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By Brian Penney

"The Iron Ore Company of Canada (IOCC} has mined and processed an iron deposit in Western Labrador along the Labrador-Quebec border since the early 1960' s. Current capacity is approximately 19 million tonnes of concentrate, 70% of which is converted to pellets at these facilities.The ore deposits are located in hills rising 150 to 300 meters above the adjacent lakes, and most of them are covered by very little overburden. The iron minerals are mainly specular hematite and magnetite hosted in a quartz formation. Crude ore averages 40% Fe that is concentrated to 65.5% Fe. IOCC is an extensive operation extending from Labrador City NF to Sept-Iles Quebec. It consists of open pit mining, concentrating, pelletizing, railway, and dock loading facilities.The Concentrator liberates iron from the silica by crushing and grinding the ore to -14 mesh (-1190 microns}. Ground ore is concentrated in spirals and filtered for transportation. Spiral tailings are treated in a Magnetic Recovery Plant (Mag Plant} that recovers lost magnetite. Mag Plant tailings are treated in a Hematite Spiral Plant (Hem Plant} that scavenges fine iron remaining in this stream.This report deals with ongoing iron recovery initiatives within the ConcentratorIron Losses in the ConcentratorIron recovery at IOCC is approximately 70.5%. This compares with recoveries that range from 65% to 86% for other iron mines in our area. Other world large iron ore producers dig and ship concentrate quality ore directly out of the ground and have an effective recovery of 100%. With increasing costs for labour, equipment, and supplies an increase in iron recovery is required to keep the operation viable.More than 90% of our iron concentrate is produced by gravity separation using spirals. The physical characteristics of the iron minerals that most effect recovery are mineral grain size and degree of liberation. We divide ground ore into three size categories -coarse, intermediate, and fines. A brief description of each size fraction follows:"

Jan 1, 1996

By Makarinskym F. M.

"This paper describes mechanical and operating modifications that were and are being made to current on-line flotation cells at Falconbridge Nickel Mines concentrators. Improved metallurgical performance and metal recoveries of some 3·4% over the past ten years are the end result of the modifications made. The paper acknowledges the contribution of operating, technical and maintenance personnel and the Company ""suggestion plan"" program. 1. INTRODUCTIONFalconbrirdge Nickel Mines Limited, incorporated in 1928 is a major product of nickel, copper,coba1t and other metals and minerals. The Canadian Nickel Division operating facilities in the Sudbury Area currently includes seven mines, two concentrators, and a smelter.For many years at all concentrators, improv0mcnts in metal recoveries have been continually under investigation. One area was to improve the flotation cell performance. This paper will deal with mechanical and operating modifications to the cells at the Strathcona and Falconhridge Ni-Cu sulphide concentrators, at the Sudbury Operations.One of the prime means to mineral beneficiation processing has been, and will continue to be, the basic froth flotation cell. The efficient operation of a flotation cell is the key to satisfactory metal selectivity and recovery. The essence of good design is simplicity. Changes to cell design can contribute to a significant improvement in metal recovery.Over the past 10 years, modifications to the flotation cells have contributed to an improvement of some 3-4” in mineral recovery. Providi11g tl1c initiative for improvements include operating, maintenance and technical personnel, as well as the employee suggestions submitted th1·ough the Suggestion Plan Program."

Jan 1, 1982

By J. E. Lee

"This paper describes the current practices and experiences, and discusses design parameters concerning slurry pumping at Inco Metals Company in the Sudbury District. It deals mainly with the long tailing and concentrate lines. Subject matter is arranged under the following headings: pumps, lines, instrumentation, system design, operation.IntroductionThe Inco Metals Company is the mining and processing section of INCO LIMITED. In the Ontario Division, it operates 13 mines, 5 mills, a smelter, an iron ore plant and 3 refineries, all engaged in the mining and recovery of nickel and copper. This paper describes the slurry pumping practices in the mills of the Ontario Division.The PumpsWe have in our Sudbury area mills most of the available types of slurry pumps, in sizes from one inch up to twelve inches, a total of about 400 pumps. The rubber-lined, horizontal shaft pump is; most numerous. However, for certain applications, the hard-metal pump is essential, and is becoming more popular for general mill service. Two types of vertical shaft pumps are used. There are a few diaphragm pumps on small thickeners, but the larger thickeners have centrifugal pumps either directly connected to the under-flow or with one pump handling several gravity underflows. We have not used piston or plunger pumps in our mills."

Jan 1, 1978

By I. A. Cameron

In 1979, John Peacey and William (Bill) Davenport published The Iron Blast Furnace Theory and Practice billed as "An up to date and comprehensive treatment of blast furnaces from fundamental principles to modern operations" (back cover). As a 1979 graduate of McGill University’s Metallurgical Engineering program, I belonged to the last "beta" student group which completed the prescribed blast furnace course work before The Iron Blast Furnace Theory and Practice was published. As my career developed, I become an international blast furnace consultant and have worked with blast furnace operators and raw material suppliers on 5 continents. The blast furnace is the dominate iron making process responsible for 70% of global steel production. Blast furnace engineers have implemented many improvements by manipulating the blast furnace process metallurgy using the principles presented by Peacey and Davenport to reduce coke consumption and increase oxygen usage and blast furnace productivity. This paper briefly summarizes some key principles presented by Peacey and Davenport (1979), describes process improvements made by blast furnace operators over the 35 years since The Iron Blast Furnace Theory and Practice was published and outlines important future developments in blast furnace technology.

Jan 1, 2014

By So-Yeong Lee, Moosang Lee, Seung Hwan Ahn, Ho-Sang Sohn, Jongshin Chang

It is necessary to understand the characteristics, phase changes and chemical reactions of flue dusts introduced from a furnace to an off-gas line in order to achieve the stable operation and the improvement. This study is to develop the dust reaction model for chemical reactions of dusts in an uptake shaft of smelting furnace and a waste heat boiler. Phase equilibria and reaction paths in this system were determined by thermodynamic calculation with experimental and industrial data. The oxidation reaction rate of dusts was determined by the gas film mass transfer controlling. And the sulfation reaction rate was evaluated by the unreacted shrinking core model. Kinetic parameters were estimated by reference data including industrial ones. The present study with the developed model shows various effects of temperatures, dust particle sizes, and O2 gas partial pressures on dust reactions. INTRODUCTION The flue dusts from a copper smelting furnace move along a furnace off-gas stream into an uptake shaft and a waste heat boiler (WHB) and electrostatic precipitator(s). It is necessary to control the dust quality in order to stabilize the operation because the sticking behaviors differ depending on the phase of dusts. Phase changes of dusts are caused by chemical reactions at given conditions such as temperature and partial pressure of gases. Therefore, it is required to understand the phase changes and chemical reactions of dusts in order to perform the improvement and stable operation. The present study carried out the investigation to understand their fundamental knowledge. Especially, this study was focused on the kinetics of chemical reactions of flue dusts, developed the model. In particular, the scope of development and utilization of the model was defined as the uptake shaft of the Mitsubishi S furnace and the S-WHB radiation section in the Onsan smelter. Information needed for the modeling work referred to data from these processes.

Jan 1, 2019

By Q. Han

Irradiation of high energy ultrasonic vibration in metals and alloys generates oscillating strain and stress fields in solids, and introduces nonlinear effects such as cavitation, acoustic streaming, and radiation pressure in molten materials. These nonlinear effects can be utilized to assist conventional material processing processes. This article describes recent research at Oak Ridge National Labs (ORNL) and Purdue University on using high intensity ultrasonic vibrations for degassing molten aluminum, processing particulate reinforced metal matrix composites, refining metals and alloys during solidification process, welding, and producing bulk nanostructures in solid metals and alloys.

Jan 1, 2014

By R. Hagiwara, S. Kobayashi, K. Yasuda, T. Nohira, K. Kondo

To establish a process for the electrochemical recovery of rare earth elements from used magnet scraps, the electrochemical formation of RE-Ni alloys in molten NaCl-KCl-RECl3 salt at 973 K was investigated. Cyclic voltammetry and open-circuit potentiometry indicated the formation of several phases of RE-Ni alloys. The formation potential for each RE-Ni alloy phase was determined from the results of scanning electron microscopy and X-ray diffraction of alloy samples prepared by potentiostatic electrolysis of a Ni plate electrode at various potentials. The optimum electrolysis conditions for the separation of Nd, Dy, and Pr are discussed.

Jan 1, 2014

By X. Cao, X. -G. Chen, K. Liu

Due to the detrimental effect of platelet iron-rich intermetallics on mechanical properties (particularly ductility) in cast alloys, it has been essential to transform these phases into Chinese script morphology. In the present work, the effects of Mn and/or Si addition and cooling rate on the phase transformation of the iron-rich intermetallics in 206 cast alloys with different Fe contents ranging from 0.15 % to 0.5 % were systematically investigated. The results obtained showed that platelet ß-Fe and Al3(FeMn), Chinese script a-Fe, Alm(FeMn) and Al6(FeMn) can be observed in the 206 cast alloys, depending on the Fe, Mn and Si contents as well as the cooling rate. It was found that the addition of either Mn or Si favors the formation of Chinese script iron-rich intermetallics but inhibits the precipitation of the platelet phases. In addition, the combined addition of both Mn and Si has a synergistic effect on the phase transformation. Furthermore, there exists a critical cooling rate to effectively suppress the formation of platelet iron-rich intermetallics for a given alloy. The threshold cooling rate decreases with increasing Fe, Mn and Si contents. Casting process maps are established to correlate the intermetallics precipitated with alloy chemistry and cooling rate for 206 cast alloys containing various Fe levels.

Jan 1, 2014

By S. Perkins, E. Young, L. Dufour, K. McVey, L. Rolandi

This paper presents a review of plant layout considerations incorporated into recent designs of SAG/Ball mill circuits for two medium sized concentrators. The plant layouts presented and the design concepts discussed, relate to smaller SAG circuits, but can equally apply to larger milling circuits. Included are design concepts and ideas introduced by the various project teams, and the focus is on the primary factors of any layout design which are safety, constructability, operability, and capital cost.

Jan 1, 2012

By T. Saksala

In this paper, the embedded discontinuity approach is applied to finite element modeling of rock fracture. A rate-dependent constitutive model based on the embedded displacement discontinuity theory is developed to describe the mode I, mode II and mixed mode fracture of rock in tension and compression. The bulk material is described as linear elastic until reaching the elastic limit. Beyond this limit, a ratedependent exponential softening law governs the evolution of the embedded displacement jump. The present approach incorporates the rock heterogeneity by random description of the mineral texture of rock. Moreover, the inherent initial microcrack populations of natural rocks are accounted for as randomly oriented embedded discontinuities. Numerical examples demonstrate the model behavior in uniaxial compression and tension. The effect of loading rate and confining pressure is tested as well in 2D numerical simulations. These simulations show that the model captures the main features of rock in confined compression and uniaxial tension. The developed method has the computational efficiency of continuum plasticity models. However, it has an important advantage of accounting for the orientation of introduced microcracks.

Jan 1, 2015

By W. Yang, R. Rajasingam, K. Mohanarangam

"Copper Electrowinning (EW) is a complex electrochemical process that involves the production of LME grade copper from copper rich electrolyte. The process involves the deposition of the copper ions onto the cathode from copper rich electrolyte with the production of oxygen bubbles at the anode. The process setups up a complex flow pattern within the cell as it is subjected to varying density gradients due to the deposition process along with oxygen bubble driven flow. It is a necessity to understand and quantify the flow behaviour within these cells in order to maintain the production of highest grade copper. In fact, the oxygen bubbles originating from the process is responsible for the generation of acid mist which is a designated as a carcinogen a major health hazard around EW tank houses. Hydrodynamic assessment of the process has so far been restricted to simple mass balances and some limited numerical modelling. All the models are based on assumed boundary conditions which has not so far been verified by any real-time physical measurement. This apparent gap has led to models which could not be directly used to track process changes or troubleshoot problems in EW tank houses. In order to address this gap, CSIRO has established a full size (width and height) transparent cell capable of simulating plant operating conditions (across the range currently used). With the use of sophisticated diagnostic analytical tools and measurement techniques it was possible to study all the operating variables (current density, flow rate, temperature, etc.) independently and their effect of bubble size, bubble velocity, gas hold-up as well as acid mist generation and its size. In order to address safety concerns in tank houses around acid mist early results outlining the factors contributing to its generation as well as the effect of various barriers to mitigate acid mist is outlined below.INTRODUCTIONA significant part of today’s copper production is through hydrometallurgical route which predominantly involves leaching, Solvent eXtraction (SX) followed by ElectroWinning (EW). Producing copper using this approach have shown to be environmentally friendly (Dresher, 2001) compared to the traditional smelting process. EW is the final step in the production of LME grade copper using the hydrometallurgy route. The electro-chemical process involves the use of a lead anode (Pb-Sn-Ca) and a stainless steel cathode to produce copper sheets using the copper rich electrolyte from the SX process and with the applications of direct current to the electrodes. This electro-chemical reaction results in the deposition of copper ions on the cathode with oxygen released from the anode as a by-product. Hydrodynamically, the oxygen bubbles create a bubble driven flow within the EW tanks with the surrounding electrolyte. A direct result of this could be seen from the quality of the copper deposited on the cathode. Most of the copper plates produced from the traditional tank houses have a rough texture at its bottom one-third while the top two-thirds have a smooth finish with a finer grain structure."

Jan 1, 2016

By Tim J. Carew, Dennis C. Martin

"One approach to stabilization of rock slopes is to place a buttress at the toe of the slope to provide additional resisting forces and increase the length and strength properties along the failure surface. This paper describes the rock mechanics and mine planning aspects of incorporating a buttress of intact rock in the lower part of the slope as part of the slope design for the south wall of the final pit at Cassiar Mine. Stability analysis techniques and results are described. Analyses results have indicated that, in order to maintain steep over-all slopes in the final pit, a buttress of intact rock shoud be incorporated into the lower section of the slope until late in mine life. The effect of the buttress is to flatten the slope and reduce the slope height thereby improving slope stability. The mining plans would be such that the buttress would be mined out during the last four months of mining when the consequences of instability would be least severe.IntroductionThe concept of using a buttress to stabilize slopes has been used in mining and civil engineering construction in may locations (Richards and Stimpson, 1977). Most buttresses involve placement of coarse rock fill timber cribs or other material as a load at the toe of an already unstable slope to provide forces which resist failure by counteracting driving forces and increasing the length and strength of the failure path.This paper describes the geotechnical and mine planning aspects of incorporating a buttress of intact rock in the design of the south wall of Cassiar Mine. The effect of an intact rock buttress is to flatten the slope and reduce the slope height, thereby improving slope stability. No actual construction is required other than normal excavation of the slope. The ""mine plans would be such that the buttress would be mined out at the end of mine life when the impact of instability would be less severe and additional ore might possibly be recovered from the slopes. Mining of the buttress could induce instability at the very end of mine life at a time when maximum ore extraction has been achieved."

Jan 1, 1986

By Marc Tardif

"The way alarm information is provided to an operator can make a huge difference in the minutes following an upset. Process alarms are often looked at as a way to help avoid catastrophic failure and serious accidents. But knowing that mineral processing is so energy consuming and that raw material is not consistent, all small upsets should also be seen as a catastrophe because they can have significant impact on product cost and quality.This paper will demonstrate how it is possible to use data from process alarms to provide operators with real time, value added information that will help them take the right decision at the right time and in turn, reduce unplanned downtime by 20 to 80% and incidents by up to 50% (number and cost),and optimize energy and capacity usage.In the era of Big Data, living in a world where we are submerged with information, one of the biggest challenges is to find the right information at the right time.Alarm rationalization projects will often focus on alarm quantity, but alarm quality is also very important. It is possible, by following a simple 6-step process to turn “alarms” into truly valuable information for operators. Based on known standards (ANSI/ISA 18.2 and EEMUA 191), this process will capture the knowledge of the best and most experienced operators and process engineers, and make it readily available to everyone, right on time, when it matters the most.INTRODUCTIONWhen spending some time in a modern control room, it is easy to notice the huge quantity of information that is available to the operator. Modern operation stations feature multiple screens with HD capability. These screens display information like process display, history trends, alarms and events list, maps with geo-located information, images from live cameras, etc. However, it is harder to assess whether all this information is really helping operators: Is all the information relevant? Are process screens overcrowded? Is the information easy to understand? Does the operator know what to do with all the information? Are there too many alarms?"

Jan 1, 2016

By F. P. Hassani, J. F. Boily, A. M. O. Mohamed, M. Hossein

The optimal geochemical parameters required to form ellringite in a lime-remediated site have been investigated with the use of thermodynamic modelling. The speciation of sulphate and 10 metals analyzed in samples of a mine tailing from northern Quebec was calculated with a computer model. The model also includes calcium, which would result from the addition of lime to the system. Two speciation calculations were done. The first one is a hypothetical speciation before the onset of precipitation and was used to devise the stability fields of minerals susceptible of forming in high pHs. The stability fields were determined by building activity ratio diagrams with sulphate, aluminum and calcium species concentrations for pHs ranging from 4 to 14. The investigation was carried out for a 25°C solution with an ionic strength less than 0.12. Thermodynamics predict that an optimal stability field for ettringite in the mine tailing samples containing 10-3 mol/L SO4-2,10-2 mol/L of AI(OH)4 requires at least 10-2mol/L of Ca+2 and a pH larger than 11.6. The sulphate contents of the mine tailing samples, however, limit the precipitation of ettringite and monosulphate could be an end-precipitate. The second speciation is in equilibrium with precipitates and provides information on the speciation of the residual metals. If ellringite could be precipitated as a stable form, it could serve as a sorptive agent for residual metals, and, due to its binding properties, consolidate tailings.

Jan 1, 1995

The mixer that is commonly encountered in hydro metallurgical operations consists of a single turbine and tank combination. However, it would be advantageous to examine some common solvent extraction mixing systems in the light of the fundamentals of chemical reactor design. The basic concepts of reactor design are commonly used in the chemical industry, and it should not be too difficult to apply them to solvent extraction. The factors that affect the engineering design of a reactor are: the reacting system; the type of reaction; and the configuration of the reactor. The reaction system in solvent extraction consists of a heterogeneous liquid phase, involving two immiscible liquids. It is essential f or the process that the reactor product can be separated efficiently in the subsequent settler. The type of reaction in solvent extraction system may be quite complex, and the picture is complicated by the presence of competing and side reactions. The reactors themselves have been generally continuous stirred tanks, and the nature of the mixer-settler makes it unlikely that the pumping mixer can be dispensed with. However, it appears that there should be some definite advantages to a system of stirred reactors in series. The kinetic experiments which are carried out should have the definition of optimum reaction conditions as one of their goals. The data obtained from these experiments must also be applicable to the design of reaction equipment. Reactor selection and design is often a unique problem for each chemical process, and does not lend itself to a systematic general approach. However, the application of chemical and physical principles to mixer design in solvent extraction should result in practical, more efficient plants.

Jan 1, 1979

By Anthony McDonald, Dominic Verhelst

"Hudson Bay Mining and Smelting Co. Ltd. (HBM&S) started up a zinc plant and smelter in late 1930, employing technology of that period. The zinc plant has since converted from a roast/leach operation to a two stage pressure leach operation to eliminate sulphur dioxide emissioms. The smelter, however, is still continuing with much of the original roaster/reverberatory furnace technology. This paper reviews the process flow of the copper smelter, with some comments on past and recent changes.Smelter FlowsheetPrior to July 1993, the HBM&S smelter operation consisted of seven areas, namely feed preparation, roasters, reverberatory furnace, converters, anode casting, fuming plant, and dust collection. A simplified smelter flowsheet is shown in Figure 1. The data for tonnage of materials moving through the circuit are presented in Tables I to 4, and are representative of the time period from July 1992 to June 1993. A change in the zinc plant technology in 1993 resulted in the elimination of a zinc-bearing sulphide leach residue from the smelter feed blend, thereby greatly reducing the zinc content of slag produced in the smelter. Consequently the fuming plant and ancillary equipment, such as the drying plant, were shut down. These areas will, however, be described. With the closure of the zinc fuming furnaces all the slag from the reverberatory furnace is now discarded to stockpile.The over-all smelter metal recoveries are 96% for Cu and rn.5010 for Au and Ag. Figures 2 and 4 indicate historical production numbers of copper, silver and gold, respectively. A review of the minor element distribution in the smelter can be found elsewhere."

Jan 1, 1994

By M. Connell, S. Bedrossian

Alkali cracking followed by chloride-based leaching is one of the prominent methods for rare earth element processing. Regeneration of the leach lixiviant, namely hydrochloric acid, is a critical operation in the process. A number of different process routes are available for recovery of hydrochloric acid from chloride solutions. The objective of this paper is to discuss various recovery routes and analyze the impact of several input variables on the variable operating cost.

Jan 1, 2014

By M. Isac, R. I. L. Guthrie, S. Ge

The Al-Mg-Sc-Zr alloys have shown exceptional potential as structural materials for transportation applications. These alloys have proved to be good candidates to be processed as thin strips via the Horizontal Single Belt Casting (HSBC) process. The HSBC process is a near-net-shape casting technology, which involves casting molten metal directly into thin strips, close to the final product thickness, at high cooling rates. It offers an efficient, economical and environmentally-friendly approach to the production of metal strips. Fluid mechanics and associated heat transfer are important aspects of any casting process, and the novel HSBC process is no exception. Three dimensional Computational Fluid Dynamics (CFD) simulations using ANSYS FLUENT 14.5 were performed, in order to assess the importance and effects of the various operational conditions of the HSBC process. This enabled process parameter optimization. Numerical predictions were validated against experimental casting results.

Jan 1, 2014

By W. B. Morrey

"In recent years, the major effort in detonator development has been concentrated on ""non-electric"" systems. Existing types all involve some form of explosive reaction to transfer ignition energy from outside the borehole to the pyrotechnic delay element contained within the detonator. These may be based on low-energy detonating cords having grained or plasticized explosive cores, shock tube energy transmission principals and explosive gas ignition systems. Each has properties of internal and external effects not present in electric conductors.The MAGNADET System introduces transformer coupling into electric blasting circuits. Safety features with respect to current leakage, stray currents of AC or DC source, electrostatic energy and radio-frequency radiation are comparable to ""non-electric"" systems, with advantages in simplicity, speed of hook-up and range of application.The transformer device used is a small ferrite ring or toroid which is an integral part of each specialized detonator. The detonator legwires form the secondary side of the transformer winding. The primary side is a single wire loop common to all units within the circuit. Power is supplied from a frequency-tuned portable exploder with unique circuit-sensing features.The MAGNADET System is expected to have particular application to shaft sinking, raising and tunnelling where the protective features as well as speed and efficiency are critical factors. Applications of the 'MAGNA' booster in quarries, open pits and longhole deck charges offer control over vibration problems and elimination of surface noise.IntroductionFor many years, electric detonators and electric blasting systems dominated surface and underground applications where controlled delay times were required. Control over the instant of detonation by blasting machines or power-line switches is the major safety feature.Electrical energy exists in many forms. It may originate from many sources. Electrical energy can be difficult to contain. It may enter or escape through a variety of conductive paths. It may fluctuate, concentrate or dissipate to pose a most elusive potential hazard."

Jan 1, 1982

By D. M. Cruden

"When two discontinuities form a tetrahedral wedge in a rock slope, a factor of safety for the wedge can be simply calculated (if motion is driven only by gravity and resisted only by friction) from plots of the normals to discontinuities on an overlay of a polar, equal-area spherical projection to which the great circles of a similar equatorial projection have been added.IntroductionThe stability of slopes in rock masses is often controlled by the discontinuities that exist in the masses. In particular, the geometry of the discontinuities constrains the ways in which the mass may fail. Displaying the orientation of the discontinuities on a spherical projection has been found to be a useful way of identifying possible failure modes. The most concise display shows the orientation of the normals (or poles) to the discontinuities that compose the fabric of the rock mass. Computer processing of large samples of discontinuity orientations is necessary if the sampling biases identified by Terzaghi (1965) are to be routinely corrected. Fortunately, displays of the poles to discontinuities (or pi diagrams) are relatively easily produced on the line printer of a computer or by a computer plotter (Cruden , 1978; Ramsden and Cruden, 1979). Unfortunately, further analysis of the stability of a rock mass has tended to use traces of typical discontinuities on a spherical projection rather than pi diagrams; examples may be seen in Hoek and Bray's book (1981)."

Jan 1, 1990