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By I. A. Cameron, F. Ham, R. Sriram

"Planned increases in electric furnace productivity and higher matte temperatures needed for the Sudbury Smelter's S02 Abatement Plan, require an improved matte tap hole. Since startup in 1978, the matte tap holes have been incrementally improved by the addition of copper cooling blocks around the refractory tap blocks. These improvements provided a tap block life of about 100 taps per campaign.In July 1993, a prototype matte taphole was installed in Number 2 Electric Furnace to develop the technology to increase tap hole service life. The design was based on a heat transfer model of the tapping process to determine candidate refractory materials and cooler arrangements. The prototype tap hole features increased copper cooling, high conductivity refractories and extensive instrumentation. Eight trial campaigns are reviewed outlining the performance of silicon carbide and graphite refractories and typical heat loads during tapping.IntroductionFalconbridge Limited operates two 36 MYA, 6 electrode submerged arc electric furnaces in Falconbridge, Ontario. The furnaces, commissioned in 1978, smelt a partially roasted nickel-copper calcine, to produce matte for converting and slag for discard. Additional details of the smelter are available in the literature(1-4).Each furnace was equipped with two matte tap holes located in the furnace end wall. Early in the campaign, matte tap holes were identified as a weak area in the furnace which could be improved. From 1981 to 1987, incremental improvements were made to the design by the addition of water cooled copper blocks. In 1993, a prototype matte tap hole was designed and installed in Number 2 electric furnace to develop the technology to increase tap hole service life. Improved service life is required to meet planned increases in electric fWl1ace productivity and the higher matte temperature needed for the smelter's S02 Abatement Plan.This paper reviews matte tap hole development since 1978; outlines the prototype matte tap hole design, refractory selection and installation; and details the performance of the prototype tap hole during the first eight campaigns."

Jan 1, 1995

By V. G. Minenko, A. L. Samusev

For efficient leaching of gold from sulfide ores and the oxidation of sulfides into sulfates, it is necessary to introduce a substantial amount of oxidant - atomic oxygen, hydrogen peroxide, ozone, potassium or sodium hypochlorite. In this paper, hypochlorite electrochemical treatment is proposed as an effective method of intensification of refractory ore leaching. The objective of the study is to increase the gold recovery from refractory ores with the application of chlorinated solutions that are modified by chemical or electrochemical treatment. The advantages of the use of the modified chlorinated solutions instead of cyanide for gold-sulfide leaching are considered to be the following: a high concentration of the oxidizing agent (hypochlorite ions) in solution helps to achieve a high speed of gold dissolution in the form of chloride complexes; the possibility to produce hydrochloric acid solutions that may be used for the recovering gold by electrolysis; the possibility of the processing of carbonaceous, arsenic-bearing and others kinds of refractory gold ores. The mechanism of the interaction of the modified chlorine solutions with gold-bearing sulfides (pyrite and arsenopyrite) was investigated. The efficiency of the application of chemical and electrochemical leaching method was proved. The main factor that limits the rate of gold dissolution is a high concentration of sulfate ions (SO4 2-) formed in the solution by the oxidation of sulfide minerals. The optimal parameters of chemical and electrochemical leaching method and effective ways to remove sulfate ions were determined. The method helps to increase the level of the gold recovery up to 87% from refractory ores. The intensification of leaching by chemical and electrochemical treatment opens up opportunities for the creation of modern efficient and environmentally-friendly technologies that may be applied for gold extraction from refractory gold ores.

Jan 1, 2016

By Mario Giavani

"IntroductionBy the 1980s, the continuous casting process had almost replaced the ingot casting of steel in Japan, Europe and North America. While economic benefits were probably initially the prime motivator, the transition rapidly proved that continuous casting in conjunction with ladle metallurgy offered a much greater degree of process control and made possible routine steel specifications not previously available.This new technology demanded improved procedures for the quantitative addition of the required metallurgical reagents, especially as regards the more volatile or toxic elements such as calcium , boron, carbon, sulphur, lead and tellurium. The injection of a thin steel tube containing the additive into the metal bath of a ladle refining station offers the best procedure for this. In the industry this has been referred to as ""Cored Wire "".Operators using this technology find that they are faced with balancing the injection speed against the small cross section of the tube to feed the required amount of reagent within the short time span available to the operation. Large-ladle shops requiring major quantities usually resort to multiple machines and high speeds. Many machines approach a maximum feed rate of 400 m/min. Higher speeds exceed the melting rate of the system, and the ferro static buoyancy of the tube will cause it to coil up the ladle wall and possibly resurface into the slag layer, and even eject itself above the surface. Under these conditions, exact control of element recovery becomes difficult, especially with the commonest addition, calcium silicon alloy.Many experts are persuaded that the final melting position of the carrier tube has major importance in establishing consistent element yield to the bath.For instance, the vapour pressure of calcium at l500 °C is close to I bar. Reaching a melting depth sufficient to accommodate this value is considered to be critical to achieving an acceptable and reproducible yield.Many studies have elaborated semi-empirical formulae to establish the melt zone depth, connecting this value essentially to the diameter of the tube , the injection rate and the superheat of the steel. The author's experience in steelmaking could not confirm such formulae in many cases, and he set about to develop a mathematical model which would be useful in addressing this problem, taking into account the several parameters which will regulate the behaviour of a filled tube immersed in molten steel."

Jan 1, 1991

By Kevin Ross

Feasibility Study Team Processing / Engineering?Hatch, Vancouver Mining / Reserves?Australian Mine Consultants, Brisbane Geology / Resources?Roscoe Postle Associates, Vancouver Environmental / Permitting?Rescan, Vancouver Tailings BGC, Kamloops Probable Mine Components Mining tending towards caving methods Underground mine accessed by shaft /conveyor & decline Processing plant producing copper concentrate containing gold Concentrate trucked to rail head for export Non saturated tailings disposal

May 1, 2006

By R. D. Brown

This article summarizes some of the principal features of the taxation of industrial mineral mining in Canada. Where the rules applicable to such operations differ from those pertaining to the production and processing of precious and base meta s (non-industrial minerals), the two sets of rules are compared. If a conclusion could be drawn from such an over-all comparison, it may be that the total tax burden on an industrial mineral mine can be considerably more onerous than on both base meta mining operations and manufacturing profits.

Jan 1, 1979

By I. H. Warren

"An analysis of form-coking processes is presented in terms-of their fundamental mode of operation and their relationship to other coking processes. Their possible future role in cokemaking is assessed. IntroductionAny consideration of prospects and possibilities for form coking must commence with the iron and steel industries-their likely future growth pattern on a world and regional basis and the potential direction of future developments in iron and steelmaking technology.From the numerous estimates which have been made of the future consumption of steel, it would appear that a growth rate of 3lllo between now and the year 2000 is likely. Radical changes in steel making technology are unlikely to be commercially adopted on any significant scale during the next twenty years . However, widespread commercialization inter alia of continuous casting and direct reduction, growth of electric furnace steelmaking and a decrease in coke rates will all contribute to a growth rate for metallurgical coke that certainly will be less than that of steel."

Jan 1, 1980

By P. A. Verhey

"This paper describes a series of wear-resistant ceramic materials which have been successfully used in the mineral processing industry in Canada. Applications include use with metallic ores, coal, potash and asbestos, and in other processes where wear degradation is of major concern. The paper will also deal with considerations involving the selection of the different ceramic materials available. It will cover the installation of ceramic materials on support structures under varying process ' conditions, as well as the other physical and chemical factors which have to be taken into account.IntroductionIn the mineral processing industry, large volumes of ores tailings and other materials are handled. The abrasive nature of most of these materials results in extensive wear to both handling and processing equipment.Wear ratios versus cost, production losses due to down time and wear-resistant material suitability for a given application all demand particular attention when viewed against the need for increased efficiencies in existing processes. As a consequence, a very active continuous search for materials with improved wear resistance has been carried out for many years.In this search, starting about 20 years ago, dense ceramic materials were tested and evaluated in certain applications, notably in the iron ore and asbestos operations in Eastern Canada. As a result of substantially better performance both in continuous extended life and ultimate economics realized , wear-resistant ceramic applications developed progressively in many other processing applications, replacing traditionally used materials.In the vast majority of wear-resistant ceramic applications, considerable extended life over previously used materials was established. This invariably was not just a fractional increase but, in most cases , in factors of double, triple and often all the way up to 18 and 20 times the life of alternative materials used previously. In certain applications, extended life could not be measured and appears to be indefinite.Obviously, as a result of such experiences, the progressively wider use of wear-resistant ceramic materials is now an established trend."

Jan 1, 1981

By D. K. Storer, W. Lee, S. Tkach

"A microcomputer-controlled multi-probe K-40 monitoring system was developed internally for the Phase II mill at the Lanigan potash mine. The K-40 probes were mounted in a variety of positions in several process streams, ranging from dry ore on a conveyor belt to brines and slurries. A description will be presented of the objectives, the equipment and the difficulties encountered in correlating results.IntroductionThe successful control and optimization of most metallurgical processes involves monitoring not only physical parameters such as flow rate and temperature, but also the chemical compositions of critical streams. Composition has proven difficult to measure on -line in industrial scale processes. However, in potash processing there is a convenient chemical parameter that has long been utilized to measure in situ the concentration of potassium chloride (KCl). Potassium has a long-lived isotope which is slightly radioactive. K40 decays by beta elimination to Ca40, ultimately radiating a characteristic gamma-ray photon. This gamma emission when detected by scintillation counter can be used to estimate the concentration of potassium in a process stream."

Jan 1, 1990

By Brian C. Maynard

"Blast design is becoming more and more important as industrial limitations change in regard to economical and physical restraints. Certainly there are ways to alter the nature of the blast by using different explosives, various hole sizes and modifying the timing and charging details. However, it is not possible to alter the fabric of the rock mass. Therefore, it is necessary to learn more about the rock mass and its role in the blast design, and the resulting fragmentation. The major determinant in the degree of fragmentation, or lack of it, is proposed to be the inherent fragmentation of the in situ rock mass. A practical method of quantifying the discontinuities existing in the rock mass is presented and discussed. Likewise, the effects of inherent fragmentation on the resulting muckpile are reviewed. Finally, a fragmentation model combining the calculated inherent fragmentation and the Kuzram model is shown using a sample blast.IntroductionIn blasting, discontinuity characteristics (Fig. 1) control the method by which the rock mass will behave. Research carried out by Piteau (1970) showed a number of characteristics important in engineering design and, as proposed, in blasting processess. These included:• the nature of their occurrence (i.e. sets or isolated);• orientation and position in space;• continuity; and• intensity"

Jan 1, 1990

By R. P. Mahant

"Extensive pilot plant investigations were conducted both on partial roasting an d electric furnace smelting from September 1973 to August 1975.The objectives of the pilot plant investigations were:(I ) to confirm the application of available process technology to treatment of Falconbridge concentrate.(2) to examine partial roasting variables.(3) to investigate electric furnace smelting of roaster calcines .(4) to develop process design and operating parameters for a commercial plant.This part of the paper will cover the following topics:Partial Roasting InvestigationsPilot Electric Furnace InvestigationsPartial Roasting InvestigationsThe specific objectives were to:1. establish process variables for maximum oxygen efficiency and bed fluidi ation.2. determine the product distribution between the roaster and the various gas cleaning stages.3. produce a mass and thermal balance."

Jan 1, 1984

By Philippe Monier, Frank C. Basham

"This paper outlines the scope and applications of 'COALMOD', the British Columbia Ministry of Energy, Mines and Petroleum Resources' computerized financial simulation model for coal mining developments. After a description of the computer system and language of implementation, the logic and scope of current model sub-routines are presented. This is followed by a presentation of examples on the current applications of the model to public policy evaluation, including benefit-cost analysis, fiscal analysis and evaluation of the effects of public infrastructure investments made in support of mining projects.IntroductionThis presentation has been developed in response to a number of requests from coal mining companies and various public agencies who have indicated interest in understanding our application of contemporary analytical techniques to public policy in the coal sector. In particular, the subject of this paper is an explanation of COALMOD. a mnemonic given to a computerized, mine-specific, financial simulation model which is assisting the Government of British Columbia in evaluations of new coal projects, assessment of public sector investments made in support of these projects and. more generally, measurement of the financial effects of current or proposed government policies, and factors outside immediate government control such as coal prices and transportation costs."

Jan 1, 1981

By Greg Johnson

Maintenance needs information about assets to optimize availability and production needs information about performance and consumption to maximize output. In considering both these needs together as, ?Asset Optimization?, the information systems that support them are critical. The theory of Asset Optimization derives from the Lean Manufacturing concepts developed by Toyota, but some changes are required to apply this to mining operations. In particular, mining operations require automated systems due to their geographic spread and they need a strong emphasis on capturing under-performance losses as well as delays and stoppages in production. Leading metal miners and coal miners alike have applied these systems to good effect in the last 10 years. The concepts developed initially in minerals processing plants are now being applied to the mines themsleves as well as the mining logistics chain. Production increases of 5?10% are achievable with the right implementation and consideration of the some key lessons learnt in the last 10 years. Putting these lessons into action is one key step in the goal of optimizing asset performance and thus utilizing the resource at lowest cost.

Aug 1, 2013

By R. Kamguem

The surface of a mechanical part plays an important role in determining performance in service. The presence of scratches left by the cutting or tearing of the material on the surface of the workpiece supports the concentration of stress and strain. This article presents the experimental study for high speed milling of the aluminum alloy 7075-T6, using cutting tools different by the nose radius and coatings (TiCN, TiAIN, TiCN + A12O3 + TiN). A multi levels factorial design of experiment (DOE) and statistical analysis was used. The roughness parameters investigated are Ra, Ra, Rv, Rc, Rsm, and Rk. The results show that the feed rate, the types of coatings and the geometry of the cutting tools have the most significant impact on the surface roughness profil. Surface finish charts according to feeds and cutting speeds were established for each tool tested.

Jan 1, 2011

By Masashige Makifuchi, Hiroki Kumakura, Kota Nagai, Takahiro Kikuchi

"A large amount of platinum group metals (PGM) are used in automobile catalyst. It is important to recover the metals from wasted catalyst. Nomura and Kageyama (2013) suggested recovery process that PGM oxides were absorbed to perovskite-type oxide based on LaScO3. In their process, the PGM in wasted catalyst as absorbed to the perovskite-type oxide as PGM oxide. It has potential to each element in the process if the perovskite-type oxide is selected properly. In this study, the PGM oxide absorption properties of various perovskite-type oxides are investigated to develop a new recovery and separation process. The various perovskite-type oxide were synthesized with metallic platinum, palladium, rhodium at high temperature in air atmosphere. And the PGM contents in the perovskite-type oxide after the experiment are determined by chemical analysis. Some of them have the properties to absorb specific PGM oxide selectively. In addition, in order to increase the amount of absorption of PGM oxide and composition of the perovskite-type oxide experimental temperature was investigated. Then it is also found that doping another specific element to the perovskite-type oxide is effective to increase the amount of absorption of PGM oxide. Then a new recovery process of PGM from wasted automobile catalyst, in which PGM can be separate to each element, was designed.INTRODUCTIONA large amount of Platinum (Pt), Palladium (Pd), and Rhodium (Rh) are used in automobile catalysis (Figure 1) (Platinum, 2013). Natural supplies for these metals are limited and PGM mining can detrimental environmental impact. Therefore, the recycling of PGMs from wasted automobile catalysis is very important. The Rose process (Figure 2) was developed as a process to recover PGM from wasted automobile catalysis. In this process, the automobile catalysis is first crushed mechanically, and then extracting agent, copper (Cu), and flux are melted at high temperature. The mixture separates into a metal phase, (Cu alloy containing PGM) and slag. The PGM is enriched by oxidizing. Cu to Cu oxide. The PGM are then recovered and separated to each element in a wet process. However, it is hard to dissolve the PGM with acid because they are chemically stable and strong oxidation agent such as aqua regia is used. Moreover, to separate the PGM to each individual element, a solvent extraction process is required."

Jan 1, 2016

By Henry Brehaut

"It is difficult to know how much environmental information is absorbed by those in a position to put it to use. The following information may seem like ""old stuff"" to those whose companies are taking steps to improve their environmental performance. This paper is directed in particular to those people who are interested in determining what further changes are required to make improvements as concerned environment citizens.IntroductionUntil recently, the author was comfortable with the fact that none of the operations for which he was responsible had any environmental charges against them. It was not until one of his operations was charged with non-compliance that the author discovered due diligence as a way to avoid a second charge, and when an unfortunate spill occurred at another operation, the meaning of risk prevention was learned. Knowledge was gained step by step to the point where finally environmental information is being heeded, rather than waiting to learn from sad experience. With the appreciation of what it takes to do a good environmental job, comes an understanding of the challenge that lies ahead, and the fact that there is a lot to learn.At a recent environmental gathering, comments from the participants varied considerably. Some just didn't understand why government was being so unreasonable, while at the other end of the spectrum one individual whose company was well along the path to becoming a good environmental citizen remarked that it was all very basic. What was immediately understandable to one went right over the heads of others, indicating the different stages that have been attained in the acceptance of environmental responsibilities."

Jan 1, 1991

By Jean-Luc Collins

"The paper deals with the impact of fleet imbalance on a deterministic evaluation of shovel fleet productive capacity. It shows that if the fleet imbalance is overlooked, then estimated fleet productive capacity will be overrated.The paper shows that fleet imbalance inflates utilization, and care must be taken when using such statistics which are derived from reported field-equipment-hours. It shows that the utilization must be deflated by a factor called 'balancing efficiency"" in order to estimate shovel productive capacity correctly. The paper also shows how fleet imbalance can be controlled by managing idle time or downtime in an actual operation.The technique used for measuring the balancing efficiency factor is based on statistical analysis of equipment utilization."

Jan 1, 1980

By Dieter Birk

"The Atlantic Coal Institute illustrates the potential for high technology employment in Maritime Canada, by using local talent and the latest equipment to address a national market. Since I983, contract research for industry and government has generated 31 man-years of high-tech employment, added $2.3 million to the local economy and contributed new technology for Canadian coal. Industry now has access to new procedures for coal minerals analysis, pyrolysis, and geochemistry applied to industrial problems of exploration, beneficiation, conversion and combustion.Research at the Institute is market-driven, based on cost recoveries from contracts. The financial performance to date exceeds that of similar industrial research institutes in major cities and demonstrates that small isolated laboratories are cost-effective. Economic renewal of Canada's resource industries will require increased R&D which in turn can be a source of local employment and pride. Small research teams are more efficient but require an enlightened policy of contracting-out by big business and big government."

Jan 1, 1987

By A. Mcdonald

"An X-Met Analyzer was purchased from Outokumpu in late 1983for use in the Hudson Bay Mining and Smelting smelter. Its first use was in the fuming plant to give zinc assays of each charge of slag tapped from the fuming furnaces. This quickly told the operators exactly when each charge had reached its economic tap-out point, and gave supervision a fool-proof method of identifying good operation. These and other factors led to major improvements in coal utilization in the fumers and to major increases in zinc oxide production. A second unit was later purchased for the reverberatory furnace to give silica and iron assays of the slag, and these were used to make adjustments in the feed composition to maintain the desired SiO2:Fe ratio in the slag. Since purchasing the units for the furnace, the oil consumption and copper content of the slag have dropped significantly. IntroductionSmelters have lagged far behind concentrators in process control by mean s of rapid product analysis. The on-stream X-ray analyzer was developed about seventeen years ago, and soon concentrators around the world were getting assays of the incoming ore, .concentrates and tailings every fifteen minutes, and using these to control reagent additions and other process variables. Almost always, the concentrate grade and recovery improved.In smelters, product streams are solids or molten materials, not the more easily handled slurries, and until seven years ago no inexpensive equipment was available to provide rapid analysis of this type of material. In approximately 1980, several companies developed instruments based on irradiating solid samples with low-intensity gamma rays from radio-isotope sources, and measuring the secondary X-rays emitted from different elements in the sample to provide an analysis of the elements desired.The smelter staff had a close look at what was needed and listed the following points as being critical:1. ability to provide Zn assays of a sample of slag within 15 minutes of taking it, in order to achieve optimum fuming times (zinc fuming , being a batch process, had the greatest potential benefit from rapid slag analysis);2. ability to give Cu and Fe assays on the slag, and on other smelter products, such as matte and converter slag;3. ability to give Si02 assays since the SiO2 content of the slag has a strong effect on fuming rate; and4. ability to stand up to an industrial atmosphere such as exists in the fuming plant."

Jan 1, 1987

By Bertrand Wolfman, William E. Stanley

"This paper reviews the traditional mine accounting systems, including ""custodial accounting"" and unit costing, and then suggests that the use of flexible budgets represents a more suitable method of reporting costs in order to assist the mine manager in improving productivity. Examples of various applications are given to show that the result is a clear reporting structure.Custodial Accounting is Emphasized in Traditional SystemsTraditional mine accounting has been mainly concerned with the accuracy of financial reporting to ""head office"" for the use of the directors and the company's bankers and shareholders. This is often called custodial accounting and it represented the main purpose of accounting when first developed in Europe hundreds of years ago. This important development permitted the establishment of enterprises which were separated from their owners because they could rely on accurate financial reports of management's stewardship.As custodial accounting is fairly broad and historical in nature, it is often not very useful to the mine manager for ongoing monitoring of performance of mining, milling, maintenance, and other support and staff groups. In spite of the considerable investment in accounting staff and computer support, many accounting systems have not been upgraded so that they accurately reflect workplace performance on a weekly or monthly basis.Budgets are Often FixedMany mines today also still emphasize fixed budgets. Thus, the mine plan which is set in the fall of one year is converted to a monthly tonnage and detailed dollar budget for periods of up to sixteen months in the future. The only certainty in this plan is that actual events will differ; timing, mix of mining methods and production volumes will differ on a monthly basis.Unfortunately, the fixed budget has no capability to reflect these operational changes. It is frozen for the full year. The result is that actual results will inevitably be compared to an outdated target."

Jan 1, 1982

By D. G. Champion

"A comparison of diesel engine power ratings with in-service capability, and the selection of unit size and total number of units are discussed in the paper. Engine specific fuel consumption and its evaluation in relation to manufacturers' tolerances and equipment load factors is reviewed along with the suitable plant layout. The potential for heat recovery is discussed in connection with simple and operable recovery systems f or exhaust and cooling circuits. Maintenance standards as related to improved reliability and reduced fuel and operating costs are also outlined. IntroductionDiesel generators are used in Canadian mining operations to provide electrical power for "" base- load"" requirements in some instances and for ""stand-by"" or ""emergency"" power in almost every producing mine in the country . There are over 300 mines in Canada of which only a handful have to generate their own electricity. Only one or two mine s enjoy access to a hydroelectric site. Consequently, the diesel engine is the principal prime mover because of its high efficiency relative to other prime movers in the size range in question.The author has been associated with several “base-load” plants in addition to participation in numerous projects requiring emergency diesel generators. Records indicate that engine performance in term s of reliability and efficiency lags behind other industries where the diesel engine is used more extensively, such as the shipping industry which is able to make a more prudent selection of original equipment and enjoy easy access to highly skilled operating and maintenance personnel. It is hoped that the contents of this paper will be of value to Canadian operators of diesel generators, in the generation of prime power or applications for back-up power."

Jan 1, 1986