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By O. Garg

This paper summarizes the computer applications in open-pit mine planning at the Iron Ore Company of Canada (IOC). A brief history of the use of computers at IOC is given, and a description of the existing facilities is outlined. The following systems are discussed: storage and retrieval of geological data; geotechnical data analysis; long-term grade and tonnage forecasting; ore grading; and open-pit mine design. Justification for using computers in open-pit mine planning is given, and possible future areas of application are considered.

Jan 1, 1979

By T. H. Etsell, P. C. Holloway

Vanadium is concentrated in the fly ash which is produced as a solid waste from oil sands operations in northern Alberta. Although a process flowsheet using sodium chloride as a roasting reagent has been developed at the University of Alberta, recent studies examine the p otential o f p otassium o r c alcium s alts a s alternative reagents for roasting Suncor fly ash to recover vanadium. Suncor fly ash was roasted with CaO, Ca(OH)2, CaCO3, CaSO4.2H2O and KC1 at 750, 850 and 950°C. Water leach extractions for the calcium compounds were low (<45%); leaching with 100 g/L Na2CO3 gave maximum extractions of 56 to 69% at 950°C. Ash roasted with KCI behaved similarly to ash roasted with NaCl. These tests indicate that similar roasting conditions (25 to 30% KCI, 850°C, and 2 to 4h) could be used to achieve similar water leach extractions (75 to 85%). However, the lower solubility of KVO3 in solution, compared to NaVO3, would make the use of KCI instead of NaCl less attractive from a process and economic standpoint. Mineralogically, leucite (KAlSi3O8) was the predominant phase in ash roasted with KCl while, in crystalline samples of ash roasted with calcium compounds, anorthite (CaAl2Si2O8) and pseudobrookite (Fe2TiO5) were identified. Ash roasted below 950°C with the calcium compounds remained poorly crystalline.

Jan 1, 2004

By Brent Robertson

Failure to meet quality objectives during the execution of any industrial project has lasting negative impacts on facility life cycle performance. Cost overruns, schedule delays, and rework are characteristics of project quality issues that arise during the project. Commissioning and start-up problems, low production, production bottlenecks, breakdowns and the necessity for operational work-arounds are characteristics of project quality issues that appear after project completion. Risks such as production facility downtime, shortened equipment life, and potential HSE violations must be clearly identified and addressed during project planning phases. Appropriate Quality Assurance (QA) and Quality Control (QC) focus must be placed on identified high-risk areas. In order to be effective, quality systems must be flexible, non-confrontational, consistent, and adaptable to projects of any size ? from capital mega-projects to small maintenance projects. All project participants must be aligned in how they are approaching quality and the difference between QA and QC must be clear to everyone on the project. Emphasis must be placed on QA activities to minimize project cost, reduce rework, manage change, and reduce the production facility operational risk. QA is focused on the work processes used to generate the design and confirming that the processes are present and being followed. Issues in the work processes guarantee that the output drawings and specifications will be less than optimal. The identification and monitoring of quality-critical processes provides a focus for QA activities. QC activities are then used to generate proof that the project was implemented correctly and become a key part of the turnover.

Nov 1, 2011

By Y. Hou, E. Arinaitwe, L. Tong

A series of dense medium separation (DMS) tests were performed on four low-grade copper ores from Mount Polley mine in order to determine their amenability to pre-concentration. The tested ores contained disseminated sulphides, mostly chalcopyrite with low copper grades (0.15% - 0.2%) and relatively high iron grades (4.76% - 5.63%). The samples were screened into different size fractions ranging from 9.5 mm to 50.8 mm and DMS tests were performed on each size fraction at various separation densities. The pre-concentration efficiency at different size fractions and separation densities was evaluated in terms of metal upgrading and distribution. Mineralogical tests were also performed on selected DMS sink and float samples in order to understand the influence of mineralogy on the pre-concentration efficiency. The results showed that significant copper upgrading was achieved for intermediate size fractions only at the highest separation density tested. The copper recoveries generally increased with particle size at all separation densities. However, it was impossible to upgrade the copper content in the ores and achieve acceptable recoveries and mass rejections at the same time. Copper recoveries and grades showed a strong correlation with iron recoveries and grades indicating that it is possible to pre-concentrate copper by recovering magnetite and other iron-containing minerals in the ore. Overall, the results suggest that the optimum separation density and pre-concentration efficiency is a function of particle size, and that the ore mineralization properties limit the performance of DMS as a pre-concentration technology for such low-grade disseminated ores.

Jan 1, 2014

By Frédéric Flament, Mary Goldman, Gille Barbery

"Pilot plant testwork on autogenous and semi-autogenous grinding was conducted at the Centre des Recherches Minérales du Québec (CRM) to investigate the effect of ball addition, solids concentration in the feed, specific energy consumption and feed size distribution.A mathematical model that incorporates breakage and surface mechanisms of loss of mass was developed to predict load size distribution of autogenous and semi-autogeneous mills. An empirical model was used to predict product size distribution of autogenous and semi-autogeneous mills.IntroductionAutogenous (AG) and semi-autogenous (SAG) grinding circuits offer potential capital and operating cost savings when compared with conventional grinding. Empirical relationships have been developed to calculate specific power consumption for SAG mills using pilot plant test results (Mular et al., 1989; Barrett and Allan, 1986). Empirical models can be obtained from plant practice data but are applicable only to the particular ore and set of operating conditions used in the model. Grinding mechanisms have to be taken into account in order to develop a model that can be applied to different ores and mills.In AG and SAG, the ore itself acts as grinding media, with the finer sizes being crushed by the coarser ones. Surface mechanisms of loss of mass, in which the inner core of the particle remains intact, also take place. In SAG milling, the effect of balls also has to be taken into account. The role of each one of these mechanisms changes with particle size and the model has to account for such changes."

Jan 1, 1991

By C. Gu

Flow field design is critical for PEM fuel cells. The flow field design can affect reactant distribution to the catalyst surface, water management, thermal management and current collection. Therefore, it has tremendous impacts on the fuel cell performance and durability as well as reliability and operational flexibility. In this paper, an optical method is used to study the reactant distribution in the flow field channels of two commonly used flow field designs, straight channel design and serpentine channel design. Images of the flow patterns are shown followed by discussions of the flow patterns.

Jan 1, 2005

By Alireza Entesari

Removal of metal ions from effluents represents a significant technical challenge. As a consequence several industries, including mining, are faced with issues relating to removal of contaminant cations and anions from solution. This study evaluates three natural mineral materials referred to as basalt, scoria, and calcined shale for treatment of metal contaminated effluents by adsorption. Adsorption tests were conducted to asses the possibility of removing cationic and anionic metal ions from prepared solutions and mine water effluents. Sustainable production of industrial minerals requires that a diverse range of added value products be introduced.

May 1, 2006

By Andreea Catalina Gluhoi

The oxidation of propylene and methane has been investigated over two series of Au/MOx/Al2O3 and Au/MIOx/MIIOx/Al2O3 catalysts (M, MI, MII =Li, Rb, Mg, Mn, Ce, Zr). Whereas the effect of the presence of MOx or MOI x/MOII x on the oxidation of methane is relatively small, a large enhancement in activity is observed for propylene oxidation. Synergistic effects have been observed by combining ceria or a transition metal oxide (high oxygen storage capacity) with an (earth) alkali metal oxide.

Oct 1, 2003

By X. Zhong

Thermal shock resistant properties of reaction sintered bauxite-based ß -Sialon bonded corundum have been investigated, and the results are compared with those of Al2O3 based counterpart. It is found they all have very good thermal shock resistance. Their residual strength ratios after one thermal shock cycle at ? T=1200°C and A T=1350°C are 61-73% and 53-65% respectively. TSR parameters are calculated based on thermal expansion, modulus of elasticity, and fracture toughness determined. The reasons for improved TSR of these composite materials are discussed.

Jan 1, 2004

By Emile D. L. Rienks

We have studied the interaction of NO with the quasi-hexagonally reconstructed Au(100) surface. Using variable temperature scanning tunneling microscopy we have observed formation of the unreconstructed phase of Au(100) after NO exposure. This NO adsorption induced phase transition is observed in a window of temperatures around 170 K. Under the same conditions, CO and O2 cannot drive the phase transition, suggesting weaker interaction. Thermal desorption spectroscopy experiments provide an estimate for the strength of NO chemisorption on Au(100) of 57 ± 4 kJ mol-1.

Oct 1, 2003

By I. Cifuentes

Chemical and physical characterization of copper electrodeposits obtained on mesh and plate cathodes in conventional and reactive electrodialysis lab-scale cells have been carried out. The effect of Fe, Mn, Cl and guar on electrodeposit composition and morphology were determined by means of metallographies, scanning electron microscopy (SEM), atomic force microscopy (AFM), inductively coupled plasma mass spectrometry (ICP-MS) and Auger electron spectroscopy (AES). Each impurity influenced the deposit morphology in a different way (e. g. grain size, surface roughness). AFM proved to be a very effective tool for quantifiying and classifiying surface quality.

Jan 1, 2007

By Michael Schindler

Uranyl mineral dissolution appears to be complex, affected by factors such as solution pH and the presence of various cations in solution, and sometimes involving formation of secondary surface precipitates. Such secondary precipitates potentially could armor the underlying uranyl mineral surfaces from further dissolution. A detailed understanding on the formation of secondary precipitate is therefore essential for predictive modeling of radionuclide fate and transport in the subsurface. Several types of secondary precipitates on the surface of uranyl minerals were examined using Atomic Force Microscopy, Scanning Electron Microscopy, and, Xray Photoelectron Spectroscopy.

Aug 1, 2010

The AG/SAG circuit discharge P80 is now increasingly referred to as the “Transfer Size” or T80 for short. From the literature it is apparent that in circuit design some approaches to the sizing of AG/SAG mills as well as the ball mills that they feed use this parameter. This paper reviews whether the use of the T80 is appropriate in this context. In the course of the review examples of AG/SAG discharge size distributions measured from range of operating circuits are used to illustrate the arguments made.

Jan 1, 2012

By Bradford C. Wesstrom

An overview of the challenges encountered at the Freeport McMoRan El Paso Copper Refinery with higher concentrations of antimony electrolyte will be shared. The observations will cover the detrimental effects on copper starting sheets, commercial cathodes and anode slimes. The study will show negative effects on quality and productivity. Experimental work will utilize a test cell to study the effects on electrolytes by different Antimony, Arsenic concentration and anode molar ratio. Best practices will be shared for producing high quality cathodes while effectively managing the detrimental effects of higher antimony electrolyte.

Jan 1, 2014

By T. G. Joseph

The strain softening relationship developed in part 1 is now applied to coal. Having determined the post-failure stress-strain curve for coal specimens, this information can then be used in a finite element program, such as Phase 2, to examine the post failure characteristics of coal pillars. Using example data, the strength of coal pillars of different width/height ratios are estimated and compared with well-known empirical pillar size-strength relationships. In addition, the post-failure stress-strain behaviour of a coal pillar is compared with an empirical relationship reported in the literature.

May 1, 2002

By Lawrence Devon Smith

What is a Failed Project? For mining projects, some key indicators of a ?failed? project are: ? Cost is more than it should be (particularly capital) ? Schedule ? It takes longer to build than expected ? It takes longer to ramp-up than expected ? It does not do what it is supposed to do ? Poor performance; output, product specifications; ? Low revenue ? High costs ? No one is happy about it: Management, Shareholders, Bankers ? Does a project fail if it does not meet expectations that were unrealistic and unattainable? ? Caution: Failure may not become evident until years later

May 1, 2010

By Q. Han

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

Jan 1, 2014

By Michael S. Moats, Shijie Wang, Timothy Robinson

In 1987, John Schloen published a survey and analysis of copper electrorefining tank room data. Following this paper, a series of copper electrorefining surveys have been conducted and presented at each of the Copper-Cobre meetings over the past 20+ years (1991, 1995, 1999, 2003, 2007, 2010 and 2013). For each of these surveys, William Davenport has been key driving force in the collection and analysis of data. To honour Professor Davenport’s contribution to copper processing, a review of the data was conducted. Historic trends and possible future technologies are discussed.

Jan 1, 2014

By H. Matsuoka, M. Kawata, K. Mitsuhashi, C. Tokoro, T. Kato

Copper sulfide minerals such as chalcocite, bornite, and chalcopyrite exhibit high floatability, thus they can be recovered as a froth product by adding only a collector in flotation process. However, when their surface is oxidized, the floatability decreases and the simple addition of collectors is no longer effective. In this case, flotation activators are required to improve the floatability. Sodium hydrosulfide (NaHS) acts as an activator for chalcocite and bornite by re-sulfurizing their oxidized surface portions. Nevertheless, the flotation conditions still require optimization in order to achieve a satisfactory recovery of copper minerals. This work addresses the study of the effect of pH and NaHS dosage on the flotation of a complex Chilean copper ore containing chalcocite, bornite, and chalcopyrite. Flotation experiments were conducted using a Denver-type flotation cell and by investigating the effect of two NaHS dosages (50, 100 g/t) and three pH values (8, 9, 10). Following this process, the surface interaction between the minerals and NaHS were analyzed using zeta potential measurements. INTRODUCTION In recent years in the mining area of metal resources, the complexity of ores and the fineness of grind required to liberate minerals have become serious problems. When ores are complex, several valuable minerals may interact with each other and reactions may become more complicated compared with an ore containing only one valuable mineral. Therefore, more processing steps may be required than for a simple ore. When the valuable minerals exist as fine grains, it is difficult to liberate them and more grinding time is required. Furthermore, the probability of collision of fine particles with bubbles in the flotation process declines and it takes much time to recover them. Flotation is one of the most applied methods to separate valuable minerals from unwanted ones using the difference of hydrophobicity (or hydrophilicity). In the flotation method, the air is fed to a cell filled with the pulp of the mineral of interest and agitation is implemented to introduce air and generate bubbles. The hydrophobic particles attach themselves to the bubbles and float along with the bubbles while the hydrophilic particles remain in the pulp. Copper sulfide minerals such as chalcocite (Cu2S), bornite (Cu5FeS4), chalcopyrite (CuFeS2) are widely known abundant copper resources. Generally, flotation is used to recover and concentrate these minerals. Copper sulfide minerals usually have high floatability. However when their surfaces are oxidized, their floatability becomes lower. When the sulfide surfaces are oxidized, activators are added before flotation to modify the surface property of the Copper sulfide minerals so that they can be floated. Sodium hydrosulfide, NaHS, is known as one of the activators. Zhao (2018) reported that NaHS is often used as a sulfurizer for oxidized sulfide minerals (Becker (2014), Clark (2000), Newell (2006), and Newell (2007)). In earlier work, the authors performed flotation tests on a sample of Chilean copper ore which contained chalcocite, bornite, and chalcopyrite using a Denver-type flotation apparatus. The sample was ground to P80 70 µm with a rod mill and ball mill. In these tests, the following conditions were used: natural pH (about pH 8.5), flotation time of 45 min, 60 g/t AP3477 (sodium diisobutyl dithiophosphate) as collector, and MIBC (methyl isobutyl carbinol) at appropriate dosage as frother. NaHS was applied at the dosage of 0, 67, and 120 g/t, respectively at the conditioning. The concentrates were collected at 6, 18, 30, and 45 min. The weights of the concentrates and tailing were measured and they were assayed for copper by ICP-AES (Optima 5300 DV, PerkinElmer Inc.). The flotation recoveries of the copper minerals were calculated from the results of MLA (mineral liberation analyser) (MLA 650, FEI) measurements.

Jan 1, 2019

By M. R. Julien

"The geomechanical behavior of rocksalt shows very distinctive features. The response of this most ductile of all low porosity rocks is dominated by inelastic processes that are strongly time- and historydependent. These characteristics must be taken into account when analyzing underground openings. Different constitutive models have been proposed and used for this purpose, and this paper presents the general formulation and applications of one of these. The SUVIC model relies on a unified approach with internal state variables producing mixed hardening to represent the inelastic behavior, which lead to specific solutions for plasticity and creep. The model equations have been implemented into a finite element code to perform numerical analyses. Simulations results are presented to show that this model captures essential aspects of rocksalt behavior under simple and complex laboratory testing conditions. Simulations are also conducted to analyze the response of underground openings. INTRODUCTIONPredicting the response of man-made excavations in rocksalt can be quite a challenge as it requires a reliable constitutive model to represent the material behavior. This softest of all low porosity rocks shows a highly non-linear inelastic behavior, very sensitive to history and rate effects (e.g. Senseny et al., 1993; Cristescu & Hunsche, 1997; Julien, 1999; Wittdke, 2014). The many deformation (micro) mechanisms acting locally in rocksalt make the construction of appropriate constitutive equations quite complex. Nonetheless, there have been significant progresses made over the last two decades or so; many of these developments have been included in a series of specialized Conferences Proceedings (Ghoreychi et al., 1996; Aubertin & Hardy, 1998; Cristescu et al., 2002; Wallner et al., 2007; Bérest et al., 2012)."

Jan 1, 2015