Search Documents

By I. Ueda, S. Ishikawa, T. Nagata

“O-SR process” in which the S-Furnace of the Mitsubishi process is followed by existing reverberatory furnaces (RFs) and Peirce Smith (PS) converters has been operated since December 2007. The S-Furnace smelts copper concentrates to produce molten matte containing 58-62%Cu which is then settled in the RFs and converted to blister copper in the PS converters. The SO2 gas generated from the S-Furnace and PS converters is converted to sulfuric acid in the acid plants. In addition to the smelting copper concentrates, the O-SR process has advantages in terms of recycling various waste/secondary materials. Automotive Shredder Residue (ASR) has been treated in the RF to reduce fossil-fuel consumption in RFs, and to recover various metals included in ASR as well, since 1993. Electronic circuit boards (E-scrap) has also been processed in order to recover not only copper but also rare resources such as gold, silver and PGMs since 2013. Strategic modifications have enabled expansion of the processing volume of E-scrap. Enhancing recycling of wastes and scraps from urban mines while reducing the consumption of natural resources in the “O-SR” process will be demonstrated and discussed in the present paper. INTRODUCTION Onahama smelter and refinery has been operating as a custom smelter since 1965. Smelting facilities were subsequently expanded to two green-charged RF furnaces and five PS converters in 1973. Since RF is a conventional old-fashioned smelting furnace that necessarily consumes a huge amount of fuel to smelt copper concentrates, saving fuel cost has been an important objective. In early 1980’s the fuel was changed from bunker oil to pulverized coal, while utilizing the combustion heat of waste tires. Furthermore, treatment of combustible waste such as shredder residue (SR) was initiated in order to save fossil fuel for smelting concentrates in the RFs. Since enhancing of the treatment of SR requires a reduction in concentrate smelted in the RFs, most concentrates were dried and injected through tuyeres into the PS.converters. These modifications enabled to reduce the amount of the pulverized coal combustion and to increase SR treatment in the RFs. SR treatment capacity has increased to 12,000mt/month because the SR market has grown after the enforcement of the Vehicles Recycling Law. Such business environment has been attributed to establish the thermal-materials recycling system of SR in which the RFs have changed their role from copper concentrates smelting furnaces to waste materials combustion furnaces.

Jan 1, 2019

By David Dreisinger

Arsenic occurs in nature in association with many valuable metals including copper, nickel, cobalt, gold and platinum group metals. The recovery of these valuable metals is of course complicated by the need to extract and stabilize arsenic in a form suitable for disposal. In this paper, a review of some recent developments related to hydrometallurgical treatment of arsenic bearing materials is provided. The key aspects of metal dissolution, arsenic stabilization and disposal are discussed.

Jan 1, 2014

By Wei Huang, Anh V. Nguyen

"Potash flotation is an industrially proven success of flotation of soluble salts, but its collector adsorption mechanism remains elusive. In this paper, specific ion effects in NaCl-KCl flotation with carboxylate collectors were investigated. Flotation recovery and contact angle were determined as a function of brine composition of NaCl and KCl. The experimental results have shown that wettability of KCl and flotation of the soluble salts with laurate collectors were dependent on brine ion composition. Specifically, adding Na+ to brines decreased hydrophobicity of KCl crystals and their flotation recovery. Both KCl and NaCl could be floated with laurate collectors. However, flotation of NaCl was greatly enhanced by adding K+ to brine whereas flotation of KCl was significantly suppressed by the presence of Na ions. The decrease in KCl recovery upon adding Na+ is attributed to the counter-ion binding in the pulp. The flotation recovery enhancement of NaCl in the presence of K+ is explained by two effects: 1) increasing K+ concentration leads to a better dispersion of collector colloids in the pulp and 2) K+ enhances the collector adsorption at NaCl crystal surfaces. The water affinity matching rule can explain the specific ion binding behaviors and supported by the SFG spectroscopic results.INTRODUCTIONPotassium is an important fertilizer. Its primary source comes from potash ores, which are a mixture of sylvite (KCl), halite (NaCl) and many other complex double salts such as carnallite (KCl·MgCl·6H2O), alkali nitrates such as KNO3 and NaNO3, and sulfates-langbeinite (2MgSO4·K2SO4) with water-insoluble minerals such as clay and carbonate minerals. Previously, these salts were recovered with a lengthy hot leaching method, with further crystallization of potassium salts from saturated saline solutions. Selective flotation has been preferred since 1940s. Various collector adsorption mechanisms have been proposed soon after the industrial introduction of potash flotation. These include the formation of the insoluble compound model (Halbich, 1933; Singewald, 1961), an ion exchange model (Fuerstenau and Fuerstenau, 1956), a heat of solution model (Rogers, 1957), the surface hydration model (Schubert, 1988), the surface charge model (Roman, 1966; Miller et al., 1992), the interfacial water structure model (Hancer and Miller, 2000) and the colloid adsorption model (Leja, 1983; Burdukova and Laskowski, 2009). Most of the early exercises attempting to propose a unified rule on collector adsorption mechanisms can be seen as heroic endeavors due to the consideration of a vast number of salts in the pulp including alkali halides, nitrates, and sulfates, even the practically insoluble heavy earth metals. Additionally, several types of surfactants with different polarization features and alkyl chain length have been employed. As for the recent models, due probably to the preferential application of long chain amines as collectors in industrial potash flotation, most researchers are only devoted to collectors with low polarization features like amines and sulfonates (Hancer and Miller, 2000; Du et al., 2014). Collector adsorption mechanisms are therefore proposed based largely on a neglect of carboxylates as collectors. However, carboxylates remain an important collector type in soluble salt flotation systems where both salt minerals can be floated using anionic collectors and cationic collectors. Fatty acid type collectors are still one of the widely used collectors for soluble salt flotation and also one of the first to be applied on an industrial scale for the separation of potash ore (Hernáinz et al., 2003; Titkov, 2004). Here we examine some recent models that are relevant to our study to reveal a long neglected specific ion binding effects in potash flotation."

Jan 1, 2016

By W. Lamb

Feed Preparation ? Five primary parameters affect the screening efficiency ? Ore characteristics ? Operational characteristics ? Screen characteristics ? Water addition and washing ? System design

Apr 1, 2005

By A. A. Ruitenberg, G. Ruitenberg, J. Chandra

"The Caledonian Belt is mainly underlain by Late Precambrian and possibly Early Palaeozoic rocks, which are in part overlain by younger strata. Most of these rocks are weakly deformed, except for those in some linear . zones, which have been intensely deformed by cataclasis. Mineral deposits related to two distinct metallization episodes have been recognized. The earliest are zinccopper- lead sulphide deposits, which have been concentrated in the axial regions of late-stage cross-folds within the main cataclastic zone. The host rocks are andesitic and dacitic tuffs which show effects of intense talcose alteration, silicification and chloritization. Deposits related to the second episode are mainly composed of copper sulphides with locally abundant tennantite and tetrahedrite, which occur in brecciated and fractured carbonate-quartz veins. These veins postdate the late-stage cross-folds. VLF-EM and high-sensitivity magnetics proved to be very effective in delineating the geology of these deposits."

Jan 1, 1972

By J. Shahabpour

"Breccias with angular and rounded clasts of a late-mineralization, ""barren"" hornblende porphyry dike set within a comminuted matrix consisting of rock fragments and quartz, cemented by quartz and K-feldspar of hydrothermal origin is observed in diamond drill cores from the Sar Cheshmeh porphyry copper deposit. Studies of age relationship between vein types, phyllic-altered clasts and the breccia groundmass suggest that the brecciation is a late event. The breccia clasts record evidence of hydrothermal reaction between the clasts and fluids responsible for the brecciation.Formation of bornite, in the breccia clasts of the originally barren hornblende porphyry dike, and in the breccia matrix, along with the scarcity of bornite in the Sar Cheshmeh deposit itself suggest involvement of fluids which are later and of different composition from the fluids responsible for the known mineralization at Sar Cheshmeh. These later fluids may be related to a later plutonic event and suggest the possibility of a later, and concealed deposit."

Jan 1, 1994

By Tim Robinson, Michael S. Moats, William G. Davenport, Andreas Filzwieser, Andreas Siegmund, Shijie Wang

This survey continues the long tradition of providing a snapshot of operating data from industrial electrorefineries. It is a supplement to previous surveys that were performed in 1987, 1991, 1995, 1999, 2001, 2003, 2007, 2010, 2013 and 2016. Analyses of current data and historical trends are presented. Examples of innovations to reduce costs, improve productivity, and improve quality are provided. In general, refineries continue to increase productivity while treating anodes with more impurities. INTRODUCTION This manuscript analyzes global survey data provided by operating copper electrorefineries. This paper continues a series of surveys of copper refining tankhouses that started in 1987 (Schloen, 1987, 1991; Schloen & Davemport, 1995; Davenport et al., 1999; Robinson et al., 2003; Moats et al., 2007, 2013, 2016). In this installment, data collected from 2015 and 2018 will be presented and analyzed. The 2015 survey data were presented at Copper 2016 in Kobe, Japan. This survey will continue the analysis of previous data to illustrate long term trends in copper electrorefining, which were originally presented at the Davenport Symposium in October, 2014 (Moats, Robinson, & Wang, 2014). Refineries who supplied surveys are listed in Table 1. Cathode production data from 2015 and 2017/18 (from surveys presented in 2016 and 2019) are provided to indicate which plants provided surveys and when. This manuscript presents operating data for ~6.5 million tonnes of copper production, which represents 30–35% of the world’s copper electrorefining production. The detailed survey results are available upon request from the corresponding author.

Jan 1, 2019

By A. -I. Abenhaim, I. Sasu, C. Perron, I. Mantegh, S. Larose

Manufacturing long shafts, such as those used in turbine engines, normally involves with drilling inside them in order to take the excessive mass out. Concentricity between the shaft axis and that of the drilled hole is very crucial as it impacts the mass distribution around the axis of rotation. It is important that the shaft mass be well balanced around the central axis in order to minimise the centrifugal forces on the bearings and supporting structure as well as any unwanted vibrations. The eccentricity problem, mostly in long shafts, comes due to machining limitations. It is difficult in long shafts to maintain the concentricity tolerances while drilling inside the shaft. In this work, we address the problem of correcting this eccentricity problem, i.e., when the axis of the inside hole deviates from the central axis. The presented work is based on a threepoint bending method and investigates its effect on the residual stresses and plasticity regions induced on the shaft. A full finite element model is presented that can used to design the solution parameters (bending load, location, etc.) and predict the effect. Limited experimental results are also presented to validate the finite element modelling.

Jan 1, 2006

By P. R. Warner

This paper reviews the development of certain aspects of the electrical specifications of Anglo American?s suite of specifications for gearless mill drives (?GMDs?). These specifications are based on experiences in both Anglo American?s and others? operations, benchmarking against large hydro generators, the advice of industry and university experts, and continuous close co-operation with OEMs. To achieve a step change in availability additional final testing and electrical protection have been implemented, insulation requirements have been specified for machines to be operated at high altitude and clean area and access control systems have been developed.

Nov 1, 2011

By Etienne Roy Grégoire

Since the early 1990s, the Canadian mining industry has been increasingly defined by the signing of Impact and Benefit Agreements (IBAs) between mining companies and Aboriginal peoples. While these agreements are intended to complement the legal system, they also serve to establish the legitimacy of mining projects and to encourage the harmonious integration of these projects into their social and environmental contexts. Beyond their practical implications, what are the effects of such agreements on the ability of Aboriginal communities to access the institutional space where the authorization of mining projects and the conditions of their implementation are decided? Can we view IBAs as a preliminary step towards the operationalization of the principle of Free, Prior and Informed Consent? This paper aims to explore the potential of IBAs as a sustainable solution to the legitimacy issues that result from the implementation of the formal regulatory framework governing mining activities in this jurisdiction. We highlight what constraints and opportunities the James Bay and Northern Quebec Agreement (JBNQA) engenders for local communities and draw attention to the ways in which the negotiation of the Raglan IBA and the environmental evaluation processes act upon each other. We find that certain structural problems - and problems of legitimacy ? related to mining in Northern Quebec cannot be solved by the sole signature of an IBA, which suggests the need for caution when considering such agreements as a panacea. The Raglan case demonstrates that IBAs, like other modes of regulation relying on the direct interface between companies and communities, would benefit from a stricter framework and more explicit ties with official regulation channels.

Aug 1, 2013

By Paul MacLean

MAC TSM ?Mining and Biodiversity Conservation 1.Corporate biodiversity conservation policy, accountability and communications 2.Facility-Level biodiversity conservation planning and implementation 3.Biodiversity conservation reporting ?Activities indicative of level AA -AAA (formerly 4-5) performance: ?Independent verification ?Integration into broader business strategy and planning processes ?Engagement with communities of interest ?Commitment to actively partner with other organisations for biodiversity conservation

May 1, 2011

By S. Perkins, E. Young, L. Dufour, K. McVey, L. Rolandi

This paper presents a review of plant layout considerations incorporated into recent designs of SAG/Ball mill circuits for two medium sized concentrators. The plant layouts presented and the design concepts discussed, relate to smaller SAG circuits, but can equally apply to larger milling circuits. Included are design concepts and ideas introduced by the various project teams, and the focus is on the primary factors of any layout design which are safety, constructability, operability, and capital cost.

Jan 1, 2012

By J. Dupre, A. Gontcharov, H. Pepin

Produced by the conventional TIG welding CMSX-4 welds had been studied. It was demostrated that microstructure of welds depended on filler materials, welding parameters and joint design. Epitaxial solidification of CMSX-4 clad deposits produced a directionally solidified structure while welding with the similar filler material. Defects free clad welds were obtained by TIG welding without preheating using similar and dissimilar filler materials.

Jan 1, 2006

By A. Welty, T. Garn, K. Lyon, B. Jakovljevic, R. S. Herbst, M. Greenhalgh, Cytec Solvay Group

"Industrial rare earth separation processes utilize PC88A, a phosphonic acid ligand, for solvent extraction separations. The separation factors of the individual rare earths, the equipment requirements, and chemical usage for these flowsheets are well characterized. Alternative ligands such as Cyanex® 572 and the associated flowsheets are being investigated at the pilot scale level to determine if significant enhancements to the current separation processes can be realized. These enhancements could be defined as higher separation factors, reduced stage requirements, or reduced chemical consumption. Any of these enhancements can significantly affect the costs associated with these challenging separation proccesses.A mid/heavy rare earth element (REE) separations flowsheet was developed and tested for each ligand in a 30 stage mixer-settler circuit to compare the separation performance of PC88A and Cyanex® 572. The ligand-metal complex strength of Cyanex® 572 provides efficient extraction of REE while significantly reducing the strip acid requirements. Reductions in chemical consumption have a significant impact on process economics for REE separations. Partitioning results summarized Table 1 indicate that Cyanex® 572 offers the same separation performance as PC88A while reducing acid consumption by 30% in the strip section for the mid/heavy REE separation."

Jan 1, 2016

By P. Woo, N. Brodusch, R. Gauvin, H. Demers

The scanning electron microscope (SEM) was primary developed for imaging applications. With the introduction of the Si(Li) energy dispersive spectrometer (EDS), simultaneous imaging and x-ray microanalysis became possible. However, long working distance and high current were needed because the position and small solid angle of the EDS detector. The high spatial resolution is generally obtained at short working distance with a SEM. Unfortunately x-ray microanalysis is never performed in the best imaging conditions. The annular silicon drift detector system is inserted below the objective lens which gives a higher solid angle (up to 1.3 sr). In consequence, a lower working distance and probe current can be used. An improved spatial resolution becomes possible during x-ray microanalysis. With this x-ray detector installed on a cold-field emission scanning electron microscope, quantitative x-ray microanalysis with high spatial resolution at low beam energy and low current becomes possible with the possibility of using the various different type of imaging at the same time. Also, since the count rate can be as high as 1,500 kcps, which lowers significantly the detection limit of elements as well as the minimum feature sizes of different phases that can be distinguished.

Jan 1, 2014

By V. I. Lakshmanan

Rare earth elements and yttrium (REEs+Y) are being used in the making of hybrid electric cars, catalytic converters, wind power generators, LEDs, hard disc drives, flat panel displays, and portable electronics. Currently China produces more than 95% of REEs+Y, which has made REEs+Y a critical strategic resource. Process Research ORTECH Inc. (PRO) has developed the innovative mixed-chloride (HCl+MgCl2) solvent extraction processes for recovery of REEs+Y from their ores. The HCl leaching system provides the opportunity to regenerate the acid, while the presence of MgCl2 in the lixiviant enhances the activity of the hydrogen ion by orders of magnitude, making the lixiviant very aggressive and resulting in high recoveries of REEs+Y. Solvent extraction steps are used for separation and purification of REEs+Y from other value metals or impurities including iron, zirconium, hafnium, uranium, thorium, niobium, tantalum and titanium. Direct individual separation of REEs+Y in a mixed chloride system allows avoiding the additional process steps of precipitation and dissolution in HCl. The resulting process has a simplified flow sheet that is closed-loop and environmentally friendly.

Jan 1, 2014

By A Smirnov

The problem of thin and very thin coal seam extraction is examined in a long perspective of Ukraine?s fuel and energy industry development. The technical and economic benefits of the coal seam selective mining technique are described, including beneficial environmental impact.

Aug 1, 2013

By James Ransford Dankwah

High sulphur carbonaceous materials like petroleum coke and rubber tyre are unsuitable as reductants in ironmaking because part of the sulphur is transferred to the reduced metal. Globally, while large amounts of petroleum coke are produced annually from the industrial processing of crude oil, billions of end-of-life rubber tyres are held in landfills and stockpiles. This work therefore investigates the potential feasibility of utilising these high sulphur carbonaceous materials as reductants in ironmaking without transferring the sulphur into the reduced metal. Composite pellets of iron oxide containing end-of-life rubber tyre (RT), petroleum coke and blends of RT/petroleum coke and petroleum coke/high density polyethylene (HDPE) were heated under argon atmosphere in a horizontal tube furnace. Reduced pellets were analysed after 10 minutes of reduction for their sulphur content. The results showed that sulphur-free metallic iron can be successfully synthesized using RT and petroleum coke as reductants. The level of desulphurisation depends on the nature of blending of the carbonaceous materials.

Jan 1, 2014

By Prodipto Ghosh

This paper is prepared as a review of existing and traditional methods related to electrical maintenance strategy. Its primary focus is to explore newer ideas and how they point the way to a more efficient and effective manner of electrical maintenance. This discussion is primarily related to large electrical distribution assets typical of heavy industry such as mining.

Aug 1, 2013

By D. J. Charlton

"IntroductionMaintenance is a business, which to be successful, requires good management, systems and reporting. The prime objective of the maintenance management group, be they large or small, must be to anticipate and prevent interruptions in operations by keeping equipment in good mechanical condition. This objective should be carried out at minimum cost consistent with maximum productiveness.The objective of this chapter is to give an insight into the various aspects of maintenance management that must be considered to effectively and efficiently operate a mill complex. The degree to which the maintenance sub-systems are developed in an operating mill will be determined by the size of the mill and the needs of the operation.The criterion of the management system used is that the system serve the operation and not vice versa. The systems presented should be considered as tools and, as with all tools, they must be sharpened and replaced as the need arises or as more effective tools become available.To understand what is involved in maintenance management, it is worthwhile to consider a systems approach to analyzing management problems. This approach was developed by J.A.B. Rae while reviewing maintenance management systems for Cominco Ltd.A very simple system involving managing results and objectives is shown diagrammatically in Figure 1.The systems approach to organizational development involves four basic elements: an objective, a result, an activity and feedback. In the analysis, the activity element is broken down into individual actions that people could be held responsible for. If we introduce the action of operating into the diagram of Figure l, we arrive diagrammatically in Figure 2."

Jan 1, 1989