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By Luke A. Balzan

Access to information is a key component for making improvements to any process. This is particularly true for all aspects of the iron mining and steelmaking process. The ability to make rapid control decisions can significantly influence process outcomes, including ensuring product specification, mining quality, transportation limits, upgrade factors, waste bypass and direct shipping, among many others. While traditional laboratory methods provide feedback for such processes, having access to analysis results in real-time can lead to positive reactive and predictive control decisions to be made rapidly, leading to significant improvements throughout the process. Scantech has been designing, manufacturing and supplying technological products to the minerals industry since 2002 to enable the availability of such realtime information to a mine or plant, with the benefits being enjoyed by a wide range of operators. This paper provides a summary of the available technologies used in the iron ore and steel industries, as well as providing a case study of their use at an Australian site, and a description of the potential benefits of a range of analysis equipment.

Aug 17, 2017

By Jodi Roberts, Curtis Deredin, Jean-Guy Paulin

"Since the establishment of the Six Sigma quality improvement program in 2001, several projects have been successfully carried out in the copper-lead, zinc, copper separation, lead upgrading and bulk flotation circuits in the Brunswick Concentrator.This paper provides an update on the process improvement initiatives that have taken place since 2004 using the Six Sigma methodology:•,The recirculation of warm water to the flotation circuit (to save on energy costs)•,Installation of a heat recovery tower to recuperate the heat lost from the zinc dryers•,Installation of an extra row of cleaner-scavenger cells for the copper-lead circuit for extra capacity, and a new reagent scheme for the copper separation circuit that have increased copper and lead recoveries.INTRODUCTIONThe Brunswick Mine Concentrator (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 concentrator utilizes selective flotation to produce zinc, lead, copper, and bulk lead/zinc concentrates. The ore is a complex massive sulphide, consisting of approximately 20% valuable minerals, 60% pyrite and 20% silicates.Figures 1, 2, and 3 illustrate the historical annual average metallurgical performance and process improvements achieved at Brunswick Mine for the zinc, lead and copper concentrate products. The objective is to continuously direct metallurgical performance towards increasing grades and recoveries while minimizing operating costs."

Jan 1, 2008

By F. Flynn, P. Downey, G. Ritson

"Bell Creek Mill which has been in continuous operation since 1987 has undergone numerous operational changes in the past three years. The addition of over 2. 5 million tons of resource at over 13 git from Hoyle Pond Mine precipitated an expansion program for the Bell Creek Mill. This paper discusses the major changes that have occurred over the past two years to increase throughput and efficiencies. In addition, the refractory ore treatment options are also discussed.IntroductionThe Bell Creek Mill is located in the Timmins Goldcamp approximately 8km NE of porcupine Ontario. (Fig I.)The mill was originally constructed by Camamax in 1987 to treat the Bell Creek ore at a design throughput of 350tpd. The flowsheet (Fig 2.) consisted of two stage crushing, grinding, thickening, leach and drum filtration with gold recovery by Merrill Crowe.As ore depleted at Bell Creek, the Mill was purchased by Falconbridge to process ore from their Hoyle Pond property. Kinross purchased the Hoyle Pond property and Bell Creek Mill from Falconbridge in 1992.The successful exploration program at Hoyle Pond has led to several expansions and process design changes, with further changes planned over the next twelve months.In 1994, the mine produced 61,865 oz. of gold at an average cost of 197US$ per oz. In 1995 production was 91, 611 oz. at a cost of 187US$ per oz. Projecting the nine months ended September 30, production for 1996 will be 155,000 oz. at a cost of 165US$ per oz.In early 1997, the CIP expansion will be complete, with a target of 175,000 oz. at a cost of 176US$ per oz for 1997. The mill throughput will have increased from 400tpd to 1500tpd between 1994 and 1997.The changes to Bell Creek since 1994 have been numerous with very little of the existing equipment still in operation. The total cost of the expansion to date is 15 million C$. This paper discusses the major projects carried out during in this time. The focus will be to highlight the justification of each project, the design and engineering, some of the initial start-up problems and solutions.Figure 3 shows a plan of the existing mill facility together with the various additions that were carried out."

Jan 1, 1997

By D. Ortiz, J. R. Frias, E. D. Mast, J. J. Fañas

Falconbridge Dominicana (Falcondo) has operated an integrated tpy nickel laterite mine and ferro-nickel processing plant since 1972 in the Dominican Republic. The operation includes mining, a processing plant, an oil refinery, and a power plant. Falcondo has improved process efficiency over the years via modernisation and better understanding of the process. The present business environment of high fuel prices and high nickel prices present a challenge and an opportunity to Falcondo's operation. This paper gives an update of Falcondo's process, improvements in energy consumption, factors affecting energy consumption and how Falcondo is facing up to the current business environment.

Jan 1, 2005

By L. Trincado

Mantoverde is a heap leach-SX-EW plant that was commissioned in December 1995 at a production rate of 42,130 ton of copper per year and 5.4 million ton of ore per year. Copper production has steadily been increased to 57,290 ton in 2002. Forecast copper production for 2003 is 60,000 ton for an ore treatment rate of 8.5 million ton. Several improvements in the heap leach process have been implemented. The main process improvements are related to the optimization of heap height, particle size, irrigation rate and leach cycle, in addition to a better heap drainage design and a solution management system. A first dump leach operation was started in 1999 at a production rate of 1,922 ton of copper. A second dump leach operation was started in early 2002 at a production rate of 2,805 ton of copper. Dump leach production will be increased over time to as much as 24,000 ton of copper. The main heap leach process improvements, as compared to the original plant design, as well as the main dump leach operating parameters are discussed in this paper.

Jan 1, 2003

By K. Norris

"The Campbell mill has undergone numerous changes over the past 43 years. However the rate of change has increased significantly in the last 4 years. A new grinding circuit, carbon-in- pulp circuit, pressure oxidation plant, and column flotation circuit are all new additions. Other changes have occurred in the last 2 years including a large reduction in sodium cyanide consumption, and the introduction of a computer controlled grinding circuit. More improvements are planned in the next 2 years. Some of these improvements include the construction of an effluent treatment plant, and the replacement of filtering and Merrill-Crowe precipitation with carbon-in-leach and electrowinning.Recent changes and improvements to the Campbell mill are a commitment by Campbell mill personnel and Placer Dome Inc. to decrease operating costs, increase gold recovery and gold production, improve industrial hygiene and safety, and meet environmental compliance with current government legislation.INTRODUCTIONThe Campbell Mine has been and continues to be one of Canada's premier gold mines. Campbell Mine is 100% owned and operated by Placer Dome Incorporated. Milling of ore commenced in 1949 at a rate of 300 tons/day producing 58,000 ounces per year of gold. In 1992 Campbell Mine will mill 1340 tons/day of ore at a grade of 0.6 ounces/ton, producing 275,000 ounces of gold at a cash cost of $205.00 Cdn./ounce.This paper discusses some of the changes that have been made to the Campbell mill in the past 4 years. The flowsheet has undergone extensive changes and will continue to change rapidly in the next 2 to 3 years. A simplified flowsheet of the Campbell mill is shown in figure 1."

Jan 1, 1992

A major Brazilian iron ore producer, SA Minerayao da Trindade (Samitri), has recently completed modifications at two operations which involve the use of Derrick high frequency vibrating screens. Details of these modifications are presented, together with a review of product quality improvements.

Jan 1, 1997

A Mineração da Trindade (Samitri) is a major Brazilian iron ore producer. Founded in 1939, privately owned Samitri operates six mines with a total production capacity of 14.5 Mt/a (16 million stpy). The mines are located in southeastern Brazil in the state of Minas Gerais. They are operating in the iron ore quadrangle, Brazil's primary iron ore-producing region. In addition to iron ore production, Samitri has the capability to produce 350 kt/a (386,000 stpy) of ferruginous manganese ore from two mines, also located in the iron ore quadrangle. Historically, about 70% of Samitri's production of lump ore, sinter feed and pellet feed is exported. Destinations include Belgium, Luxembourg, France, Germany, Trinidad and Tobago, China, Turkey and the United States. Alegria Mine In September 1989, Samitri started a new processing plant to treat itabirite, a low-grade iron ore. The goal of the plant was to produce sinter feed (coarse fraction) and pellet feed (fine fraction). Primary separation of sinter feed from pellet feed was accomplished with conventional vibrating screens making a 0.4-mm (40-mesh) cut. The screen oversize was stockpiled as sinter feed. The undersize was deslimed with hydrocyclones and upgraded by conventional froth flotation. Resulting pellet feed grades ranged from 3% to 3.5% Si02. A change in pellet feed requirements by Samarco Mineração SA, a Samitri subsidiary, called for Si02 levels below 1 % and increased production levels. Moreover, market demands called for a change in sinter feed size distributions. Unfortunately, lower pellet feed Si02 levels could not be achieved with the existing process. This was because of the presence of 35% +0.15 mm (+100 mesh) in flotation feed. Flowsheet development. Laboratory and pilot-plant studies conducted at Samitri's research facility found that to achieve lower Si02 levels, the +0.15 mm (+100 mesh) in flotation feed must be kept below 5% to 10%.

Jan 1, 1997

By M. J. King

The Chino Smelter embarked on a program to reduce smelter emissions. Fugitive sulfur dioxide and particulate emissions were reduced by (i) removing the flash furnace settling chamber and (ii) installing a baghouse, to treat converter secondary emissions. Neutralization plant capacity was increased, to accommodate increased flow from the flash furnace off-gas cleaning system and to reduce costs.

Jan 1, 1998

The implementation of a process information management system (PIMS) is to provide a single online, real-time information system. This system provides a unique and completely open view for everyone, based on the key business drivers. It is structured around the three key concepts: process, maintenance and stocks. It combines numerous applications and provides accessibility to common tools and reports, through a web-based user interface, for every one from the floor operator to the General Manager. This æunique and commonÆ view displays raw, online process information that provides a quick health check of the operation at a glance, highlighting areas that require further investigation. The system is based on a hierarchical system of views, from the overview of the whole plant flow sheet to the more detailed operational shop view. It provides a synthetic view between continuous and batch operations, enabling the tracking of each batch produced. The batch view displays the critical batch components, and a comparison with each component of an ideal batch. This enables detailed analysis of each batch to identify areas of improvement. The information system will consist of an online reconciliation of stocks and flow data. This enables focus on the recovery of each process unit on a regular basis. This paper discusses the design strategy for the Process Information Management System, to ensure a unique and open view on the key business drivers is achieved and implemented successfully.

Jan 1, 2005

By E. F. Loros, T. J. Smolik, V. G. Lofftus

Since plant start-up in January 1983, Golden Sunlight Mines Inc. has implemented several process changes and improvements. Among these are a pulp preaeration circuit and a sand tailing retreatment circuit. The preaeration circuit reduces reagent consumption during gold dissolution. The sand tailing retreatment circuit was added to recover and process separately pyrite concentrate to maintain acceptable overall gold recoveries with the more refractory sulfide ores. Research and plant operating data along with process and improvement descriptions are presented.

Jan 1, 1987

By V. G. Lofftus

Since plant start-up in January 1983, Golden Sunlight Mines, Inc. has implemented several process changes and improvements. Among these are a pulp preaeration circuit and a sand tailings retreatment circuit. The purpose of the preaeration circuit is to reduce reagent consumption during gold dissolution. The sand tailings retreatment circuit was added to recover and process separately pyrite concentrate to maintain acceptable overall gold recoveries with the more refractory sulfide ores. Research and plant operating data along with process and improvement descriptions are presented.

Jan 1, 1987

By Farlow C. Davis

Magma Copper Company, San Manuel Division, is a wholly owned subsidiary of the Newmont Mining Corporation and located at San Manuel, Arizona. The ore body is a dessiminated porphry copper deposit in quartz monzonite. The primary copper mineral is chalcopyrite with minor amounts of chalcocite, bornite, and covellite. The molybdenite occurs mainly on fracture faces or else associated with quartz veinlets. Pyrite is the major sulphide mineral in gangue. The feed to the concentrator from the underground mine is approximately 0.720 percent copper and 0.029 percent molybdenite. The concentrator has a design capacity of 62,000 tons of ore daily. After a standard ore treatment circuit consisting of grinding, rougher flotation, regrinding, and cleaning, a bulk concentrate is produced which contains 27 to 29 percent copper and 1.0 to 1.2 percent molybdenite. This concentrate is pumped to the molybdenite plant feed thickener.

Jan 1, 1977

By J Col, D La Rosa, W Valery, A Jankovic

Metso Minerals Process Technology Asia-Pacific and South America (MMPT) has been working with operations around the world to increase their efficiency through æMine-to-MillÆ or Process Integration and Optimisation (PIO) projects. These projects have delivered significant improvements in mine efficiency, mill throughput and reduced operating costs at mines around the world. The MMPT methodology involves rock characterisation, site auditing, data collection, modelling/simulation and implementation of integrated operating and control strategies on site. This results in significant benefits to the operations û for example, 5 to 20 per cent increases in concentrator throughput have been measured. MMPTÆs rock characterisation utilises simple and inexpensive measurements that can be performed by trained site personnel. The advantage of these measurements is that a large amount of data can be collected in a very short timeframe, as the samples do not require shipping to an outside laboratory. Typically, a PIO project starts with a site visit to perform blasting and process audits, collect high quality data including measurements of run-of-mine fragmentation and survey data around all crushing and grinding circuits. These measurements are combined with rock characterisation and the definition of strength and structure domains to model the complete production chain. Site-specific models of the blast fragmentation, crushing, grinding and flotation processes can then be developed. This proven methodology has applications ranging from greenfield projects to long-standing operations with AG/SAG or conventional grinding circuits. Process improvements can be higher mining productivity, higher mill throughput, decreased overall operating costs and higher flotation or leach recovery. This paper discusses a recent application of PIO conducted at a large open pit operation in South America and emphasises the potential that every operation has to ædo more with what they haveÆ.

Jan 1, 2007

The current mining operations at Newmont Boddington Gold Mine (NBG) commenced in 2008, and commissioning of the processing plant started in the latter half of 2009. Metso Process Technology and Innovation were engaged to assist NBG with commissioning and project ramp-up through the implementation of a comprehensive ?Mine-to-Mill? Process Integration and Optimisation project. This methodology entailed extensive data collection which included drill and blast audits, ore characterisation, comprehensive comminution circuit surveys and review of operational data to assess the limitations within the current mining and processing operations. The results of these investigations have been used to define the operating base line of both the mining and processing areas and identify improvement opportunities. The use of modelling and simulations, utilising actual production data, has allowed for multiple scenarios to be evaluated, minimising the requirement for actual trials and thereby minimising impact on the operation. Improvements implemented to date include: the introduction of routine rock strength measurement for inclusion in block models, modifications to blast design improving ROM fragmentation and downstream comminution process performance, and changes to improve performance of secondary crushing and grinding circuits. Close cooperation between the mine and plant personnel is playing a significant role in overcoming the challenges presented to this operation and further improvements are targeted for the second full year of process plant operation.

Jan 1, 2012

By S. Tavani, T. Rees

The current mining operations at Newmont Boddington Gold Mine (NBG) commenced in 2008, and commissioning of the processing plant started in the latter half of 2009. Metso Process Technology and Innovation were engaged to assist NBG with commissioning and project ramp-up through the implementation of a comprehensive “Mine-to-Mill” Process Integration and Optimisation project. This methodology entailed extensive data collection which included drill and blast audits, ore characterisation, comprehensive comminution circuit surveys and review of operational data to assess the limitations within the current mining and processing operations. The results of these investigations have been used to define the operating base line of both the mining and processing areas and identify improvement opportunities. The use of modelling and simulations, utilising actual production data, has allowed for multiple scenarios to be evaluated, minimising the requirement for actual trials and thereby minimising impact on the operation. Improvements implemented to date include: the introduction of routine rock strength measurement for inclusion in block models, modifications to blast design improving ROM fragmentation and downstream comminution process performance, and changes to improve performance of secondary crushing and grinding circuits. Close cooperation between the mine and plant personnel is playing a significant role in overcoming the challenges presented to this operation and further improvements are targeted for the second full year of process plant operation.

Jan 1, 2012

By Toshihiko Emi

The quest for cleaner steel is driven by increasingly stringent requirements from the manufacturing and construction industries. Key issues are the occurrence and removal of inclusions; These are discussed in the context of the unit processes of deoxidation, refining, transfer and casting of molten steel. Process thermodynamics and kinetics are also discussed. Recent progresses achieved and problems yet to be solved are elaborated, and an integration of the unit processes into a system to produce extra clean, steels with better performance is presented.

Jan 1, 1999

By C. G. Anderson

Extraction of valuable resources from complex orebodies will become more common. This is obvious for two reasons. First, the cleaner and more readily processed ores have continually been depleted through centuries of mining. Second, new technologies have evolved for effectively handling complex ores. One of these new processes has been in place at Sunshine since 1984. Based on sulfuric acid oxygen pressure leaching with nitric acid as an oxidizer, this patented technology allows silver and copper to be efficiently recovered from a complex sulfide concentrate. As efficient as it is, this process represents novel technology found nowhere else on an industrial scale. As such, a research program was undertaken in 1989 to optimize this leach process and to better understand it. From this study, several potential plant improvements were found and recommended. As a result, two of these options, nitric acid replacement by sodium nitrite and concentrate regrind are now used in day to day operation at Sunshine. Patenting of these changes was recently accomplished (1). Thus, the development, perceived mechanisms, plant integration and potential applicability of this technology will be covered in this paper.

Jan 1, 1994

By Frank Agyemang, Zainab Nasrullah, Richard LaDouceur, Mehran Saddat

To sustain the circular economy, defence applications, and other renewable technologies, recycling rare earth elements (REEs) and other critical elements from their secondary resources is important. This cause has resulted in rigorous research and development for viable extraction and separation of REEs. Previously, Sm-Co recycling has been done with technologies, which fall under the categories of pyrometallurgy, physical separation, and hydrometallurgy. All these methods have limitations associated with energy, cost, and environment. Reportedly, the chemical leaching technology has successfully recovered and separated Sm-Co. Still, it has limitations associated with slow mass transfer and leaching kinetics, and there is a need to intensify the process to make it time efficient. This approach has also adversely impacted the environment by an extensive use of toxic, corrosive, non-selective, and expensive reagents. In this research study, chemical leaching of Sm-Co was performed using this new class of solvents, Deep Eutectic Solvents (DESs), which fall under the category of ion metallurgy. Four different DESs were used, proven to be green, non-toxic, biodegradable, cheap, and selective for cobalt over samarium by 82% leaching conversion. To improve the slow mass transfer and leaching time, this new technology of resonant vibratory mixing (RVM) was also tested. RVM intensifies mixing by establishing near instantaneous, low energy mixing conditions through resonance. It has been shown to improve the adsorption kinetics and was tested for the leaching kinetics. Four combinations of DESs were prepared, which are made up of two quaternary salts: Choline Chloride and Tetra Butyl Ammonium Chloride, and three organic compounds: Oxalic Acid, Urea, and Ethylene Glycol. These combinations were used for chemical leaching of Sm-Co with leaching factors of time, temperature, and type of DESs. After leaching, the samples were tested with and without resonant vibratory mixing with conditions of time, intensity (%), and type of DESs. Samples were analysed with Induced Coupled Plasma - Optical Spectroscopy (ICP - OES). Future work will involve a life-cycle assessment to assess the RVM technology with other conventional mixers, and an extensive study of DES properties to improve selective leaching.

Feb 1, 2025

By Shuli Teng, Vladimir Sujansky, Matthew Rawls, Ivan Junarsa

In recent years significant advances have been made in chemical processing technology. In particular, process intensification using micro-technology has had some success in changing and improving chemical processes including mixing. Process Intensification is the miniaturization of unit operations and processes whereby a smaller compact piece of equipment takes the place of a larger one at the same given capacity or mass flow rate. This paper summarizes research into the application of the technology for manufacture of high internal phase water in oil ammonium nitrate emulsions (ANE’s) at low energy cost and with very low oil/fuel blend content. The emulsions can be used as precursors for preparation of explosives. The quality of the emulsion prepared was assessed through droplet and crystal analysis and compared with that of emulsions made by conventional large scale jet mixing technology.

Jan 1, 2014