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By Magnus Evertsson, Johannes Quist

HPGRs have since introduced in the 1980s (Kellerwessel, 1993; Schönert, 1988), now become integral comminution units at several minerals processing plants around the world. Even though a lot of the initial issues concerning performance, availability and wear have been addressed and solved there are still phenomena and aspects which can be improved and understood further. Schönert and Sander (2002) presented experimental results and a mechanistic model including the internal force dynamics between the rollers and the compacted bed. They derived expressions for the pressure distribution involving most of the influencing terms and effects. However, in order to solve the differential equations several of the terms vanish by assumptions. The Schönert and Sander model reflects the experimental data in many aspects but the predicted shear force distinctly deviates from the experimental results at the angular position of the peak pressure level. This finding suggests that the particle to particle interaction and breakage process in the different zones seen in Figure 1 are complex and difficult to model using analytical models. A numerical modelling approach using DEM does not require the same amount of assumptions and simplifications of boundary conditions. Hence such modelling may provide further knowledge and vital understanding. In this paper the breakage process is simulated in order to investigate the shear slip behaviour and how it relates to different operating variables. A laboratory scale HPGR corresponding to the experimental setup used by Schönert (2002) have been modelled in EDEM (DEM-Solutions). The bonded particle model (BPM) is used for modelling quartz particles (Potyondy, 2004). The breakage model strength parameters are calibrated against interparticle breakage experiments in an Instron 400RD compression device. The contact model parameters are calibrated using calibration methods developed by Quist (2015). The floating roller dynamics are modelled using a spring-damper system. Results present insights regarding the interparticle slip behaviour as well as the frictional tangential force distribution on the rollers. The simulated roller pressure distribution shows good correspondence with previously reported findings in the literature.

Jan 1, 2016

By R W. Drybrough

The program to increase production at Sherritt Gordon's Lynn Lake property, which began in 1956, included increasing the rope speed and the horsepower of the ore hoist at the "A" shaft. Because of the limited power sup-ply from the two 7,000-hp. hydroelectric plants, and the ? 3,600 hp. predicted for the combined hoisting requirements of the three production shafts, it was considered desirable to lessen the impact of this type of load on the relatively small power system by equipping all future hoisting arrangements with Ward Leonard direct-current drives. The manually operated 8-by 4-ft. hoist at the "A" shaft had a rope speed of 1000 f.p.m., and was driven by a 385-hp., 380-r.p.m. wound rotor motor with liquid rheostat control. This A.C. drive was replaced by a semi-automatic Ward Leonard direct-current drive with a 515-hp., 566-r.p.m., shunt wound motor, providing a rope speed of 1,500 f.p.m. During several months preceding the con-version, all possible preparations were carried out to keep the changeover period to a minimum, and this resulted in a total shutdown time of twelve days. The capability of the "A" Shaft hoist was increased from 109 tons per hour to 134 tons per hour, and both mechanical and electrical maintenance were reduced considerably. The total cost of the conversion amounted to $130,000. The hoistmen who had been required for the manual A.C. drive were transferred to the new Farley shaft, and the reduction in operating labour costs of the "A" Shaft hoist

Jan 1, 1965

By J. O. Wheeler

"DEFINITION OF THE REGION, ITS BOUNDARIES, AND PHYSICAL AND GE'OLOGICAL CHARACTERISTICSTHIS PAPER concerns the Western Cordilleran region, embracing most of British Columbia, the southern half of Yukon Territory and the southwestern most part of the District of MacKenzie. It excludes Vancouver Island and the Queen Charlotte Islands, which are discussed in a background paper on the Pacific Continental Shelf. The region is bounded on the south by the northwestern United States, on the west by the continental shelf and Alaska, on the north by the front of the Ogilvie Mountains, on the northeast by the axis of the MacKenzie Mountains and on the east by the Rocky Mountain Trench.The region is dominated by two mountain chains that con tain icefields and glaciers: the St. Elias, Coast and Cascade Mountains in the west; the Selwyn, Pelly, Cassiar, Omineca and Columbia Mountains in the east. The Intermontane region between these mountain chains consists of lower mountains and plateaus. In the mountains, the region above the timberline and many of the steep valley-walls provide good exposures of rock, but these areas are subject to rockslides and landslides and in winter to snow avalanches. Much of the Western Cordillera was covered by ice-sheets at various times during the Pleistocene epoch. Consequently, the larger valleys in the mountains and much of the Intermontane region contain much glacial drift and alluvium and only limited exposures of rock. This same terrain in the Southern Cordillera, however, is the most favourable for agriculture. Parts of the region, particularly in the two mountain chains, are heavily forested. Elsewhere, the forest cover is less, with grassland prevailing in the south and tundra in the north."

Jan 1, 1969

By J. O. Wheeler

"DEFINITION OF THE REGION, ITS BOUNDARIES, AND PHYSICAL AND GE'OLOGICAL CHARACTERISTICSTHIS PAPER concerns the Western Cordilleran region, embracing most of British Columbia, the southern half of Yukon Territory and the southwesternmost part of the District of MacKenzie. It excludes Vancouver Island and the Queen Charlotte Islands, which are discussed in a background paper on the Pacific Continental Shelf. The region is bounded on the south by the northwestern United States, on the west by the continental shelf and Alaska, on the north by the front of the Ogilvie Mountains, on the northeast by the axis of the MacKenzie Mountains and on the east by the Rocky Mountain Trench.The region is dominated by two mountain chains that con tain icefields and glaciers: the St. Elias, Coast and Cascade Mountains in the west; the Selwyn, Pelly, Cassiar, Omineca and Columbia Mountains in the east. The Intermontane region between these mountain chains consists of lower mountains and plateaus. In the mountains, the region above the timberline and many of the steep valley-walls provide good exposures of rock, but these areas are subject to rockslides and landslides and in winter to snow avalanches. Much of the Western Cordillera was covered by ice-sheets at various times during the Pleistocene epoch. Consequently, the larger valleys in the mountains and much of the Intermontane region contain much glacial drift and alluvium and only limited exposures of rock. This same terrain in the Southern Cordillera, however, is the most favourable for agriculture. Parts of the region, particularly in the two mountain chains, are heavily forested. Elsewhere, the forest cover is less, with grassland prevailing in the south and tundra in the north."

Jan 1, 1970

By P. G. Dunn, J. Fitzgerald

ABSTRACT The scheduling of underground mining activities is a complex task that must simultaneously satisfy a large number of constraints. A schedule optimization tool (SOT) for underground mine planning is described, and its use for investigating strategic decisions is illustrated through a case study. The maincomponents of the SOT include (a) a genetic algorithm that searches for optimal schedules, (b) guidance for the application of heuristic rules, and (c) sliding, which implements just-in-time development. Findings indicated that preliminary scheduling performed before invoking the SOT, intended to provide a good starting point for the search, did not ultimately lead to higher value schedules.

Jan 1, 2010

By J. H. McMillan

Most of the recent papers read before the Institute have dealt with purely scientific matters, or with experiences in the various phases of mining operations. Very little, if anything, has been said concerning the part played by the human element in the industry. It is now opportune to consider this vital factor if we are to cope with the complex work of the present-day miner and, at the same time, meet the demands of the executive for greater efficiency. It is time we made an inventory of our knowledge to determine if we are absorbing the information so essential to modern mining practice. We must keep in close touch with all new ideas and developments in our chosen field and keep ourselves up-to-date in regard to everything pertaining to mining operations in general. The man who ceases to study ceases to advance. There are men who on attaining an executive chair give up all study, because they think they have reached the pinnacle of success. Modern industrial business, and coal-mining is no exception, demands that executive officers shall be 'live wires' -- men who are not only well-informed as to their immediate duties, but who are closely in touch with all matters of importance affecting the industry as a whole. We may be graduates of schools and colleges, but the training we receive in these institutions is only the foundation for our later work. Certainly no executive officer can know too much concerning the work he is engaged in, and the more he knows the more pleasure he will get out of his work.

Jan 1, 1925

By O. C. Rojas, J. Sanhueza, J. C. Vargas

Empresa Nacional de Minería (ENAMI) is dedicated to the promotion of small and mid scale Chilean mining industry. Paipote, ENAMI Copper Smelter, processes a variety of mineral products as the result of this promotion. The mineral products characterize a wide variation of copper, iron, sulfur and precious metals content as well as the significant dispersion in the content of impurities, such as arsenic, antimony and bismuth. The Smelter Modernization Program, initiated in1997, introduced a series of technological and operational changes. The development of operational planning and control strategies was necessary to optimize the blending of a wide variety of concentrates and the control of metallurgical processes in order to ensure the stable operation, fulfillment of environmental regulations and the quality of produced copper anodes. A permanent optimization process carried out in the last decade led to the permanent increase of the smelting capacity and the production of anodes and sulfuric acid. Additionally, introduced improvements affected the smelter efficiency and metallurgical recovery, demonstrating the possibilities of the optimization of a small smelting facility reflected in good metallurgical and economic results. This paper presents the smelter evolution, introduced technological and process control changes as well as incorporated new reactors and equipment as a continuous process of optimization.

Jan 1, 2007

By Colleagues from Process and Operation departments, Guy Chevalier

"QCM's pellet plant, located in Port-Cartier, Quebec, produces up to 8.6 million tons of iron ore pellets annually. Four different types are produced: three for blast furnace operations and one for direct reduction furnaces. The paper presents the scientific approach that led to the installation of new process equipment to improve the reducibility of direct reduction pellets (DR pellet). The findings, the equipment selection and some post start-up modifications are presented.This low silica DR pellet is used in Midrex and HyL shaft furnaces. A good DR pellet has to meet strict chemical, physical and metallurgical specifications. An important metallurgical property is its ability to release oxygen when exposed to reducing gases. Considering that the market for DR pellets is expanding and being aware that reducibility is critical for our clients, a program to improve the latter was undertaken. Test work showed that one factor which has a negative effect on reducibility is the proportion of particles larger than 75 microns. Knowing that the best way to reduce the amount of coarse particles was to close our open grinding circuits, we began evaluating the most suitable classification equipment applicable to our process operations. We settled on hydro-classifiers based on their very sharp cut and their low operating costs. In light of the hydro-classifiers performance it was also decided to replace the hydro-cyclones of an already closed circuit.INTRODUCTIONAt the Québec Cartier Mining pellet plant, continuous improvement programs are aimed at increasing levels of consistency and improved chemical, physical and metallurgical properties. This is being accomplished while still maintaining pellet plant production volumes to satisfy market demands.QCM produces three types of pellets for blast furnace use: acid pellets, designated as ""BHF"", fluxed pellets, designated as ""BAF"", and low silica fluxed pellets, designated as ""BSA"". For direct reduction, a low silica acid pellet or DR pellet, designated as ""BBS"" is produced. This low silica DR pellet is used in Midrex and HyL shaft furnaces.The demand for DR pellets has been increasing during the last few years and is believed to continue so in the future. Wanting to be present in this growing market QCM found that it would be essential to work at improving its DR pellets quality. Efforts have been focused on improvements in three areas: SiO2 reduction, elimination of sticking and increasing reducibility. Improvement programs have begun with laboratory research followed by plant trials and full-scale implementation as a cooperative effort among QCM, COREM, and key customers."

Jan 1, 2002

By S. Jain

Construction industry is considered as labour intensive, having shortage of skilled labour, unsafe with large number of industrial accidents. Construction industry requires high technology automation products (Robots) for improving productivity, safety, quality etc. Robots are developed by various countries in different areas like demolition, earthwork, bridge, tunnels, road work, underwater works, trenches and piping, maintenance etc. however they are still not used to their full potential by construction industry. Hence in this paper, the authors propose a ?model for adoption? of robots in construction industry. This model considers how a construction firm will adopt full scale robots like manually controlled machine, tele-controlled machines, computer controlled machines and cognitive robots and assimilate them through various stages.

Aug 1, 2013

This paper presents the results of research aimed at proposing new solutions in the area of belt conveyor elements. Many factors, such as energy consumption costs, and operating costs of belt conveyor elements, including belts, idlers and drives have an impact on the operational costs of conveyors. The paper presents special tests of new materials for the bottom cover of an energy-saving belt conveyor, which decrease rolling resistance. It also presents large-scale in-situ tests of a high-output belt conveyor for the purpose of simultaneous measurements of various types of conveyor belts (standard vs several energysaving types) under typical operating conditions of a lignite surface mine. Improvements in materials used for the bottom belt covers, supported by specially developed comprehensive tests of the new types of belts have provided valuable results of various proposed solutions. Since the tests of belts were done at exactly the same time and in the same operating conditions, direct comparison of the results is valid and should lead to a substantial decrease in the conveyors? drives? energy consumption, which will improve the effectiveness of belt transport and minimize its negative influence on the environment.

Aug 1, 2013

By C. Kim

The integration of three-dimensional (3D) data with infrared thermography has received much attention for its potential use as input data for building energy simulations. Therefore, researchers have proposed methods to integrate 3D data with infrared thermography obtained by different sensors. These studies show the potential of the integration of 3D data and infrared thermography using various systems. However, these studies have ignored property aspects of infrared thermography, such as the low resolution of infrared thermography and external environmental influences. Thus, their proposed methods to integrate 3D data and infrared thermography are inadequate because these problems can affect the resulting building energy simulation. This research proposes a framework that integrates infrared thermography and 3D data while accounting for the resolution and shadow effect of infrared thermography. The proposed framework consists of three steps. In the resolution enhancement step, bi-cubic interpolation is proposed. In thermal data correction from the shadow effect, the shadow area is detected from the visible image, and then the shadow effect is removed from the registered infrared thermography. Finally, enhanced infrared thermography is mapped to the 3D data obtained by a laser scanner. The performance of the proposed framework was evaluated using test images obtained from a building in operation. The experimental results show that the proposed framework provides a 3D thermal model that is useful and accurate in simulating building energy. It is expected that the 3D thermal model can be used for accurate energy simulation of existing buildings. In addition, the proposed framework can be applied in defect detection for buildings. Furthermore, this novel approach enhances infrared thermography using visible images.

Aug 1, 2013

By H. J. McQueen

Friction stir welding (FSW) generates complex microstructures in the nugget and thermomechamically affected zones (TMAZ) that have led to diverse explanations. However, consideration as an extension of microstructure development in piercing/extrusion can lead to a better understanding of flow patterns and microstructures during FSW. Furthermore, the intense strains in the nugget/TMAZ can be interpreted by comparison with ultra-high strains in torsion that exhibit dynamic recovery as extending into regions with high angle boundaries strongly serrated with spacing near the subgrain size defined by the high temperature. The subgrain diameter and extrusion pressure have been shown to be dependent on the Zener-Hollomon parameter Z (=t exp(Q/RT), Q activation energy, R gas constant) combining temperature T and strain rate E in the same mariner as for torsion and compression. Moreover, such tests exhibited steady state stress os above a certain strain Es (rising as Z increases) in which T, , subgrain diameter and dislocation spacing remain constant. Due to the subgrain boundaries (SGB, low angle <5°, i.e.,LAB), continually rearranging by migration, decomposition and reformation, the subgrains remain equiaxed in elongating grains, whose boundaries (GB) become serrated as they migrate to absorb SGB. As confirmed by straining in torsion at constant T and Z. , more subgrains bordering the greater GB area have several high-angle facets (HAB) ; these small cellular regions with a mixture of HAB and LAB facets are designated HAB-subgrains. As serrations in neighboring grain boundaries impinge, the grains pinch off becoming shorter; this occurs at higher strains as subgrain size decreases with rising Z. The pinching-off makes the neighbors thicker so the grains never become thinner than about two subgrain diameters. In conjunction with such geometric dynamic recrystallization (gDRX), GB&apos;s undergo a net migration into grains with denser substructure, enlarging those with larger subgrains. Consequently a better name has been proposed: grain dimensioning dynamic recovery (gDRV).

Jan 1, 2007

By F. Rashchi, N. Naseri Joda

Recycling of electronic wastes is an important subject both from an environmental point of view and also the recovery of valuable materials. In this research, PC board scraps were leached to recover Cu, Ag, Au and Pd. Due to the high cost of the shredding process and to avoid secondary pollution from odors and dusts, board scraps were cut into 5X5 cm2 pieces. To determine the most effective leachant, aqua regia, nitric acid, hydrochloric acid, ammonium persulfate and potassium persulfate were tested. The effect of the leaching parameters, the leachant concentration, temperature, leaching time and liquid to solid ratio were studied and optimized using response surface methodology.

Jan 1, 2011

By E. Asselin

Electrochemical polarization experiments were conducted on alloy 625 in ammonia solution between 25 and 225°C and the results were compared with those of an oxygen solubility model. Results confirm that corrosion is under oxygen control, Normalized corrosion rates are determined based on the rate of oxygen diffusion to the corroding surface, and the corrosion rate at 200°C (-9.7 µA.cm-2) is roughly 24 times higher than the corrosion rate at 25°C (0.4 nA,cm-2), An oxygen-solubility model for Supercritical Water Oxidation (SCWO) conditions was generated using the Redlich¬Kwong-Soave (RKS) equation of state, Results of the model confirm many of the experimental observations from SCWO reactors which suggest that corrosion is at a maximum at temperatures just short of the critical point, The RKS/oxygen diffusion model predicts that the corrosion rate at 365° C is ?85 times higher than the corrosion rate at 25&apos; C. Given that a normalized corrosion rate is obtained, this type of model could be useful for selection of SCWO reactor materials.

Jan 1, 2005

By A. Valdivieso

Reducing accident rates keeps getting more and more complex as the usual tools enter a curve of diminishing results. Fortunately, nothing modifies behaviour in a stronger and wider way than having a robust safety culture. On the other hand, managing cultural change is difficult and the risk of back-fire is very high, especially if the workforce does not trust our intentions. A personalized approach of well chosen and targeted actions tends to be the only yet difficult option. We have found, via experience in the metallurgy and chemistry industries, a way of preparing the company and the workforce to accept these sorts of culture changing measures faster and easier. Using company-wide changes based on workplace perception, yields the most optimal acceptance. It is based in the principle that we all use clues in our environment as guides to choose our behaviour. So, controlling the perception that our workplace generates can affect behaviour and simplify our task before it even starts. It is a matter of using the tools that other disciplines such as marketing, social engineering and architecture bring to us and adapting them to a very defined objective: Having our installations “sell” safety so that our people unconsciously believe that they must adapt to safety values in order to “do well” in said environment. INTRODUCTION After decades of improvements in accident rates, we are understandably hitting a diminishing results curve: most actions that spectacularly reduced accidents in the past (e.g., Innovation in Personal Protection equipment, adapting international standards and legislation, and innovative safety programs; Figure 1) now hardly get us the exponential gains we saw years back, regardless of the investment we put on them. Furthermore, the improvements in safety of the last 3 decades have been creating new sets of issues that start to show their face such as: By reducing accidents we can create feelings of invulnerability as we lose view of the consequences. With innovative protection equipment we increase Risk Homeostasis, meaning that people behave in a more dangerous way in order to maintain a constant level of risk in their lives (Getting closer to fire after getting better fire-proof garments for example). Too much Legislation can create a feeling of disengagement from personal responsibility. And despite improvements, we haven’t really solved the production vs safety confrontation, it is now stigmatized and less visible, yet it tends to reappear in moments of weakness.

Jan 1, 2019

By L. E. Puddington, A. L. Mular

"Since the inception of spherical agglomeration, few investigations to exploit commercially the technique in the metallurgical field have been conducted. Of these, none appear to have been carried sufficiently far to demonstrate commercial feasibility.This paper describes a continuous agglomeration-separation process that can rapidly handle large tonnages of ore material. A small pilot plant de-signed from information obtained with the semi-batch unit described herein is currently in operation.In the absence of a reagent recovery system or cheap reagents, the process is probably not economically attractive for many common ores. However, for iron ores, the fuel content of the agglomerates can be used in a subsequent step such as direct reduction."

Jan 1, 1968

By Walter Valery, Sergio Vicuna, Roberto Valle, Hamer Arevalo, Ben Burger, Lui Vargas, Alex Jankovic, Jim Seidel, Eduardo Nozawa

This paper describes the design, the first three years of operation and optimization of a large, single stage SAG mill at Minera Yanacocha’s Gold Mill facility located in northern Peru. The Gold Mill was commissioned in March 2008 with a 32’ x 32’ EGL, 16.5MW single stage SAG mill, to process 5 million tonnes per annum high grade oxide Au/Ag ore. Operational control, feed size distribution, grinding media, mill liner, grate and pulp lifter optimisation have allowed the mill to operate 15-30% above design throughput rates, but with a product P80 coarser than design. As part of the optimization, full grinding circuit surveys were conducted. Historical operating data and survey data were analyzed and used to evaluate possible circuit changes and determine alternative operating strategies. A number of changes were implemented which allowed the SAG mill to operate similarly to a large ball mill and achieve finer mill product that was closer to design. This paper summarizes life to date data analysis and improvements made by Minera Yanacocha as well as the grinding circuit optimisation study conducted by Metso Process Technology and Innovation.

Jan 1, 2012

By David J. McDougall

"IntroductionThe production of pig iron, wrought iron bars and castings in Quebec during the 18th and 19th centuries has been so closely identified by historians with the Forges du St. Maurice on the St. Maurice River a few miles north of Trois Rivières (Three Rivers), that one is sometimes left with the impression that it was the only iron works that ever operated in the province. There were however, about twelve others, one of which was so completely re-built that it should probably be considered as a separate entity. All but two were constructed after the midpoint of the 1800s, coinciding with the growing Canadian demand for ""charcoal pig"" for railway car wheels and castings for industry, and about half of them were technically, if not economically, successful. The misconception about the Forges du St. Maurice may have come about either because of its long history of somewhat less than continuous production over a century and a half, or a tendency of Quebec historians to concentrate on events in the French-Canadian rather than the English-Canadian milieu, but whatever the reason, the other Quebec iron work s have been generally ignored. All but one of the Quebec blast furnaces could be described as ""preindustrial"" with capacities ranging between three and ten tons per day, the exception being the Radnor furnace built in 1892 with a maximum production of about 35 tons per day and an alleged capacity of 50 tons per day.Until a railway network was completed in the 1880s, the location of all the Quebec iron works except the Grantham Iron works was dictated by close proximity to adequate ore reserves because horse transport was of little use beyond a ten-mile radius. The other essentials of forest resources (mainly soft woods) for charcoal, limestone for flux and water power, were generally available except within a few miles on either side of the St. Lawrence river. Among the dozen iron works established in Quebec between 1732 and 1880, seven used bog iron ore in charcoal-fired furnaces."

Jan 1, 1983

By S. Amid, D. Fisk

"Wireless technologies are permeating the mining and metals industry and enabling a myriad of benefits. With standards such as IEEE 802.11 for wireless devices and ISA100.11a for wireless field instruments protecting their investments, customers look to benefit from the cost and flexibility offered by wireless devices. Using wireless field instruments, plants are eliminating the costs associated with wired system by 50 to 70% and using these savings to install more field instruments, which, when used smartly, enables them to optimize their processes efficiency and equipment reliability. Wireless also empowers a mobile workforce by allowing them to have access to key process and maintenance data directly from the field. This paper describes how wireless can help operations and maintenance personnel to be more effective. Three case studies, illustrating how the mining and metals industry is taking advantage of the technology today, are presented:1.,Optimisation of the water recovery process using wireless2.,Field operations improvement with wireless handhelds3.,Improving fleet maintenance through wireless mobile equipment management"

Jan 1, 2011

By Fabio Mielli

In these times of increasing costs and diminished returns, energy consumption is one source of savings that remains relatively untapped in the mining sector. Typically, 15% to 40% of operational costs can be attributed to energy in mining operations. This ?process variable? is a complex, multi-faceted variable that involves government regulations, societal pressures, cost and competitiveness. A mining company able to successfully embrace an energy efficiency program is more often than not a successful mining company. Production optimization programs, relatively common today, provide increased production, increased availability of assets and, in many cases, improved quality. They generally ignore the energy question altogether. Production Energy Optimization combines reductions in energy consumption with production improvements to reduce the cost per unit of production while improving emissions reporting. An energy strategy in mining and mineral processing operations is a critical component of Production Energy Optimization. This strategy must support the financial and operational integrity of the business. Developing a successful energy strategy requires a well structured approach such as following: ??Understanding where energy is being used and why, ??Recommending and implementing energy conservation measures, ??Driving visibility to targets and results, ??Re-evaluating continuously. The objective of this paper is to help you better understand the process, tools and technologies that enable mining organizations today to address energy and sustainability issues more tactically and proactively.

Aug 1, 2013