Search Documents

By T. J. Wells

THE blast furnace is the base of the steel industry, since there is no commercially practical way of converting iron ore directly into steel. In three hundred years, the blast furnace has developed from a small unit using charcoal as fuel and producing about one ton of iron in twenty-four hours to a furnace making upwards of 1,500 tons a day. The principle of the blast furnace is briefly this: A descending column of stock, consisting of ore, fuel, and flux, is met by an ascending stream of gases, consisting in part of gases formed by the combustion of the fuel and in part of pre-heated air which is blown into the lower part of the furnace. The flux combines with the impurities in the ore and the ash in the fuel to form slag, which is drawn off as liquid.

Jan 1, 1943

By Luis A. Tondo

The Paracatu Expansion Project III in Brazil was implemented between 2006 and 2008 to increase the existing capacity from 20 to 61 Million tons per year of gold ore treatment. This expansion led the Brazilian subsidiary of the Canadian Kinross Gold Corporation to become the single largest gold producer in Brazil and the largest single gold concentrator in the world, with a nominal capacity to treat around 167,000 tons per day of ore. This paper describes the Project Development areas for the Paracatu Expansion, using the approach proposed by the Project Management Institute (PMI) and the methodology included in the PMBOK (Project Management Book of Knowledge). The author has more than 20 years of experience in the gold mining industry, having worked as a plant metallurgist, mill superintendent and development manager for RPM until he took the position as the Project Manager of the Paracatu Expansion III in 2005. Luis Tondo has a BSc in Mining Engineering from UFRGS-Brazil, an MScEng from the University of Queensland - Australia and an MBA degree from FDC-Brazil. Luis is currently based in Santiago-Chile, acting as the Project Director for developing projects in Latin America for the Kinross Gold Corporation.

May 1, 2009

By P. F. Venus

In December 1977, a large pillar was removed by blasthole mining methods at lnco's Creighton No. 3 mine. Although the 2,363.000-ton blast was not a size record for a single underground blast at Inco, it did represent a significant departure from conventional blasthole mining. In terms of the application of nominal 6-inch-diameter boreholes underground, coupled with bulk slurry explosives, the magnitude of the blast is considered a first and very important development. The application of large-diameter boreholes in underground operations was first tried successfully in 1973. Since that time over 13/4 million feet have been drilled in this adaptation of an open-pit technique to underground operations. The blast, which required 708 holes, totalling 131,500 feet of drilling, was loaded in a six-week period, using special slurry handling techniques developed jointly by Inco and CIL. Inco operating and engineering personnel consider this application of large boreholes and slurry explosives for blasthole mining a very important milestone in modern mining technology.

Jan 1, 1978

By G. J. Heferen, A. Pranowo, N. J. Aslin, P. O. Eriksson

Glencore Technology (GT) has over four decades experience supplying stainless steel cathode plates (“cathode plates”) to the electro-refining and electro-winning industry. Cathode plates are typically the single biggest capital investment in a refinery. Refineries may view cathode plates as fixed asset or consumables depending on their operational characteristics. This paper examines the issue of cathode plate life and the strategies and philosophies used by different plants in the management of their cathode plate asset. Some plants operate with their original plates after more than 20 years. Others accept high turnover and regular maintenance as normal operating practice. Reference data are provided on plate life for various operating plants including benchmark plants achieving best-practice plate life and operating cost. The role of the electrode handling equipment on cathode plate longevity is also examined, including latest developments in Cathode Stripping Machine, robotic copper stripping, and full-automation production cranes. The ability to identify and manage the population of plates in service is also critical for maximising plate life and minimising its overall operating cost. This paper discusses a novel and unique RFID system for tracking and managing cathode plate inventory. INTRODUCTION Permanent cathode plates The adoption of permanent stainless steel cathode electrodes in the electro-refining of copper was the most significant process development since the first commercial electro-refineries were built in the late 19th century. It provided significant improvement over the labour intensive and complicated starter sheet system. Copper grows over the permanent cathode blade for a number of days before being stripped, and the permanent cathode can be returned straight back to cells for the next cathode cycle. Glencore Technology (formerly Mount Isa Mines (MIM), then Xstrata Technology) has been manufacturing permanent stainless steel cathode plates from the late 1970s with the birth of ISA PROCESS™, and the Kidd process that came one decade later. Invented and commercialised by Mount Isa Mines, the ISA PROCESS™ was first implemented into Copper Refineries Limited (CRL), Townsville, in 1978. The KIDD PROCESS by Falconbridge evolved in the 1980s and was first implemented into the Kidd Creek Tankhouse, both operations converting from traditional copper starter sheets.

Jan 1, 2019

By R. H. Waddington

Historical The limitations of reverberatory furnace operation have prompted many investigators to consider electric furnaces for melting electrolytically refined cathode copper. In the majority of cases where experimental work was performed, the furnace used was of the granular resistor, induction, or indirect-arc rocking type, and attempts to adapt the three-phase direct-arc furnace to copper melting appear to have been relatively few. In 1935, the International Nickel Company of Canada, Limited, carried to an advanced stage its experimental investigation of continuous melting of copper in the three-phase direct-arc furnace, and demonstrated that this process was technologically and economically practicable. Trial operations were conducted at the Huntington, W.Va. works of the Company, and were followed by the installation at Copper Cliff, Ontario, in 1936, of a full-scale unit for commercial operation. Two years later, a second unit was installed -which raised the electric melting capacity to a point permitting complete replacement of the coal-fired reverberatory furnace operation in the production of refined copper castings.

Jan 1, 1946

By W. Dietzel

Fracture mechanics based techniques are used to gain insight into the phenomenon of stress corrosion cracking (SCC) and to develop guidance for avoiding or controlling SCC. From constant extension rate experiments under rising load or rising displacement conditions the susceptibility of high strength steels, aluminum, magnesium and titanium alloys to SCC and hydrogen embrittlement can be assessed. Such tests on pre-cracked specimens are also well suited for studying the mechanisms leading to SCC by employing appropriate models for the degradation of metallic materials which take into account the uptake of atomic hydrogen from the corrosive environment. Measurements of crack growth resistance curves using the crack tip opening displacement as fracture parameter can be compared with simulated R-curves obtained from modeling of the mechanism of hydrogen embrittlement. The materials investigated are a high strength steel and a magnesium alloy both exposed to environmental conditions which fostered the uptake of hydrogen.

Jan 1, 2010

By C. I. Godwin

"The relative-value (R-value), discrimination-factor (D-factor), and vector-ratio (V-ratio) method (RDVM) provides a geological knowledge-based statistical and geological-genetic interpretation scheme for geochemical data that enhances discovery in geochemical exploration. The practical advantage of RDVM is that it synthesizes geochemical features geologically related to ore-deposit discovery in three steps: reclassifying element concentrations using log-probability plots into R-values; calculating geologically defined D-factors from R-values; and determining V-ratios. D-factors are the sum of R-values, divided by the number of R-values summed. Based on the analyses selected, D-factors mimic rock or mineral deposit signatures. V-ratios refine interpretations of rock type and vector to orebody locations.RÉSUMÉ La méthode de la valeur relative (valeur R), du facteur de discrimination (facteur D) et du rapport de vecteurs (rapport V) (RDVM), fournit un schéma d’interprétation des données géochimiques basé sur les statistiques et les connaissances géologiques et la génétique géologique; ce schéma contribue aux découvertes en exploration géochimique. L’avantage pratique de la RDVM est qu’elle fait la synthèse des caractéristiques géochimiques reliées géologiquement à des découvertes de gisements de minerais en trois étapes : une reclassification des concentrations des éléments au moyen de courbes de probabilité logarithmique en valeurs R; un calcul des facteurs D définis géologiquement à partir des valeurs R et la détermination des rapports V. Les facteurs D sont la somme des valeurs R divisés par le nombre de valeurs R additionnées. Selon les analyses choisies, les facteurs D imitent les signatures de la roche ou des gisements minéraux. Les rapports V peaufinent les interprétations des types de roches et dirigent vers des emplacements de gisements."

Jan 1, 2016

By O. K. Mahabadi, A. Lisjak, B. S. A. Tatone, N. Vlachopoulos

"Numerical simulations are widely adopted in the design of several types of rock structures, including tunnels, caverns, rock cuts, and open pit and underground mines. In recent years, analyses based on the hybrid finite-discrete element method (FDEM) have been shown to provide a realistic representation of rock mass deformation and fracturing processes. To date, the FDEM approach has successfully yielded qualitative and quantitative results for several practical rock engineering applications, yet it has lacked the ability to consider the implementation of rock-reinforcement measures. Since rock reinforcement is often used in civil and mining applications to improve the strength and deformational behaviour of a rock mass, the ability to incorporate such features into FDEM analyses is essential to extend its applicability to a broader range of problems. The work presented in this paper represents an important first step towards developing a simulation tool that can be used for practical rock engineering applications, including the design of underground excavations and rock slopes.INTRODUCTIONRock support and reinforcement measures are often employed in civil and mining rock engineering projects in order to maintain or improve the strength and deformational behaviour of rock masses. The preferred type of reinforcement or support elements along with the preferred layout and timing of installation depend on the in-situ ground conditions, the nature of the rock mass and excavation method. Over the last two decades, numerical modelling has been increasingly used to design and attempt to optimize rock reinforcement and support systems. As such, most rock engineering-specific modelling software now offers various approaches for modelling different rock reinforcement and support elements."

Jan 1, 2015

By Rob Boom, Yasuyuki Tozaki, Greg Traquair

The objectives of the business case are to examine a proposed metallurgical project and answer fundamental questions about project feasibility, risks, opportunities, and value. A business case fulfills these basic functions: estimates economic value; helps to understand competitiveness; serves as a risk management tool; and serves as a communication tool. A business case evolves with the project life cycle, and supports the gate reviews at the end of each phase of engineering, through to project construction and operations. A business case must be holistic, including all elements of scope that can impinge on project risk and value.

Jan 1, 2015

By H. Lundberg

Introduction The world has been suffering from an excessive production of all kinds of raw materials, and the metals and petroleum are no exception. As a consequence, at the moment, the urge to find new mineral deposits is almost non-existent and prospecting languishes. But from previous experience we know that sooner or later new supplies will be needed. Mineral deposits become exhausted, and to keep up the supplies of our metals and petroleum, new deposits must be found. Even now, a supply of petroleum of domestic production would not be unwelcome in Canada. It is not, therefore, so entirely malapropos to discuss means of finding ores and oil as it would seem. Almost any physical property connected in definite manner with minerals and rocks may be made the basis of geophysical exploration. This is particularly true of electrical resistivity, and its utilization in electrical prospecting has been the deciding factor in the discovery of such big ore-bodies as Buchans mine, Newfoundland, and the large copper ore-bodies in northern Sweden, etc., as well as in the solution of many foundation and structural problems. The importance of electrical prospecting has been growing steadily, and already there exists hardly any exploration project involving geological problems which may not profit by its application. Electrical prospecting is marching on, and neither temporary failures, nor incompetence, nor over-optimism, nor ill-will and pessimism, nor bad times and business depression, will be able to halt its progress.

Jan 1, 1931

By Q. Zhang, J. A. Finch

"Sphalerite flotation in the absence of copper activation at moderately alkaline pH has been observed in laboratory studies. An in-plant test of this observation was conducted at Kidd Creek Mine LTD. using a portable minicell flotation circuit. The results confirm that raising the pH causes sphalerite flotation.The testwork with the minicell circuit is described. The circuit, built around 2, 51 cells donated by the Noranda Technology Centre, was funded by Air Liquide and NSERC. It includes a data acquisition system to monitor continuously dissolved oxygen, pH and Pulp potential.INTRODUCTIONFlotation of sphalerite is normally practised by adding CuSO4 as an activator under alkaline pH. Recently there have been a number of laboratory and plant examples of sphalerite flotation without deliberate addition of cu++ ions (Girczys, 1972; Mukherjee, 1976; McTavish, 1980; Marouf et al., 1986; Mielczarski, 1986; Leroux et al., 1987; Palsson and Forssberg, 1989; Sandoval-Caballero et al., 1990; Zhang et al., 1991).In batch tests, with a sample of Pb/Zn ore from Polaris, Leroux et al. (1987) found that sphalerite became floatable after adjusting pH to 9. 5-11: they ruled out natural floatability or the formation of elemental sulphur on the surface but suspected iron hydroxy compounds were responsible. Sandoval-Caballero (1990) conducted a continuous minicell test at Brunswick Mining and obtained a 44 % Zn recovery and 40.5 % Zn grade concentrate without deliberately adding CuS04 at pH= 10.5. With single mineral studies, Zhang et al. (1991) revealed good sphalerite floatability (over 80% recovery) in pH range 8 to 11 and found that this floatability was related to pH, dissolved oxygen (DO) level and Fe++ species present in the system.To explore further the conditions under which sphalerite can float without addition of CuSO4 , a continuous pilot test using minicells was performed at Falconbridge Ltd., Kidd Creek division. The set-up is briefly described (a more detailed description is given elsewhere in these proceedings) with emphasis on the data acquisition system - dissolved oxygen, pulp potential and pH were monitored continuously. Results of testwork investigating pH, CuS04 addition and gas composition are presented."

Jan 1, 1992

By Frederik H. Kriel, John Ralston, Craig Priest

"Stream-based microfluidic solvent extraction offers a novel alternative to bulk-scale mixer-settler operations. However present maximum throughputs are restrictive and there are engineering challenges that need to be overcome before the technology is robust. This is especially the case for mineral processing, where circuits must be able to handle variable feed streams with long retention times and where maintenance should be minimized. This paper highlights research directed at investigating and evaluating these challenges for actual mineral leach solutions of metal ions. Molecular and particulate channel fouling is discussed. Most extraction systems studied to date show no effects that would preclude use of the technology. For rare earth elements (REE) with fast extraction rates, scale-up of volumetric throughput to 100 L/h using suitable arrays of channels, microfluidic chips and modules is shown to be achievable using a small contactor (approx. 2 m3) platform. This requires only 2–3 % of the typical aqueous phase inventory and residence time used in an equivalent mixer-settler. For a circuit with 100 contactors, the overall residence time would be less than 1 h, using an aqueous inventory of 40 L.INTRODUCTIONHydrometallurgy is of pivotal importance in many mineral processing circuits around the world, with liquid-liquid solvent extraction (SX) a key step in the separation of many base metals (e.g. Cu and Ni), radioisotopes, precious metals, and the ‘technology’ metals, such as rare earth elements (REEs) (Ritcey & Ashbrook, 1979). The standard equipment for SX in mineral processing is the mixer-settler, in which liquid dispersions are created, by agitation, to increase the surface-to-bulk ratio and, thus increase the mass transfer rate between the liquid phases. In stream-based microfluidic SX (microSX), these high surface-to-volume ratios are achieved by contacting microscopic streams (Ciceri, Perera, & Stevens, 2014), rather than forming small droplets, so that phase disengagement can be accelerated (essentially instantaneous via branching of the two streams of liquid at a channel junction). MicroSX is profoundly different from bulk mixer-settler SX operations and offers exciting opportunities for processing hydrometallurgy solutions (Kriel, Holzner, Grant, Ash, Woollam, Ralston, & Priest, 2015; Priest, Zhou, Klink, Sedev, & Ralston, 2012). Nonetheless, the advantages of using microfluidic environments are presently balanced by very significant challenges relating to throughput, process control, coupling of stages, flow stability, and fouling. If these challenges can be met using smart chip designs, process control and clever engineering, high-value/low-volume SX processes stand to benefit greatly."

Jan 1, 2016

By B. Tonn, F. Kröger

"The continued development in engine technology is leading to an augmentation in power density which steadily elevates the requirements for thermally and thermo-mechanically highly loaded components such as cylinder heads and pistons. Due to these high performance requirements conventionally applied Al-Si alloys have reached their application limits, since their mechanical properties deteriorate quickly under the influence of heat. Improved applicability is given by Al-Cu-based casting alloys which have a superior high-temperature strength than Al-Si alloys. Since Al-Cu alloys exhibit insufficient casting characteristics, especially regarding hot tearing susceptibility and increased tendency for porosity, it is currently not possible to cast geometrically complex components in robust permanent mold casting processes. The further development of Al-Cu alloys is aimed at finding an optimum between improved castability while high-temperature strength and thermal conductivity are not deteriorated. It is known that a high amount of eutectic reduces the hot tearing susceptibility of an alloy, but it reduces thermal conductivity at the same time. In this paper it will be presented how the conflicting objectives – improved high-temperature strength, good thermal conductivity and reduced hot tearing susceptibility – can be brought together to develop an optimized Al-Cu alloy for application in permanent mold casting.INTRODUCTION At the beginning of the 21st century car, engine blocks were primarily made of gray cast iron (GJL). Less than half a decade later, the choice of material had shifted towards lightweight materials. Ever since, the car engine manufacturing is dominated by aluminum-based alloys. The weight of car engine blocks could thus be reduced by around 50% due to the lower specific weight of aluminum alloys compared to gray cast iron. Furthermore, the high thermal conductivity of aluminum alloys allowed a reduction of complex cooling channel systems and thereby promoted the advancement of this material group. The further development in engine technology leads to an augmentation in power density which elevates the requirements for thermally and thermo-mechanically highly loaded components. For example, in diesel-powered car engines the upper required limits can reach an ignition pressure as high as 230 bar and gas temperatures of up to 1000°C. Thereby, thermal loads can cause high alternating thermal stresses (Grzincic, 2003) which can effectively be reduced by providing high thermal conductivity."

Jan 1, 2017

By Luis Magallanes-Hernández

"Industrias Peñoles, S.A. de C.V. (Peñoles) in Mexico, is a major silver producer. The Peñoles Mining Division has eight Mining Operations and in seven of them, flotation is used to concentrate the metal and mineral values. Common metals and minerals values are: metallic gold and silver, gold-silver alloys, silver sulphide minerals (acantite, pyrargirite, argentite, proustite); lead sulphide mineral, galena; zinc sulphide mineral, sphalerite; and copper sulphide minerals (chalcopyrite and bornite).In the last years, a special emphasis has been given to using modal analysis to identify ore mineralogical limitations, in order to direct efforts into key areas where opportunities exist to improve the metallurgical results.This work aims to share Peñoles mineralogical and metallurgical results, through presenting, discussing and drawing conclusions on these results; as well as pointing out areas where more work is needed to improve the Concentrator´ performance.PEÑOLES BACKGROUNDPeñoles´s mission is to add value to non-renewable natural resources on a sustainable manner. It was established in 1887, and it is a mining group with integrated operations in smelting and refining non-ferrous metals, and producing chemicals. Peñoles is the world’s top producer of refined silver, metallic bismuth, and sodium sulphate, the leading Latin American producer of refined gold, lead, and zinc.Peñoles Mining Division is integrated into eight mining business, located on five different states in Mexico. Metal productions for the Mining Division during 2003 were: 343 thousand gold ounces, 48.4 million silver ounces, 81.3 thousand tons of lead, 235.1 thousand tons of zinc, and 10.6 thousand tons of copper."

Jan 1, 2005

By Tom C. Palangio

The mining industry has come to rely on imaging devices to monitor and record all kinds of activities. We use them to measure, improve the process, ensure security, increase production and automate machinery. Cameras can be installed in locations most people wouldn?t want to live and be our ?eyes? to record the events at that location. This paper discusses digital imaging, the equipment, methods, techniques and information that can be learned from digital devices used in mining operations. The guy who said ?a picture is worth a thousand words? probably understated it. Images are the perfect way to document conditions before, after and even during mining activities. Today?s wide choice of cameras, camcorders and other digital devices allow us to record most activities and events. The technology is advancing at a high rate. Digital cameras and camcorders are marvels of technology with high resolution optics, compact size, automatic time and date stamp, great battery life, shutters to freeze motion and computers to auto focus and eliminate jitter (image stabilization). Add to this the economical price and ease of use and everyone in this industry should be aware of the possibilities.

Oct 1, 2010

By A. del Campo A.

The roast segregation process, which was patented in 1974, makes use of a set of chemical reactions that are different from the traditional sequential oxidation of iron and copper sulfides used by all modem pyrometallurgical processes to treat copper concentrates. It allows metallic copper to be obtained via sublimation of copper chloride at temperatures in the range of 700-800 OC. In addition it avoids melting the concentrate, doesn't require transferring molten materials, doesn't need flux addition and allows nearly all of the sulphur to be removed in one stage as a high-S02 gas stream. Most importantly, it allows a decrease in the use of energy to approximately 6 million BTU/ton of anodes. This represents a saving of approximately 40%, compared to the potential of the most advanced processes presently used. Such a promising process has been waiting for its first industrial application for more than 30 years. This article examines the technical difficulties that have delayed application of the roast segregation process to beneficiate copper concentrates. Special emphasis is made on material handling aspects, discussing the possibility of using a well designed mass flow silo as the main processing vessel to carry out the segregation stage. Cu2007

Jan 1, 2007

Phelps Dodge has recently operated a commercial scale, super fine grinding circuit of copper concentrates for use in a medium-temperature pressure leaching process. Two 355 kW vertical stirred mills were installed in series, targeting a grind of 80% passing 7.5 µm and 98% passing 15 µm as outlined in Phelps Dodge's concentrate leaching patent portfolio. This paper details the operation and results of the test program at Bag dad, as well as some of the operating challenges encountered.

Jan 1, 2007

By T. R. Skerry, H. P. Hudson, T. E. Warren

"ALTHOUGH coal is generally the cheapest fuel on the basis of heating value it has been at a disadvantage in competition with other fuels because means have not been available for efficient •Conversion of its thermal energy to mechanical work. Taking the •railway application •as an example, the cost of Diesel oil is about three times that of its thermal equivalent in coal, but the overall efficiency of a Diesel locomotive is about five times that of a coal-fired steam locomotive. Accordingly, the Canadian railways are replacing all coal-fired steam Locomotives, as they are retired from service, with Diesel units. This conversion in itself represents a major loss to the coal industry because the value of railway fuel is approximately 130 million dollars per year, and there are other applications in the medium power range where oil is displacing coal. There is, therefore, a strong incentive to attempt development of an efficient coal-burning engine.Coal has never been a promising fuel for reciprocating internal combustion engines because of the time required for its combustion in pulverized form . This is not less than one-tenth of a second so that the speed of such an engine would have to be very slow. There are also serious difficulties of a mechanical nature arising from the necessity for intermittent combustion and the use of close-fitting pistons."

Jan 1, 1952

By Anna M. Ferrero

Stability condition of underground excavations have to be assessed to guarantee safe operations within the quarrying working areas. This objective requires a reliable assessment of the rock mass natural state of stress and of the stress redistribution induced by the excavations. This goal is often complicated by difficult geological conditions induced by tectonic stresses, complex topographies and large and irregular excavation geometries. Consequently, the acting state of stress needs to be measured by specific in situ measurement devices. This work refers on an in situ measurements campaign carried out by CSIRO tests in an underground quarry located in the Carrara marble basin. The difficult path carried out for interpretation of the measurements is described in this paper. In particular, the numerical modeling performed using the Boundary Element Method (BEM) first, to study the influence of both surface topography and excavation geometry and then the Distinct Element Method (DEM) to evaluate the influence of rock discontinuities in the measurement zone are illustrated in this work. Parametrical analysis of the rock mass mechanical features is also described in order to calibrate the numerical models and analyze the experimental results. The work has been carried out trough several phases, which are: characterization of the rock mass through geostructural surveys: this allowed us to classify the rock mass and determine the mechanical and physical parameters necessary for modeling; on-site measurement of stress levels through the application of over coring techniques; numerical analyses for the simulation of excavation phases, using the Examine3D (BEM) engineering analysis code. comparison between the measured stress levels and those numerically calculated and subsequent calibration of the BEM model; Numerical model of the forecasted excavation based on the calibrated (BEM) model.

May 1, 2009

By A Hitchen

A general outline is given for the determination of copper, nickel, cobalt, zinc, lead, cadmium, bismuth, manganese, uranium, molybdenum, vanadium, sulphate and fluoride by polarographic or amperometric methods in a variety of ores or metallurgical products. The detection of oxygen in gas mixtures by an amperometric method used as a safety device is also discussed. Introduction I N this paper, a general outline will be given of the polarographic and amperometric methods used for the chemical analysis of various ores and metallurgical products in the Chemical Analysis Section of the Extraction Metallurgy Division of the Mines Branch. The methods to be discussed will be confined to those based on the use of normal D.C. polarography and will not include those methods which utilize a cathode-ray, square wave, pulse or A.C. type of polarograph. For the sake of convenience, ? the polarographic methods will be discussed according to the type of supporting electrolyte employed, as the same electrolyte may serve to determine more than one element in more than one type of ore. Amperometric methods will be discussed according to the element to be determined rather than

Jan 1, 1965