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By J. E. Amadi-Echendu, F. Stober, J. Ndlovu, L. R. Nelson

The Polokwane Smelter Complex (PSC) relies on a single 68MW high-intensity six-in-line furnace to smelt a planned 650 000 t/a dry concentrate to produce a platinum group metals (PGM)-bearing matte. As typical of a greenfields venture, considerable attention was paid to the project development and implementation stages of design, engineering, construction and commissioning. Somewhat unusual though, was the role of a dedicated multi-disciplinary "Operational Readiness" and support team, comprising the owners team and specialists from the furnace designer, HATCH, to effect a safe and rapid ramp-up to the design smelter capacity of 68MW. The challenges encountered in developing an effective partnership will be discussed. The modus operandi and roles of the "Operational Readiness" team during the design, procurement, construction and commissioning stages as well as that of the operational support team within the overall ramp-up objective will be presented. The "Operational Readiness" team was responsible for:

Jan 1, 2005

By N. Schmalbein, L. von Ketelhodt, L. Kotelo

"The mining industry continues to remain challenged. Lower commodity prices, increasing labor costs and more importantly diminishing reserves are amongst some of the primary factors contributing to the difficulties faced. Ore sorting technologies have demonstrated their potential to improve the downstream beneficiation performance. The general processing route sees all primary crushed material milled for liberation and then processed in accordance with characteristics of the gold therein, i.e.: refractory golds would require direct leaching or oxidation whilst free gold would follow the conventional cyanidation process, after gravity concentration. Ore dilution increases the associated operating costs within each stage of this process. The opportunity to process the same throughput at a higher grade can only be achieved through pre-concentration. Sensor based sorting has been examined on numerous occasions by various gold producers. Test work carried out on different bulk low grade gold ores has shown the successful applicability of ore sorting to remove waste, whilst maintaining high recovery rates of gold. The results of a combined XRT/Laser sensor sorter have shown grade improvements of over 300% from feed grades of 0,25g/t to 1,15g/t at gold recoveries of 66% and waste ejection rates of 85%. This paper presents some of the results from the work undertaken by STEINERT with respect to gold sulphide ore sorting and presents a modelled financial scenario, which can enable a company to target and reclaim low grade ores.INTRODUCTION The mining and minerals processing industry presents with many different challenges including, volatile commodity prices, increasing labor costs and more importantly diminishing reserves. Conventional processing routes will continue to play a crucial role in the beneficiation process, however innovative methods of reducing operating costs and optimizing on the overall circuit performance is where technologies such as sensor based sorting come into the fore. Sensor based sorting as a dry mechanical process not only reduces water consumption by eliminating unnecessary waste but also reduces the requirements for reagents in the downstream processes. Sensor based sorting under dry conditions presents a highly efficient alternative to wet pre-concentration methods such as dense medium separation (DMS)."

Jan 1, 2017

By M. Lindgren

"Hydrometallurgical processing involves process stages, like leaching, that create harsh environment for stainless steels. High acidity, the presence of chlorides and oxidizing ions combined with relatively high temperature create risk for both uniform and localized corrosion. Advanced electrochemical techniques were employed to study uniform and pitting corrosion of two stainless steel grades 316L and 2205. Results obtained with the linear polarization resistance technique combined with the harmonics distortion analysis, electrochemical noise and coupled multielectrode array systems are compared to the results of conventional electrochemical techniques and immersion tests.INTRODUCTIONHydrometallurgical processing has become favoured in metals production in recent years due to energy costs, leaner ore bodies and environmental factors. Because the hydrometallurgical processing route is flexible, various types of secondary raw materials, like flotation tailings, dusts, sludges and slimes can also be treated in addition to conventional mineral concentrates (Sarveswara Rao & Acharya, 2008).Hydrometallurgical processing relies on aqueous chemistry, usually acids, at temperatures around 100°C for the recovery of metals from ores, concentrates, recycled or residual materials. The processing route can typically be divided into three stages: leaching, solution concentration/purification and metal recovery. The processing environment is aggressive, especially in leaching. High acidity, relatively high temperature together with impurities, like chloride ions, place high demands on the corrosion resistance of construction materials. The dominant corrosion mechanism may be uniform corrosion or localized corrosion depending on the process conditions (Ekman & Torsner, 2010). This complicates the prediction of corrosion rates and, consequently, cost effective material selection.Traditional means to evaluate uniform corrosion resistance of stainless steels are immersion tests and the results are published in the form of iso-corrosion diagrams (Outokumpu Stainless, 2010). For the localized corrosion, namely pitting and crevice corrosion, immersion tests can be used but the duration of the test is rather long because an incubation period takes place prior to the occurrence of the actual localized corrosion damage. Electrochemical techniques, traditionally in the form of cyclic polarization scans, have been employed to assess the susceptibility of a material to pitting corrosion (Papavinasam, 2008). They cannot, however, give any indication of the pitting corrosion rate and lack potential for on-line measurements."

Jan 1, 2012

By R. E. G. Caines, P. Alport

"Operating heavy equipment in Labrador, where the winters are 8 months long and the temperature frequently drops below -40°F (-40°C) for days and sometimes weeks presents unique problems in both the operation and maintenance junctions. Winterization programs must be well designed and implemented at the proper time. These programs must include the proper selection of fuel oil, engine oil, hydraulic oils, greases, cooling system fluids, etc. More often than not, modifications have to be made to the original equipment in order that it can be operated safely and economically in the Canadian North. Manufacturers usually design equipment for a less harsh environment and the user makes adaptations by trial and error.Operators have to be trained for the proper operation on ice- and snow-covered roads in an open-pit mine. Special emphasis must be put on haulage road conditions. In this paper, the authors will cover some specific maintenance procedures, equipment modifications and operator training problems experienced by the Iron Ore Company of Canada in its open-pit operation in Labrador.IntroductionT he Iron Ore Company of Canada is engaged in open-pit mining , concentrating and pelletizing of iron ore. The company operates in two provinces, Quebec and Newfoundland (Fig . 1) . The Knob Lake operation "", based in Schefferville, Quebec, has mine sites located both in Labrador and Quebec . The Caro l Lake Project is situated in Labrador, 25 kilometres east o f the Quebec border at Labrador City. The Carol operation mines, concentrates and pelletizes it s o re before rail transportation to the seaport o f Sept-lies via the Quebec North Shore and Labrador Railway."

Jan 1, 1984

By J. E. Gill

THE 1938 season was marked by a distinct lull in exploratory activity in the Province of Quebec. Quebec was not unique in this respect, but the condition appears to have been more acute here than in most other parts of the Dominion. Various causes may be suggested to account for this. The general disturbance in political and economic conditions throughout the world has certainly had an adverse influence. Uncertainty induced by changes in the mining laws of Quebec in 1937 contributed. A third cause was the belief, now held by many, that the easily accessible deposits in the main producing belt extending eastward from. the Rouyn district have now all been found and that new discoveries in this field will henceforth come more slowly and more expensively. A fourth is the lack of conspicuous success by companies and individuals who have interested themselves in less accessible areas to the north, notably the Chibougamau district. A fifth, the unattractive appearance, as viewed on published geological maps, of the vast area extending northward to Ungava bay and Hudson strait. A sixth, the attraction of such speculative funds as were available to the Northwest Territories, where spectacular finds were reported in the fall of 1937. Whatever may be the relative importance of these causes, languor in exploration will ultimately be reflected in production returns. This appears, therefore, to be an opportune time to take stock of the general position of the Industry in the Province and to consider ways and means of counter-acting those conditions which are now impeding, or will in the near future impede, its expansion. At the request of the Institute Secretary, Mr. Carlyle, I have prepared a brief summary of accomplishments to date and a discussion of some of the geological aspects of the problem.

Jan 1, 1939

By Kéiko H. Hattori, Neil T. Pettigrew

"Abstract- The Legris Lake Complex is a northeast-trending, 7.3 km long by 3.5 km wide, maficultramafic intrusive complex located in the western Wabigoon Subprovince of the Archean Superior Province. It is one of a series of mafic-ultramafic igneous complexes, the most notable of which is the Lac des Iles Complex, host to Canada’s only producing Pd mine with reserves of 93.5 Mt grading 1.53 g/t Pd as of December 2001 (North American Palladium Ltd., Annual Report 2001). Cu-Ni- PGE mineralization was first discovered in the Legris Lake Complex by a local prospector late in 1999. Shortly thereafter, the property was jointly optioned by Avalon Ventures Ltd. and Starcore Resources Ltd., who continue to discover significant Cu-Ni-PGE mineralization.One of the most notable features of the Legris Lake Complex is the occurrence of extensive brecciation caused by multiple injections of volatile-rich magma. The Cu-Ni-PGE mineralization is hosted by leucogabbro within a 2 km long by 600 m wide, highly brecciated area in the northwestern area of the Complex. The mineralized rocks contain disseminated to blebby sulfides (1 to 5 vol.%), comprising chalcopyrite + pyrite ± pyrrhotite + millerite ± pentlandite, typically surrounded by epidote. The majority of the Cu-Ni-PGE mineralization displays low ratios of Pt/Pd (~0.20) and high ratios of Cu/Ni (~2.9), which are similar to those of the Lac des Iles and the River Valley mafic-ultramafic complexes. The lithologies in Legris Lake Complex bear similarities to the heterolithic gabbro of the Twilight and Roby Zone deposits at the nearby Lac des Iles mine. However, the mineralization at Legris Lake, which is restricted to leucogabbro overlying unmineralized clinopyroxenite, is similar to that of stratiform deposits such as the Stillwater and Munni Munni complexes. The mineralization at Legris Lake is best explained by the late-stage, immiscible separation of a sulfide melt from volatile-rich parental magmas and the subsequent minor redistribution of metals by deuteric fluids."

Jan 1, 2001

By J. H. Gray

"IntroductionIn 1980, Fording Coal Limited started conceptual planning studies which led to major changes in the long-range mining plan at their Fording River Operations. These new plans have been completed and are now in operation.To assist personnel in a timely completion of this major revision to the long-range plan, existing in-house drill hole data base and scheduling systems were used and a computerized Mine Modelling and Planning System was purchased. With these tools, plan s were developed which led to completion of initial access to the peak of Eagle Mountain and the start of mining operations in March 1983. As mining area s open up and new geo logical data is obtained, detailed plan s are being extended and revised.With the geology and mine plan s on line, this work can now be done with less effort and plans ca n be adapted to provide flexibility in mining operations. Changes in market conditions can be accommodated by moving mining operations into different seams for different coal types. The computer systems are used to revise pit designs and schedules accordingly."

Jan 1, 1986

By O. P. Garg

Based on improved methods of collection and analysis of geotechnical data, slope angles have been steepened in some mines of the Iron Ore Company of Canada at Schefferville, Quebec. This paper describes the slope design case history for Fleming NO.3 mine and illustrates the application of modern techniques. The new design has resulted in significant financial savings due to a reduction in required waste stripping.

Jan 1, 1978

By Lawrence Devon Smith

"The concept of risk is well established in the mining industry. It is acknowledged when estimates of reserves are expressed as proven or probable, when mining and metallurgical recoveries are applied to the ore, and when contingencies are added to costs. However, it is difficult to provide a quantitative assessment of risk. The significant sources of risk in a mineral project and how these are addressed in project evaluations are discussed.The discount rate is examined as a fundamental means of reflecting risk in discounted cash flow evaluations. Current industry practice is discussed, and a methodology for the analysis of risk levels is proposed that assesses the constituent components of the discount rate: real interest, mineral project risks, and country risk.IntroductionThis paper examines the components of the discounted cash flow discount rate and proposes a method of estimating project-specific discount rates. The motivation for this work comes from experience of project evaluations in which owners and purchasers had agreed on virtually every aspect of the evaluation except how much the project was worth. Agreement was reached on reserves, grade, recovery, capital costs, operating costs, taxes, and, by combining these components, even on the final cash flow values. The only difference in opinion concerned the discount rate to be used in the calculation of the net present value. Depending on the life of the project, such differences of opinion can cause a variation of more than 50% in the value placed on a project! This is illustrated in Figure I."

Jan 1, 1995

By Robert B. Parsons

"This article addresses the relationship between mine evaluation, the tax system, and economic risk. It is based on a paper presented by the author at recent seminars in Moscow and Tashkent on the subject of mine evaluation.IntroductionTaxation can have a strong influence on the feasibility of a mining project. For the most part, because metal prices are determined on a global basis, the mining concern is not able to pass on to its customers any portion of taxes which the concern has to pay. Taxes are a direct charge against the project. The purpose of the article is to highlight the various ways whereby different taxes can affect the financial viability of a mining operation.The first part of the paper identifies different forms of taxation, and the second part of the paper addresses the different forms of taxation in terms of risk analysis and impacts on the mining project. Finally, the third part of the paper makes brief mention of using the taxation system to provide incentives with respect to investment in mining activities."

Jan 1, 1993

By R. I. Cavanagh, A J. Last

THE USE of higher grade charges in blast furnaces in the form of sintered or pelletized concentrates has been increasing rapidly. The question of beneficiation of iron ores for this purpose is therefore receiving much attention as more deposits are developed. Many iron ores may respond well to magnetic roasting procedures followed by magnetic concentration, however, in most cases other more standard ore dressing methods are competitive and cheaper. For magnetic roasting as applied to iron ore beneficiation, the present question is "Can it be economically justified in situations where it appears to produce good results?" The following collection of information on the general status and operations of magnetic roasting methods may be helpful in considering this question. Magnetic Roasting Magnetic roasting involves the transformation of non-magnetic iron oxides, hydrated oxides and carbonates by means of heat and suitable

Jan 1, 1961

By A. I. A. Salama, M. W. Mikhail

"The existing methods of block diagram manipulation and vanishing variable for flowsheet simplification used in coal and mineral processing circuit evaluation and optimization cannot be easily implemented on digital computer.The signal flowgraph technique is proposed to represent and simplify determination of the relationship between intermediate or end variable and the feed in the flowsheet. Typical and existing circuits are used to demonstrate the application of the proposed technique which can easily be implemented on digital computers.IntroductionRecently there has been much interest in the analysis and optimization of coal and mineral processing circuits to assist in the pre diction of coal and mineral processing plant performance. The block diagram and the vanishing variable were introduced and utilized in the analysis of plant flowsheet. Although the block diagram approach is useful, it requires manual manipulation of the circuit block diagram which may present difficulties in the situation of complex circuits. Moreover, it may not be easy to implement on a digital computer.In this paper, the signal flowgraph technique is proposed to represent the circuit flowsheet and to simplify the determination of relationships between intermediate or end variables (fractional mass) and the feed for any coal and for any mineral processing circuit comprising size and density separators. These relationships are utilized in the analysis and/or optimization of the circuit. The proposed technique is illustrated by considering typical and existing circuits."

Jan 1, 1987

By R. H. McCorkell

Measurements of radon in air and aqueous solutions can be affected by leakage from vessels in which samples and standards are kept and by absorption and later release of radon by the materials of these vessels. The author had received various oral communications concerning the se processes : e.g ., that natural rubber and greases absorb large amounts of radon, whereas silicone rubber and grease do not; and that radon is readily lost from polyethylene bottles and that inverting glass bottles containing aqueous samples reduced radon loss from them . However, the results of actual tests and quantitative data showing these effects were not available. For this reason, it was necessary to make numerous measurements of the leakage and absorption of radon in the course of designing apparatus and methods for measuring radium and radon concentrations. It was thought that the data obtained might be of use to others, and consequently they are compiled in the present note .

Jan 1, 1980

By A. Scheltema Beduin, H. Oterdoom, A. Haaks, C. Kempe, A. Liedtke

The bath level measurement is applied in many furnaces to keep control of the level of slag and metal or matte inside. The BLM is used mainly in bath processes, and has not seen much evolution in its basic functionality. For a closed DC FeCr furnace, special demands based on the furnace design and extreme process conditions were considered for the design of a bath level measurement in order to collect valuable information about the furnace operation. This paper will describe these demands and the solutions for them, followed by some of the uses for the BLM in a closed FeCr furnace. Some of the future developments on the BLM conclude this presentation.

Jan 1, 2015

By Habib Zughbi, Paul Zulli

"A key step towards sustainability in iron and steelmaking is to optimise the use of raw materials and energy consumption, and consequently minimise CO2 emissions. Models based on a Process Integration (PI) approach play a key role in evaluating various scenarios and the impact of introducing changes in raw materials and operational conditions on the overall energy consumption and CO2 emissions. BlueScope uses a PI based comprehensive model for its Port Kembla Steelworks (PKSW), called the Integrated Steelworks Energy and Emissions Model (ISEEM). ISEEM is tightly coupled to the configuration of PKSW. It is based on mass and energy balances as well as thermodynamic relationships. ISEEM is a steady-state model and is used to predict overall and detailed unit-by-unit energy consumptions and CO2 emissions. It is also used for plant-based scenario modelling. This paper investigates the impact of major changes to PKSW configuration, including the shutting down of a blast furnace and cokemaking battery, on the energy consumption and CO2 emissions of the plant. It discusses some of the issues involved in updating the model and some identified opportunities."

Jan 1, 2015

By A. McLean, W. Q. Chen, W. Yan, M. Barati, Y. D. Yang

In order to maximally remove the harmful impurities phosphorus and reduce the loss of valuable elements from Si-based alloy for production of solar-grade silicon, thermodynamic properties of the Si-based alloy were studied. In this work a new model, the Molecular Interaction Volume Model (MIVM) derived from statistical thermodynamics, was successfully used in the Si-based and Si-Fe-based alloy. The calculation started from binary Si-Fe, Si-P and Fe-P systems, then the thermodynamic parameters of ternary systems could be derived based sub-binary systems. Using the activity coefficients of the elements in the Si-based alloys and the saturated vapor pressure of the pure substance of the components, mass fraction of P during vapor-liquid equilibrium can be calculated. The calculated thermodynamic parameters were compared with experimental data available in different publications, and it is found that the thermodynamic parameters calculated using MIVM model are in good agreement with the measured results. The calculated result shows that the mass fraction of phosphorus during vapor-liquid equilibrium of Si-Fe-P melt increases with the increasing phosphorus content and decreasing temperature. This is an important direction for experimental practice in vacuum or low-pressure EML refining of ferrosilicon for potential production of solar-grade silicon without significant vaporization loss of valuable element.

Jan 1, 2015

By P. Maltais

Over the last 10 years, Computer Aided Design, Finite Elements Analysis and field testing of prototypes have enabled the cycling industry to grow and to significantly improve its products. However, today's cyclists have become more and more demanding, making these classical design approaches almost obsolete. Devinci understood that problem four years ago and fully revisited its design approach; to offer bicycle frames better suited to real life riding, one must fully know those real life conditions. In partnership with the University de Sherbrooke, Quebec, Canada, Devinci then developed a bicycle enabling them to measure the actual load applied on a bicycle frame in real-time for real riding conditions: the instrumented bike. Today, Devinci uses its instrumented road and mountain bikes, combined with virtual prototyping and laboratory testing capabilities to develop better bicycles, faster.

Jan 1, 2006

By E. Wolmarans

The selection of the main mineralised zone (MMZ) concentrator milling circuit has followed a comprehensive route over the preceding 10 years. Many knowledgeable parties have contributed and assisted in developing the milling circuit according to the best available information. The final selection of the flow sheet was completed after DRA conducted a techno-economic study on four possible comminution circuits ranging from conventional crushing and ball milling to fully autogenous (AG) milling. The results from all the above mentioned work indicated that it is possible to treat the MMZ ore at the desired throughputs to the desired grind sizes in a fully autogenous grinding circuit. The flow sheet was designed to treat the main mineralised zone (MMZ) arising?s from both underground and open cast operations and incorporates a fully autogenous grinding (AG) circuit. Commissioning of the 375ktpm concentrator at Nkomati Nickel began in August 2009 with the first ore reporting to the mill on the 15th of September 2009.

Jan 1, 2012

By R. S. Douglas

Introduction The operations of The Granby Consolidated Mining, Smelting and Power Company, L1mited, have always been concerned with the mining of low-grade copper ores. In the fifty years of this Company's existence, nearly 60,000,000 tons of such material has been successfully mined and treated. During these years, many changes in mining practice took place. However, at Copper Mountain, due to the large tonnages of very low grade material, it was realized that something more than changing mining methods would have to take place if these low-grade orebodies were to be mined at a profit and the Company and. its employees enjoy many years of successful operation and employment. Production costs were mounting commensurately with rising taxes and the increasing cost of supplies, labour, freight, and smelting, while the value of the product on the market was not increasing in price to compensate for the higher costs of production. A survey of the mineable ore in 1944 indicated that, of the 12,000,000 tons in the reserves, only 3,500,000 tons was now profitable ore. This reduction in the commercial ore reserves was a serious matter, as it meant that the mine had only two years of life at the profitable shipp1ng rate of 4,800 tons per day. Further, the location in the mine of the orebodies making up the 3,500,000 tons was not suitable for such high production.

Jan 1, 1950

By A. Ducastel, S. Connemann, A. Stark, F. Bouillot, C. Fricke-Begemann, LSA, H. Knapp, L. Horckmans

"Refractory materials are essential for all high-temperature applications in industry. Depending on the position in the furnace and specific process requirements, refractories are produced from several raw materials, such as dolomite, magnesite, bauxite, graphite or chromite. Most of these raw materials are not rare but strict quality requirements limit the producers of refractories to only a few deposits in the world. Thus, raw material supply is a critical factor for the production of refractories and accounts for 40-50 % of the total costs of refractories.A possible way to lower dependency on raw material supply is recycling of spent refractories. Main challenge in recycling is the separation of different brick types from each other and the removal of impurities, such as steel or slag. The European FP7 project REFRASORT aims to apply sensor-based sorting for separation of spent refractories. Sensor-based sorting is known from food industry, recycling and mineral processing and has proven its reliability. Nevertheless, some adjustments are necessary compared to applications in mineral processing because of other sensor-types and a higher number of products in one sorting step. This paper presents the results of feasibility tests for sensor-based sorting of refractories with near infrared spectroscopy and laser-induced breakdown spectroscopy (LIBS). Both sensors showed the potential to identify different brick types but the most promising results were obtained using LIBS technology. INTRODUCTIONRefractories are solid, ceramic products, which can sustain temperatures of more than 1500°C, without losing their stability or shape. Bricks of refractories have to withstand corrosion in contact with liquid steel or slag. Various high temperature applications, such as the production of glass, steel, copper or cement, require high quality refractories. The quality requirements of refractory bricks are strict, because small impurities can lower the thermal strength significantly."

Jan 1, 2016