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ABSTRACT Understanding process histories and worker exposures in nickel production operations is critical in determining the role nickel compounds play in respiratory cancer incidence. As part of a series on Vale Canada’s (previously known as Inco) nickel processing operations, this paper includes descriptions of Ni electrolytic operations at refineries in Port Colborne, Ontario (1922–1984), and Thompson, Manitoba (1961–present). Industrial hygiene measurements, by area and personal sampling, of workplace aerosols at these operations are reported.

Jan 1, 2014

By B. R. Conard

Copper refining at Vale Canada (previously known as Inco) has been associated with Ni production. Because Cu and Ni carry risks for adverse health endpoints through inhalation exposure, it is critical that their aerosol levels, and the metallurgical processes through which they enter the air, are understood. Because certain Ni substances have been linked to respiratory cancers, it is also important to characterize the amounts and types of Ni compounds in occupational settings. This paper describes electrorefining and electrowinning operations near Sudbury, Ontario (1930–present), and gives aerosol measurements (1978–present).

Jan 1, 2014

By J Bean

Iluka Resources Ltd developed the Jacinth-Ambrosia Mine (Jacinth) in the Eucla Basin during 2009 and 2010. In this arid climate the operation relies on hyper-saline groundwater from a palaeochannel for process and potable water supplies. The water is hyper-saline, acidic and mildly reducing, with high ferrous iron concentrations. Ferrolysis commences on exposure of water to oxygen, resulting in increased acidity and the conversion of dissolved ferrous iron to insoluble ferrihydrite. The unstable groundwater forces a careful balance between interventions relating to maintaining pipeline efficiency, corrosion protection and processing aspects. Providing an oxidising environment at the head of the pipeline will result in the precipitation of akaganenite and goethite in the pipeline, which over time reduces pipeline efficiency. However, sending too much ferrous iron forward may reduce processing performance.The processing plant experiences changes in water chemistry in response to the variability of iron concentrations and pH within the pipeline, and the spatial and chemical variability of ore. As the main orebody at Jacinth contains little buffering capacity a source of carbonate in the overburden is carefully used to allow the cost-effective control of process water pH.This paper highlights the importance of understanding the chemistry of saline make-up water, ore, and overburden when designing water treatment facilities and heavy mineral processing facilities.

Oct 5, 2011

By M. Kalicinski, M. Lyssyy

"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 real-time 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 case studies of their use in African and Australian iron ore and European steel, as well as a description of the potential benefits of a range of analysis equipment.INTRODUCTION Access to information is critical for any process, and is a fundamental component for making process control decisions. In order to yield effective processing outcomes, it is important for that information to be readily available, preferably as quickly as possible, and to be as accurate as possible. While speed and accuracy are often traded off against each other, there are numerous technologies available in a processing environment that allow for both rapid flow of information and a high level of accuracy. The use of on-belt analysis equipment has a long trusted history of use in a number of mining and processing environments and industries, providing information such as elemental composition and grade of conveyed materials, moisture content, waste proportion and energy information. Australian company Scantech has been a provider of such equipment since 1981, and has become an industry leader in both the supply and development of on-belt analysers across a range of industries."

Jan 1, 2018

By Wayne C. Stewart

Freezing of high pressure air lines and pneumatic equipment has been a recurring problem in the Thompson Smelter. The particular severity during the winter of 1989-90 resulted in costly process disruptions and repairs. A process improvement team with representatives from operations, engineering and both maintenance supervision and the shop floor was established to develop solutions. Their mandate included process evaluation, design, equipment and in-plant commissioning. In 1990, upon recommendation of the team, we installed three Refrigerant/Desiccant air dryers with a total capacity of 20,000 S.C.F.M. to service the Smelter. This paper discusses processes and process improvements associated with this installation.

Jan 1, 1993

By Xiao-dong Xiang, Hong-bo Jin, Ming-sheng He, Huo-guo Pang, Can-hua Li

The specification of the steel slag aggregate will be mutated if the ag- gregate is prepared by a single type crusher. The specification stability of the steel slag improved significantly when the jaw crusher and the cone-crusher are com- binedinthecrushingprocess.Thecombinationofthecrusherandscreenisapplied to produce steel slag aggregate while the roller washing process for removing the dustfromthesurfaceofaggregate.Apilotproductionlinehasbeenestablishedby this technology. The specification stability and the road performance indicators of thesteelslagaggregateshavebeengreatlyimprovedbythispilotproductionlineas compared with the traditional production line. The particulate of the steel slag aggregate is decreased by 81% compared to the traditional line. (cid:1) (cid:1)

Mar 1, 2018

Jan 1, 2007

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 T. Maio

Twelve years ago, Kennecott Utah Copper modernized its Refinery in conjunction with the modernization of the Kennecott Smelter with the latest flash smelting and flash converting technologies. The Refinery modernization consisted of installation of new polymer concrete cells, installation of KIDD TPS (total production stripping) system, installation of automated materials handling system, and the construction of a new hydrometallurgical slimes treatment process and precious metals plant. This paper outlines the Refinery operations and process improvements. Also presented are the newly implemented technologies and operating results of one of the world' s largest and most modern electrolytic copper refineries.

Jan 1, 2007

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 C. Otto Walls

Six years after the start of gold heap leaching at Smoky Valley Mining, Round Mountain, Nevada, three areas of process improvements are examined to show how productivity was increased. Original design concepts and practices are reviewed in order to compare to current methods. The evolution of change in heap mainterance is also reviewed.

Jan 1, 1984

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