well.INTRODUCTIONSEcstall Mining Limited, a wholly owned subsidiary of the Texas Gulf Incorporated operates the Kidd Creek Mine, one of the world's major base metal producers, near the old gold mining centre of Timmins, Ontario. Discovered in 1964, the property was brought into production in November, 1966. Originally designed for 9,000 tons per day, the operation now treats 10,000 tons per day of two different ore types mined from a single open pit. In the near future, open pit ore will be supplemented by ore from an underground operation now being readied for productionAt the Ecstall Concentrator the ores are processed by selective flotation in three individual circuits. The whole plant is highly automated and control is coordinated from a central control room. The treatment process follows conventional practices although fine grinding is required for optimum flotation recoveries. Normally, two circuits treat copper-zinc ore at a combined rate of 6,500 tons per day while the third circuit treats 3,500 tons per day of silver-lead-zinc ore. Special production averages 2,400 tons per day."

Jan 1, 1973

By S. V. Ulianov, A. Y. Senchenko, E. M. Kurchevskaya

"A process sample of old copper-containing tailings (-2.0+0 mm) from an iron-ore plant was tested in TOMS institute in order to develop a process for copper concentrate production. The study of tailings material composition indicated that -0.2+0 mm fraction was efficient and contained 97.26% of copper. Copper is predominantly concentrated in chalcopyrite which is present both in free form and in intergrowth with ore and rock-forming minerals. Study of chalcopyrite using an optical microscope and Qemscan SEM determined that the most grains surface was covered with oxide films. Additionally, a lot of grains had micropores on their surfaces that indicated a partial mineral leaching. The oxide films did not make it possible to float copper minerals from head material. It was recommended to apply an attrition operation to restore chalcopyrite floatability. In order to increase selectivity a regrinding stage for a primary copper concentrate was introduced to obtain P80 26 um. Taking these recommendations into account a flotation flowsheet was developed to process the old Cu-containing tailings. The flowsheet allowed us to obtain a concentrate with 23.5% Cu content at 71.5% recovery.INTRODUCTIONStudy of material composition is an important prerequisite for development of a minerals processing technology. Mineralogical study contributes to search for an efficient technology to recover valuables and for prospective methods of minerals processing.The use of such up-to-date analysis methods and equipment as Qemscan and Mineral-C7 allows one to determine minerals size, liberation degree, and mineral associations. Mineralogical data can reveal reasons for hard processing of minerals prior to development of the process.The advanced process mineralogical methods used to study Cu-bearing pond tailings indicated several factors that influenced development of the process. The first one is a barren size fraction which is to be removed from the process in order to considerably reduce the costs connected with grinding. The second is the presence of films on chalcopyrite surface; in this context, a preliminary attrition of the material was recommended. The third factor is finely disseminated Cu minerals in sulphide and in the rock, which predetermined selection of particle size for flotation. All these data led to significant decrease in time required to develop the process technology. The developed process flowsheet based on the obtained mineralogical data is present in Figure 1."

Jan 1, 2016

By Chris Larsen, Carole Fortin, Dave Scott, Curtis Deredin, Ian Orford, Jean Guy Gauthier, Andy Trusiak, Lyne Côté, Mike Cooper

"Upon successful commissioning of the Stage Grinding Project (Cormier et. al., 2002), process improvements predicted through pilot plant testing were obtained in several flotation circuits, resulting in higher grades and recoveries for zinc and lead concentrates. Subsequent to establishing new baseline operating conditions from the Stage Grind Project implementation, additional opportunities were identified, and through the application of Six Sigma methodologies further gains were made. Six Sigma improvement projects were carried out in the copper-lead, zinc, lead upgrading and bulk flotation circuits. The overall performance increase resulting from incremental improvement projects has been substantial.Most remarkably, given the operational maturity up to the late 1980’s, the Brunswick concentrator team has continued to deliver a steady stream of major improvements over the past fifteen years. While senior managers and their programs have changed several times, there have been some critical constants over the long run. Common elements have been a commitment to team work, a commitment to recruit and maintain technical personnel, a structured business improvement framework supported organizationally by senior management, and focus on a few priority initiatives rather than trying to fix everything at once.The paper briefly discusses the longer term setting and then endeavors to illustrate, with examples, how improvements are presently achieved by applying the Six Sigma quality program.INTRODUCTIONThe Noranda Inc. Brunswick Mine, located near Bathurst, New Brunswick, is one of the world’s larger lead/zinc mines. Milling of ore began in 1964 from the No. 12 orebody, with an expansion in 1966 to accommodate ore from the No. 6 mine. In excess of 100 million tonnes have been milled to date. The concentrator employs differential flotation to produce lead, zinc, copper, and lead/zinc bulk concentrates. The ore is massive sulphide, with approximately 20% valuable minerals, 60% pyrite and 20% silicates."

Jan 1, 2005

By C. H. Dionne, J. A. Holmes, B. J. Huls

"Falconbridge Limited is presently developing flowsheet alternatives for implementation at the Strathcona Mill. The main thrust for change arises from the need to reject more pyrrhotite from the concentrate. To maintain appropriate levels of sulphur in the smelter concentrate, however, enhanced removal of non-sulphide gangue minerals must be realized. This could best be done in the Non-magnetics flotation circuit.Laboratory investigations were followed by an on-stream pilot test at Strathcona. The application of a column cleaner on the Non-magnetics concentrate resulted in significantly lower levels of fine gangue at equivalent sulphides recovery.This paper discusses the laboratory and pilot testing and results, with a focus on piloting. Also included is a discussion of the Strathcona Mill Flowsheet and the role of the Nonmagnetics flotation circuit.INTRODUCTIONFalconbridge Ltd. is currently developing means to reduce atmospheric sulphur dioxide emissions. One alternative is a reduction in the amount of pyrrhotite in Strathcona Mill concentrate, which reports to the smelter. Pyrrhotite in the Falconbridge ores contains an average of 39 percent sulphur and 0.64 percent nickel. By comparison, pentlandite contains an average of 33 percent sulphur and 34 percent nickel.A consequence of the rejection of pyrrhotite is a decrease in the sulphur assay in the remaining concentrate. This decrease causes downstream difficulties in the roasting process. Therefore, the content of non-sulphide gangue in the mill concentrate must also be reduced in order to maintain sulphur grades adequate for roasting. The resulting concentrate will have lower sulphur dioxide emissions while maintaining nickel production."

Jan 1, 1991