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By S. Amira

In the last two decades, many new creep-resistant magnesium alloys have been developed for high temperatures applications. Their mechanical performance and corrosion behaviour were reported for various experimental conditions. However, these conditions often led to uneven comparison basis. In the present study the microstructure, mechanical properties and corrosion performance of four of these newly developed creep-resistant magnesium alloys were systematically compared. Specimens were obtained from experimental box-like components that were die-cast and thixocast in comparable conditions. Their mechanical and corrosion properties were compared using similar testing conditions. Results show that the creep resistance, strength and impact resistance of specimens are comparable but systematically lower compared to specimens cast under optimized conditions. The reduced concentration of elements such as Al, Ca, Sr and Ce lead to a decrease of the corrosion resistance of the magnesium alloys in 3.5% NaCI solution.

Jan 1, 2007

By T. T. Chen

A detailed mineralogical study was carried out to characterize the products generated in a conventional copper refinery anode slimes treatment circuit. The anode slimes, which are first leached in sulphuric acid media under an oxygen pressure to dissolve the copper and much of the tellurium, were found to contain various Ag-Cu selenides, PbSO4, Ag, Au and BaSO4. The resulting Ag2Se, Ag3AuSe2, Se, Au, PbSO4, BaSO4, SnO2 and silicate-rich leach residue is dried and pelletized. It is subsequently roasted to convert the selenium to Ag2SeO3, volatile SeO2 and water soluble Na2SeO4. The roasted product, which was found to consist of Ag2Se, PbSe, PbSO4, BaSO4, Ag3AuSe2, Au and Sn02, is smelted and refined in a Dore furnace to produce a Dore metal that contains a (Ag,Au,Pd,Cu,Pt) alloy together with traces of CuO and a Cu-Pb oxide phase. Parting plant mud shown to contain AgC1, Ag, Au, (Au,Ag,Pd), Ag2Cu2O3 and Ag20, and scrubber mud containing PbSO4 and AgC1 are also fed to the Dore furnace. The Dore furnace sequentially separates a silica slag which was found to consist of Ag, Sn02, BaSO4, Pb-Sb oxide, Fe-Sb-Ni-Cr oxide and a Pb-rich silicate phase, a soda-rich slag containing Na2CO3.H2O and Na2(Se,Te)03, and a niter slag containing Na2TeO3, Na2(Se,Te)03 and a Na-Te-Se-Pb-Ba-Cu oxide phase. The Dore metal is electrorefined in Moebius cells to yield high-purity silver and a gold mud which was shown to consist of a (Au,Ag,Pd,Cu,Pt) alloy and traces of CuO. Silver is leached from the gold mud and the resulting gold sand is cast into anodes and electrorefined in Wohlwill cells to produce pure gold.

Jan 1, 2007

By D. Sbarbaro

In many modem concentrators the use of supervisory systems in their grinding circuits has meant more consistent operations and increases in capacity. These systems rely on a series of specific algorithms that uses different pieces of information and drives actions over the process. One of these algorithms is the ball mill overload detection, which plays an important role in any supervisory strategy designed to maximize ore feed rate in wet grinding circuits. This paper introduces different overload detection algorithms, and compares them in terms of the time taken to detect the overload condition. This comparative analysis is based on highly noisy power draw measurements obtained in an industrial plant.

Jan 1, 2007

By Z. Jun, L. Kerning

Jinlong copper smelter and refinery, originally designed for 100,000tpa primary copper and started up in 1997, has been expanding its capacity on the basis of operational optimization and by modifying its facilities. Currently it is producing 210,000tpa primary copper, and the new phase of expansion project with a target capacity of 350,000tpa primary copper is ongoing. This paper reviews problems and improvements made with operation and equipment in the past years. Recent plant operation is briefly described. The expansion projects completed are summarized and the ongoing expansion project is present.

Jan 1, 2007

By K. Yamaguchi

To contribute highly efficient and environmentally conscious copper smelting process, several topics in chemistry of the continuous converting were discussed. Through the reviewing the authors' thermodynamic simulations, it is recognized that small amount and low copper content of the coexisting slag is preferable. Some discussions were added to the Takeda's diagram for Cu20-Fe0x-Ca0 ferrite slag, and the activity curves of the constituents were derived. Thermodynamic calculations were carried out on the copper contents of the slag during the blister copper formation. The dissolution of copper in slag decrease somewhat with increasing temperature, but the effects of increasing S02 pressure and decreasing %S in copper are considerable to increase in copper content of the slag. The optimum oxygen enrichment in the supplied air, and regulation of the oxidation degree for the blister copper are important in practice. The gypsum phase separation in the calcium ferrite slag was also evaluated thermodynamically, and concluded that decreasing temperature, increasing CaO content or S02 pressure, and extensive oxidation of the blister copper tend to separate CaS04. 0

Jan 1, 2007

By E. Roman E.

A novel anode slime purification process was developed and tested at pilot scale in the Chuquicamata Refinery. The process consists of three main stages: First, an atmospheric alkaline leaching at 90°C, under controlled pH and ORP operation parameters where metalloid impurities are preferentially removed from the anode slimes with high efficiency. In a second stage, alkaline washing of the mud leached with addition of reducing agent, with the intention of reducing the silver of the AgCl to metallic silver releasing the chloride, and finally, copper and other remaining impurities are leached out in mild conditions (60°C, one hour in sulphuric acid). In a side process Se, Te, and Sb are recovery with high efficiency from the alkaline liquor as chemical grade products. The global balance shows a high mass loss yielding a final product with high precious metal and low impurities content showing advantages in both a technical and economic point of view with a clear environmental sustainability. This treatment allows either the direct sale of the purified anode slimes or its pyrometallurgical treatment to obtain metal doré without emissions of Se, Sb and As. Chemical mechanisms for this novel process are also described.

Jan 1, 2007

By M. Maldonado

This work details the application of a decentralized control strategy to a pilot flotation column working with a two-phase system (water-air). The process is represented by a multivariable system composed of three inputs and three outputs. The selected control variables are the froth depth, the air hold-up and the bias rate, whereas the corresponding manipulated variables are the set-points of the local flow controllers of tailings, air and wash water. All controlled variables are estimated using electrical conductivity based techniques. In particular, the results of a new method for estimating the bias rate, based on the measurement of the volumetric fraction of wash water under the interface, is presented. This method reduces the coupling problem associated to the bias estimation as a difference between feed and tailing water rates. Moreover, the nominal system transfer matrix can be represented by an upper triangular matrix, in such a way that the closed-loop system stability reduces to the stability of the independent control loops. The experimental results show that the closed-loop system performance, particularly that of the bias rate loop, is strongly dependent on the air flow rate, reaching in some cases the saturation point of the controller.

Jan 1, 2007

By P. H. Rodriguez

The aquatic hazard classification system of the OECD and EU requires that sparingly soluble metal substances (SSMS) be tested using the OECD Dissolution/Transformation protocol in order to quantify the release of the ecotoxicological relevant species (dissolved ions). The SSMS category contains massive forms of metals, which due to their low solubility and slow transformation characteristics are a special case. The main factors that produce the release of metal into solution are exposed surface loading, pH, and stirring rate. The classification system at present prefers the use of mass loading as opposed to surface loading, in which case the amount of metal released will primarily be a function of the pH, and mass loading. Within the framework of the European Copper Voluntary Risk Assessment, coordinated by the European Copper Institute, we have proposed and developed a methodological procedure in which we demonstrate that surface area is an intrinsic property of a SSMS and we link the exposed surface loading to the toxicity reference value in order to obtain an aquatic hazard classification for massive metals. As example, the aquatic hazard classification for copper massive will be discussed. This approach is recommended for metal massives and metal powders.

Jan 1, 2007

By F. Chiesa

Forty aluminium A356 castings were poured on a Low Pressure Permanent Mould industrial machine, 500x700mm in platen size. The 152mm wide casting comprised three steps, 25mm, 13mm, 6mm in thickness and a 2.5mm overflow which allowed to assess the thin wall capability of the process. The casting campaign, which produced 40 parts, allowed to test the influence of various production parameters including the time of application of the pressure in the crucible, artificial cooling of the mould and casting rate. The thermal history in the mould was recorded over the 40 cycles, which allowed to construct a reliable thermal model of the mould/casting assembly. The metallurgical quality of castings representative of the various conditions was assessed in the 25mm, 13mm and 6mm plates. This included measuring the level of microporosity, the dendrite fineness (DAS), along with the tensile properties in the T6 condition. The radiographic quality per ASTM E155 was also determined. Modelling filling and solidification allowed to verify the validity of the predictions based on available relationships relating microporosity, secondary dendrite arm spacing (DAS) and local tensile properties (Quality Index, Q) to the local thermal solidification parameters.

Jan 1, 2007

By M. Doggett

All 231 Canadian primary gold mines that produced from 1946 to 2004 were analyzed with respect to their production and economic characteristics. Trend analysis revealed that the average annual capacity of Canadian gold mines, as measured by ore processed or gold produced, has increased over time. Conversely, the average grade of gold mines has decreased over time. The distribution of gold output is highly uneven: for example, the 22 giant mines producing more than 100 t (metric tonnes) of gold account for 62% of total output. Small mines producing less than 10 t Au account for 54% of total mines, but less than 4% of total gold. Each historical mine in the database was evaluated on the basis of a set of economic and technical assumptions to determine if it would be economic to develop today. Based on the net present value using an 8% discount rate, only 103 of the 231 mines were determined to be economic. About 80% of the uneconomic mines had less than 10 t of contained gold, and 63% had less than 5 t. It is concluded that these small mines would not be viable today due to a combination of real capital cost increases, and more stringent permitting and environmental regulations. The implication is that future gold supply in Canada will hinge on the discovery and development of a new generation of larger mines. Given that only one giant mine has been discovered in the past 20 years, it seems likely that gold output will decrease in the future.

Jan 1, 2007

By B. Burke

Magnesium and its alloys are attractive materials for use in automotive and aerospace applications because of the low density and good mechanical properties. However, difficulty in forming magnesium and the limited number of available commercial alloys limit their use. The present paper reviews the efforts to improve the attractiveness of magnesium through non-traditional processing, and presents preliminary results of current work on producing magnesium alloys via powder metallurgy P/M. P/M can be used to alleviate the formability problem through near-net-shape processing, and also allows unique chemical compositions that can lead to new alloys with novel properties. The feasibility of producing magnesium powder metallurgy products utilizing the industrially dominant process of mixed powder blending, uniaxial die compaction and controlled atmosphere sintering was investigated. An alloy composition based on the commercial Mg alloy AZ31 (3% Al, 1% Zn) was used to facilitate comparison to similar wrought products. The optimal processing conditions (compaction pressure, sintering time and temperature, and quenching temperature) were found to maximize sintered density and mechanical properties.

Jan 1, 2007

By K. Pienimäki

Boliden Harjavalta Oy has produced copper since 1945. The essential idea has always been continuous development of process efficiency and environmental friendliness by using the Best Available Techniques (BAT). The ongoing development step is to increase the production capacity up to 210 000 tpy of anode copper and 155 000 tpy of copper cathode. One of the focal issues in this action is modernization of the copper refinery to utilize permanent cathode technology. This paper describes the refinery project and the technology used in it.

Jan 1, 2007

By M. Hamamoto, M. Furuta, S. Tanaka

The Tamano smelter and refinery has expanded its production from 228kt/y to 260kt/y since 2006. It was not a big jump, but efficient and economical improvements were executed. These were not only de-bottlenecking and modernization of the smelting plant, including the acid plant, but also additional processes were commissioned, e.g. slag cleaning furnace and steam dryer. On the other hand, a conversion to permanent cathode process in the #2 tank house made the biggest impact on production efficiency for the refinery plant. In order to overcome the drastic change of copper business, although each scale is not so big, continuous improvements are very important to survive. This paper mainly describes the recent improvements of the smelting plant.

Jan 1, 2007

By L. Haavanlammi

The Outokumpu HydroCopper® process is a chloride based atmospheric leaching process alternative that can treat a variety of different concentrates. Chalcopyrite and other copper sulfides can effectively be leached under atmospheric pressure in strong, aggressive chloride solution using copper (II) ions as oxidant. Impurities are removed from the solution as carbonates and ion exchange. Copper is precipitated from the purified pregnant leach solution as copper (I) oxide, which is filtered and reduced by hydrogen gas to metallic copper powder, which is melted and cast into copper product. Sodium chloride solution from copper (I) oxide precipitation is decomposed in a chloralkali electrolyser, to products of which are circulated back to the process. The process has been designed for copper concentrates and is a fast and economical way to produce copper wire rod directly from concentrate. The process can efficiently handle impurities like arsenic and mercury, which can be harmful in the pyrometallurgical processes. The process has been tested in the laboratory and 1 ton/day demonstration plant scale and it has been proven to be commercially viable. The process has been designed to meet the strictest directives for emissions. Other environmental factors are carefully considered to obtain the highest possible eco-efficiency.

Jan 1, 2007

By C. Carrasco

Caletones Smelter, Division El Teniente of Codelco Chile, has used Teniente Converter (TC) as the only smelting unit since November 2000. The modernization project considered the shutdown of the last reverberatory furnace, the installation of the fourth Teniente Slag Cleaning Furnace, the installation of a new fluidized bed dryer and the modification of the concentrate injection system into TC. The modernization project and related investments allowed for the increase of the smelting capacity up to 1.25 million t of concentrate annually.Next stage of the smelter expansion in the year 2004 considered the increase of the smelting capacity up to 1.44 million t/year. The expansion required technology modernization and the installation of the new equipment, such as concentrate injection system, oxygen plant, fluidized bed dryer and storage bin. Currently the annual smelting capacity is about 1.35 million t of copper concentrate, being limited by sulphuric acid plant treatment capacity. This paper presents the technology and production evolution in the Caletones Smelter in the years 2000 - 2006, demonstrating the potential of development and competitiveness of Teniente Converter as world-wide recognized smelting/converting reactor.

Jan 1, 2007

By S. Kawai

Natural convective flow of the electrolyte solution plays an important role in several electrochemical systems. Copper refining electrolysis is the most important industrial process to produce high purity copper on large scale. Turbulent natural convection develops along vertical plane copper electrodes installed in an unstirred electrolyte accompanying with the electrochemical deposition and dissolution of copper during the electrolysis. It introduces the electrolyte stratification phenomenon. Thus, the electrolyte is circulated in a special way depending on each electrorefining tankhouse. The theoretical discussion is indispensable to understand the coupling phenomenon between the ionic mass transfer rate and the morphological variations of electrodeposited copper. In present study, the mass transfer rate of both Cu2+ and H+ ions as well as the momentum transfer rate is numerically analyzed accompanying with the turbulent natural convection along 1 m high Cu metal electrode surface.

Jan 1, 2007

By T. Lu

Microwaves have considerable potential as an energy source in both mineral processing and metals extraction. In this research, the utilization of microwave radiation for the heating of a gibbsite type bauxite ore was investigated. Firstly, thermogravimetric studies were performed in order to characterize the dewatering processes of the ore. Secondly, both the real and the imaginary permittivities, which are the fundamental properties that determine the interaction of microwaves with any given material, were measured for the bauxite ore as a function of temperature. The changes in the permittivities were shown to be related to the dewatering processes. Subsequently, the effects of operating variables such as processing time, sample mass, particle size, microwave power, sample bulk density and carbon and magnetite additions on the sample temperature in a microwave field were studied. The results showed that under suitable conditions the bauxite ore could be readily heated. Therefore, there is considerable potential for the application of microwaves for the heating of bauxite ores.

Jan 1, 2007

By Craig M. Sams

"Variable speed mill popularity has grown during the last 10 years with almost every SAG mill fitted with a variable speed drive. In addition, many of today’s larger ball mills are running a variable speed drive for various reasons. In the past, motor suppliers, especially gearless drive suppliers, have considered mills as being an overpriced rotor. This has lead to mills demanding more torque than what a motor can generate. This paper identifies the reasoning of what has happened and how to mitigate the mismatch in the future. Technical and economical issues are discussed, allowing mill operators to make an informed decision of which path to take in deciding what motor to put on a mill.INTRODUCTIONIt has been generally accepted in the past that motor suppliers and specialists in engineering companies understand the workings of a SAG mill or a ball mill and although there is a fair knowledge within the industry, in regards to mill torque requirements, the advent of variable speed drives in ball mills has shown the writer that a complete understanding of the mill torque requirements are not fully understood.This paper will discuss two aspects of mill torque requirements, (operating torque at various charge levels and start up torque), and how it relates to specifying the proper motor torque requirements.MILL OPERATING TORQUEMill operating torque at a given charge level and density in a mill is essentially constant throughout the entire speed range. For the purpose of this paper, we will take a 38’x 22.5’, 20’ EGL, SAG mill and provide the power draw at variable speeds but fixed loading conditions.The power draw and mill torque of this mill at 8% ball charge and 28% total loading (Highlighted) is shown below as Figure 1, at variable speeds."

Jan 1, 2007

By P. Duran

The metallurgical gas handling system at Chagres Smelter, like that of many smelters, can be the limiting constraint to processing more concentrate through the smelter. Mass and energy balances for the metallurgical gas handling system processing off-gases from the flash furnace and Peirce-Smith converters have been used by both operations and process engineering groups to help evaluate different operational scenarios in which the use of the installed capacity could be maximized and/or an operational strategy can be change with the purpose of removing a bottleneck or justifying an investment to relieve a constraint in the gas handling system. The present work describes the development of these process balances that were carried out in Exce®. The results were validated with operational data and, subsequently, some cases of industrial interest were simulated, detecting some conditions that were limiting the operation due to the present installed capacity in the Chagres Smelter.

Jan 1, 2007

By C. L. Reichardt

"Pressure exerted on gold producers by regulators, project financiers, and civil society in the wake of the Baia Mare tailings spill in Romania during 2000 prompted most responsible gold companies to sign up to the International Cyanide Management Code for the Manufacture, Transport, and Use of Cyanide in the Production of Gold (the Code). The Code stipulates a ‘cradle to grave’ approach more comprehensive than that applied to any other mining reagent and poses particular challenges for operators who use cyanide-bearing tailings for backfill. This paper examine some of the challenges for Code compliance facing deep underground gold mines that employ backfill technology, most particularly the requirement to demonstrate that the potential migration of cyanide (and its degradation products) from emplaced backfill will not have an unacceptable impact on worker health and safety or on the receiving environment, either during mine life or after closure.Although the Code only contains a single reference to backfill, more careful consideration confirms that most sections of the Code that deal with tailings management are potentially applicable to mines where tailings material is used for backfill. Certain principles of the Code also pertain to aspects of operations, worker safety, emergency response, training, and dialogue with stakeholders relating to backfilling practice.For gold mines of the Far West Rand, the most significant cyanide-related risks associated with backfill operations relate to worker exposure to cyanide-bearing seepage and HCN gas. There is potential for seepage of cyanide-bearing water from backfill to compromise the beneficial use of surface and groundwater, and thus impact on downstream users and ecosystems. However, the extreme depth of mining and the specific geological and hydrological controls on the Far West Rand suggest that the potential environmental risks associated with backfill are likely to be considerably less significant than the cyanide-related risks to the workforce."

Jan 1, 2007