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By D. Bouchard, M. Forté, A. Charette

A transparent replica of a casting die was built to achieve a better understanding of the filling mechanisms of aluminum in high pressure die casting. Water and tomato paste were respectively used as analogues for the Newtonian liquid aluminum and the non-Newtonian semi-solid aluminum. The transparent die was installed on an industrial casting press and filling was filmed with a high-speed camera. Differences between the Newtonian and non-Newtonian fluids are presented and discussed.

Jan 1, 2006

By Andrzej Luszczkiewicz, Magdalena Duchnowska, KGHM Polska Miedz S. A., Witold Pawlos, Jan Drzymala, Alicja Bakalarz, Przemyslaw B. Kowalczuk

A pre-flotation process of the Kupferschiefer ore with only frothers produces a concentrate enriched in carbonaceous matter and tailings for further upgrading steps. A partial removal of easy-to-float components of the feed before the main enrichments steps by flotation (rougher, scavenger) improves overall efficiency of separation of valuable elements from the ore. Since the types and doses of frother used for pre-flotation effect the process, the aim of this study was to determine the influence of selected frothers on the efficiency and selectivity of the Kupferschiefer ore processed by KGHM Polska Miedz S.A. A series of pre-flotation tests in the presence of different poly(propylene glycols) ethers, poly(ethylene glycols) ethers and aliphatic alcohols were conducted. The obtained results indicated that the types and doses of frother determine the flotation selectivity of copper and total organic carbon. The evaluation of the pre-flotation process was based on the analysis of selectivity parameters calculated from the recoveryrecovery Fuerstenau upgrading curves as well as the values of copper and organic carbon grades in the flotation products. It was shown that pre-flotation performed in the laboratory scale using a suitable frother provides higher overall flotation selectivity of organic carbon with lower overall flotation recovery of copper in comparison to flotation without the pre-flotation step. Thus, the pre-flotation process improves the quality and quantity of the final concentrates produced from the Kupferschiefer ore.

Jan 1, 2016

By J. Petit, P. Girard, A-M. Gilbert, D. Faucher

L&apos;annee 2000 a été une année stratégique et significative pour l&apos; Aluminerie de Bécancour dans la réduction des gaz a effets de serre. L&apos; équipe s&apos; etait donne comme defi un jour d&apos;arriver a l&apos;objectif de zero effet d&apos;anode dans les sa11es de cuve (720 cuves au total). Le cha11enge s&apos;averait tres ambitieux car la fa<;on d&apos;alimenter une cuve d&apos;electrolyse pour obtenir son maximum de rendement faraday est de travailler le plus pres possible de l&apos;effet d&apos;anode pour eviter l&apos;embourbement de ce11es-ci. Ceci signifie que techniquement nous a11ons en moyenne, quotidiennement, 12500 fois pres de l&apos;effet d&apos;anode sur !&apos;ensemble de nos 720 cuves qui produisent aujourd&apos;hui environ 405 000 tonnes d&apos;aluminium liquide annuellement. Des 695 kg equivalent en C02 par tonne d&apos;aluminium produite en moyenne annue11ement, de 1990 a 2000, nous en sommes rendus ace jour a environ 35 kg equivalent en C02 par tonne produite. Nous sommes pres d&apos; atteindre notre objectif mais les demiers gains sont plus difficiles a atteindre. Les strategies d&apos;automatisme et d&apos;informatique, incluant l&apos;aspect de !&apos;implication humaine sur les bonnes pratiques de travail sur les cuves d&apos;electrolyse, sont les cles de ces resultats.

Jan 1, 2006

By Minghui Li

China is the largest coal producer in the world. In 2012, the coal production in China is 3.65billion tonnes, accounting for approximately 49% of global coal production. The raw coal production in 2012 was 3.8% more than the year 2011. 56% of total raw coal has been washed. The increase in raw coal production also promotes technology to be developed and brings separation capacity become larger and larger in coal processing in China. At present, over 40 extra-large scale coal preparation plants (each plant has capacity of more than 10 Mtpa) are in operation in China, the largest one is 32.5 Mtpa. Heavy medium separation are widely used in new built coal preparation, the washing limit for thermal coal feed lower and lower, the equipment selection tends larger which brings the whole washing system simplified, the local equipment developed and manufactured are more and more used. By discussing designs of several typical thermal coal preparation plants and coking coal preparation plants in China, this thesis introduces the current design of China?s extra-large coal preparation plants, and sums up the prevailing design features and trends of extra-large coal preparation plants.

Aug 1, 2013

By Ken G. Stowe, Stephen L. Chryssoulis, Christian Bendel, Joe Y. Kim, Ewald Niehuis

"TOF-SIMS (Time-of-flight secondary ion mass spectrometry) was used to detect collectors sorbed onto the surface of mineral particles in concentrate and tailings samples from the Brunswick, Matagami and Kidd Creek concentrators. This technique uses ion beams from either Cs or Ga sources to sputter the particle surface, a method which reduces fractionation of the collector molecule during sampling.In the Brunswick Zn circuit, sphalerite particles lost to the scavenger tails had less amyl xanthate and isobutyl xanthate compared to sphalerite recovered to the Zn final concentrate. Xanthates were detected on the surface of sphalerite particles floating to the CuPb final concentrate.At Matagami, significantly more isopropyl xanthate and isobutyl dithiophosphate were detected on sphalerite recovered to the Zn final concentrate, compared to sphalerite lost in the Zn rougher tails.In the Zn circuit of Kidd Creek, sphalerite lost to the tails had on average ten times less xanthate compared to sphalerite recovered into the Zn final concentrate. Xanthate was also detected on the floated pyrite particles. In addition to isobutyl xanthate, amyl xanthate was also detected on the floated sphalerite and pyrite particles.This preliminary investigation has (a) demonstrated the ability of TOF-SIMS to detect individual collectors on particle surfaces from plant samples and (b) shown that TOF- SIMS is an excellent tool, complimentary to TOF-LIMS, in establishing the surface chemistry of minerals as related to mineral processing."

Jan 1, 1995

By D. L. Millar

The hydraulic air compressor (HAC) is driven only by water, held up by a dam, to create relatively low head (typically 10-20 metres), such that the developed hydropower is used to cause flow in openings deeper underground. Air is entrained in the water at the inlet to the sub-surface openings (an air to water volume ratio of 1:1 is reported to be optimal) and is compressed as it is carried along by the deepening water flow. At depth, and with lower water velocities arising from larger cross sectional area tunnels, air bubbles separate out of the water flow and are collected in a receiver space above the flowing water. Water, free of air, then passes back up a return shaft (up-pipe) and rejoins the river or stream flow. In principle, an HAC can produce any pressure and flow rate required, given large enough shafts and enough water supply with head sufficient to overcome frictional resistance in the sub-surface tunnels. Practically, as air solubility in water increases with pressure, HAC installations with depths greater than 100 metres may lead to higher rates of compressed air loss, without special separation measures. A modern HAC application for mine refrigeration and cooling is presented.

Aug 1, 2013

By L. Li

To accommodate the large payloads and harsh operating conditions associated with heavy vehicles in the mining industry, off-the-road (OTR) tires are typically used with heavy mining vehicles. These tires have increased abrasion and wear resistance due to their thicker tread, sidewall and bead thicknesses. Given these features, OTR tires are much stiffer than conventional passenger vehicle tires and cannot be mounted to a single-piece rim without damaging the structural integrity of the tire during the mounting process. Therefore, multi-piece wheels are used with OTR tires to facilitate mounting. While these assemblies are necessary, several instances of their failure have been reported to result in injuries or fatalities within the mining workplace. Many of these failures were specifically reported to be caused by the disengagement of the wheel lock ring - a component used to securely engage the assembly during operation. In this study, a threaded-connection locking mechanism has been proposed in place of the traditional lock ring design. The performance of this threaded-connection was numerically evaluated in a pull-out test against a conventional five-piece wheel assembly. The pull-out test was devised as a means of quantifying the engagement ability of each wheel?s locking mechanism. A high degree of modelling accuracy was maintained throughout the analysis by validating the vertical and horizontal static loaddeflection behaviour of the rim model of the five-piece wheel assembly against experimental data. Through validation, the model data were found to be within 10.5 and 4.80 %, for vertical and lateral loaddeflection behaviour, respectively. Results from the pull-out analysis found that the threaded-connection demonstrated a 113 % increase in the force required for disengagement to occur relative to the conventional five-piece design - a force of 9,550 kN in total.

Aug 1, 2013

By C. R. Kato, G. Proulx

"Within the continuous scenario of reduced aluminium price and plants production costs increase, the energy consumption optimization in the aluminum electrolytic pots continues as the main focus for the producers. Energy consumption was chosen as a key performance indicator to drive the efforts and actions for improvements. Alcoa improved the energy consumption by approximately 3% from 2005 to 2015. This improvement was a result of best practices implementation, new technologies introduction, strategic actions with plant curtailments and management practices. The main objective of this paper is to highlight the importance of the management practices for planning and operational improvements beyond the technology changes. About 10 years ago, Alcoa reorganized its approach to retain knowledge in the Smelters by using a Best Practices format. For each specific subject, a skilled team defined the minimum requirements and the Best Practices for several aspects of operation and maintenance, which affect the environment, safety, cost, customers and performance. These Best Practices were deployed to all Smelters combined with training sessions to process and operation professionals. We will describe how the Best Practices were organized, the deployment strategy used, and the approach to measure the plants’ success. We will describe the management approach that includes Manufacturing Analyses focused on 3-year potential, annual planning, and weekly monitoring of plant stability. A manufacturing analysis is organized at select plants with cross-functional participation of specialists from technical, operational, procurement and finance. The output of a manufacturing analysis includes a roadmap of enablers to improve energy efficiency. A quarterly follow-up of enabler deployment is held with the plant and resources that participated in the analysis. Annually, there is a Planning Process where energy consumption enablers are selected to be implemented during the next 3 years for each plant. A monthly critical analysis is made by the plants with regional best practice support. On a weekly basis, key performance indicators are reviewed with determination of a stability index for each plant. Any deviation signal of unstable condition is alerted and supporting resources are diverted to the plant to reverse trend with countermeasures.INTRODUCTIONDue to factors like excess aluminum in the market and lower consumption in China, the LME price is declining along the last years, as showed in Figure 1. In 2011, the price peaked at US$ 2,400/ton and since then, continues to trend down and approaching the lowest level at US$ 1,500/ton in the last 5 years."

Jan 1, 2016

By Mi, Dong Liang, Jingyuan Bai, Victor Zhou, Xujun

Squirrel cage induction motors are the mostly used motors at present. Currently, the rotors of the squirrel cage induction motors are produced by aluminum die casting technique with the advantages of low cost of rotors. It is well known that the copper’s electrical conductivity is around 40% higher than that of aluminum. If copper is used to replace the current widely used aluminum in rotors, the total loss of motors will be reduced, hence increasing the overall motor efficiency. Copper rotors can be used to produce high efficiency and even super premium efficiency motors without enlarge the motor frame size. Considering the huge quantity of motors, the die casting process is the best solution to produce copper rotor with economic cost. Because of the characteristics of copper, it is difficult to produce copper rotors by casting similar to that done in aluminum rotors. In order to improve the die casting quality of copper rotor, a new tooling structure was developed and the casting process of copper rotor was simulated and analyzed by Any-casting software. The filling process, solidification process, inner gas distribution and residual melt modulus were analyzed. It was found that the design of symmetrical runner and inner runner on both sides was helpful to reduce the impact of molten copper to the cavity surface during the filling process. The use of Slag traps array can reduce die casting defects inside the end rings. That will be helpful to improve the rotor quality. INTRODUCTION Squirrel-cage AC induction motors are most widely used in the world. In 2017, the total installed capacity of AC motors in China has reached more than 1.2 billion kW, and the annual power consumption accounts for about 60% of the total national electricity consumption. To improve the efficiency of squirrel-cage motor will be helpful to energy conservation and environment protection. There are several ways to improve efficiency of induction motors, using copper rotor is one of the most effective solutions. It is well known that the copper’s electrical conductivity is around 40% higher than that of aluminum. If copper is used to replace the current widely used aluminum in rotors, the total loss of motors will be reduced, hence increasing the overall motor efficiency. Copper rotors can be used to produce high efficiency and even super premium efficiency motors without enlarge the motor frame size.

Jan 1, 2019

By E. Thune, F. Stålesen, E. O. Stensholt, O. M. Dotterud, E. E. Henriksen, P. O. Ramsdal

"The development and commercial operation of the Falconbridge chlorine leach process have been described in papers in 1985 and 1987. Since this time, various process improvements have been implemented and the capacity of the Kristiansand refinery has been increased to 85 000 t/y Ni, 40 0000 t/y Cu and 4500 t/y Co. The focus has been on continuous improvements in productivity, the use of energy and other costs. Several environmental issues have also been eliminated or reduced since 1987. IntroductionThe first nickel refining operation in Kristiansand, Norway, started in 1910 based upon raw materials from Norwegian mines. In 1929, Falconbridge Nickel mines purchased the refinery to acquire information and the patent rights to the Hybinette refining process that was practised at the small Kristiansand refinery. Falconbridge ownership has now, for more than 70 years, provided a strong base regarding raw material supply, financial resources and technical support for further expansions and major technical improvements at the refinery.The main concepts of the new chlorine leach process were developed in the laboratories from 1966 to 1969 and the process was piloted from 1970 to 1972. The main stages in the commercial plant were started in the 1975 to 1981 period. After 1981, there have been a number of process modifications, plant expansions and improvements to operating practices. The developments up to 1988 have been described in previous publications (Stensholt et al., 1986, 1988).This paper presents an overview of the process and how it is practised at Falconbridge Nikkelverk AS (FNA) today and describes some of the main changes that have been implemented since 1988. During this time, the nickel capacity has been expanded from 54 000 t/y to 85 000 t/y and the cobalt capacity from 2000 t/y to 4500 t/y. The paper describes how these expansions were achieved together with continuous improvements in operating efficiency and also gives an overview of the main environmental concerns at the refinery."

Jan 1, 2001

By Floyd B. Bowen

Pumping methods are used, almost exclusively, to transport materials in the mining, beneficiation and chemical processing of phosphate rock in the Florida phosphate pebble field. Matrix pumping systems capable of pumping 15,000 g.p.m., transporting 15,000 long tons (dry) per hour, are now in use. They utilize 16-by 48 Yz -in. pumps, driven by 1.250-h.p. motors, discharging into pipelines 20 inches .in diameter .and sometimes several miles in length. As an average, it is necessary to pump 3 tons of matrix to the beneficiation plants, and to dispose of 2 tons of sand tailings and clay as waste, in order to produce 1 ton of shipping-grade rock. The washers and flotation plants, where the clay and phosphate and silica particles are separated, require the movement of large volumes of slurries with densities ranging from 2-3 per cent to 45 per cent solids, by weight. Extensive waste disposal systems require the pumping of dilute clay slurries in quantities of up to 50,000 g.p.m.,

Jan 1, 1963

By John Canterford

Quay Magnesium Limited (QMG) listed on the Australian Stock Exchange in late September 2004 having raised approximately A$30 million with the object of designing, constructing, commissioning and operating a 15,000 t/a magnesium alloy production facility in Nanjing, China, Site construction commenced in February 2005 with installation of all major components completed by the end of October 2005, Hot commissioning was simultaneously commenced with the final stages of installation, leading to the first stage of continuous ingot casting by mid November 2005, Since that time ramp-up to the name plate capacity has been undertaken, This presentation highlights some of the more significant technical and logistical hurdles that have had to be overcome in order to meet the high quality product specifications required by a range of QMG customers.

Jan 1, 2006

"In developing a backfill system handling tailings feed to and from the storage silo, it is necessary to establish a slurry laboratory to develop the technology and silo design criteria. This paper presents the principles involved in such development and the importance of testing principles for optimizing the slurry system. Evaluation procedure based on experiments is applicable to a wide range of materials and allows silo design by scaling up the data gained from model tests. Silo simulation has been successful to design and operation, so becomes an effective approach to backfill applications. IntroductionThe silo is a device comprising specialized equipment and operating with related procedures for storing and handling the mill rejects as backfill slurry. It provides a steady supply of the solids slurry, prepared at desired pulp density under the continuous feed conditions. Because the silo system is designed to accomplish specific objectives when dealing with a particular mill tailings slurry, it is necessary to characterize certain slurry properties, behaviour of the solids slurry and understand the silo performance to establish design criteria. Bench-scale, pilot-scale and dewafull- scale experiments were employed in developing the load-storage-discharge system, and routine procedures are now available for pre-design testing. Silo model experiments and full-scale tests were conducted to define the design parameters and evaluate the silo performance. A silo can be designed by scaling up the silo model geometry and data obtained during tests.Since the early 1960s, silo backfill systems have been widely established. The shape and size of the silo and the operation procedure, as practised, all appear to be relevant to successful operation. Understanding the basic material properties and behaviour of solids slurry retained in the silo will help perfect the silo design, operation procedure and, consequently, improve the silo performance."

Jan 1, 1997

By W. H. Moore

It seems necessary, at times, that we should reconsider some of the more obscure causes that lead to explosions of gas and coal-dust in mines, in the hope that a recapitulation will keep before us that old and true saying "eternal vigilance is the price of safety". This explosion, while not extensive (resulting in only two much to be regretted deaths) enlarged our vision as to the possibility and probability of other explosions with more disastrous results. As this is only a partial report I shall have to omit many things that are generally included in describing a mine explosion. The mine was worked exclusively with electric cap-lamps -only firebosses and other officials carried safety-lamps. All shots were examined and fired by firebosses with a small hand-battery. Monobel was used exclusively for blasting, and clay for tamping. The system of haulage iri use was main-rope and winches, horses being employed for gathering. Compressed-air was the motive power for all winches and pumps, excepting the pumps at the shaft-bottom which were steam-driven. The mine was wet with practically no dust anywhere, except what was being made at the coal-face in the getting of the coal. Gas was found occasionally, generally in the brushing, especially where the brushing was carried up to a small seam, 2 to 6 feet above the main seam. The place where the explosion took place was known as Leigh&apos;s heading, which was being driven to the rise, immediately inbye of the siding (off No. 1 left, off the new slope) and was about 90 feet up from the level.

Jan 1, 1926

By P. O. Parfitt

At the McIntyre mine, there are two distinct operations: a gold mine with narrow veins, mined by cut-and-fill methods, and a copper mine with large, open, long-hole stopes. The application of the Critical Path Method to scheduling work in the copper mine, where it has been used successfully for several years, is de-scribed briefly. This application is relatively simple. Use of C.P.M. has now been extended to the gold mine. To replace the former method of scheduling from bar-charts, a procedure was developed for scheduling automatically. To handle an operation of this size and complexity, a computer was essential. Improved schedules are now being produced, with a saving in time.

Jan 1, 1967

By L. Jacobsson, J. E. Lindqvist

A series of laboratory tests were conducted to study stress-induced spalling on medium to coarse-grained granite specimens. The specimens made from cylinders had two manufactured notches on opposite sides aimed to represent the tangential loading around a circular opening. Specimens of three different sizes were tested with notch radii, 98.5, 225 and 375 mm, representing 197, 450 and 750 mm diameter holes, to study the effect of notch radius on the spalling initiation stress. The cracking was monitored by acoustic emission sampling. The fracture patterns were investigated visually on polished slabs and by microscopy on thin sections. The crack analysis describes how the cracks propagate in relation to the grain structure in the rock and to the macroscopic stress field.

Jan 1, 2015

By Michael McClintock, Bern Klein

"The high pressure grinding roll (HPGR) is a relatively new comminution technology that is gaining popularity for providing energy efficient solution to hard rock mining operations. A significant barrier to increased adoption of HPGRs is the present requirement for large amounts (excess of 2 tonnes) of sample for pilot testing, which may not be possible for most early stage projects. Three methodologies have been developed at NBK Institute of Mining Engineering at the University of British Columbia that may be used for sizing design optimization of HPGR circuits. All three methodologies use a MTS pistonpress to simulate HPGR comminution. These tests are capable of providing information regarding energy consumption, energy breakage relationship, reduction ratio, and product size distributions. In a period of slow economic development, these methodologies are critical to allow the industry to cost effectively understand the operational benefits of HPGR implementation. This paper examines previous test work done at UBC, as well as the development of an HPGR and piston press database for use in sizing and budgeting of HPGR circuits.INTRODUCTIONCurrently, the mining industry faces several challenges due to falling commodity prices and escalating costs. This has applied pressure for operations and projects to reduce costs and improve project economics. In addition engineering and metallurgical budgets have shrunk as companies try to conserve cash. Improvements and optimization of milling and comminution circuits is one area project economics may be significantly improved. By considering alternative comminution technologies such as the high pressure grinding roll (HPGR), energy operating costs may be greatly lowered. Many have begun to implement HPGR crushing as an alternative to semi-autogenous grinding (SAG) mills, including KGHM and, Sierra Gorda, and Freeport Mc-MoRan’s Cerro Verde operation. However, implementing new technology for companies with little or no HPGR experience may not be practical. An operator must consider both feasibility and economics of a circuit. Currently, consideration of the HPGR requires expensive pilot scale testing for which large sample sizes are needed. In addition, few laboratories are equipped for running pilot scale HPGR test programs. Furthermore, the results of pilot HPGR testing are dependent on the quality of the sample, which cannot represent variations across a deposit. In contrast, ball mills and SAG mills can be sized using the Bond Mill Work Indexes that require a small amount of sample which enable a number of different geological blocks to be tested to allow engineers to have a complete understanding of how the comminution circuit will perform for the life of mine."

Jan 1, 2016

By H. C. Cooke

Those who have followed the geological developments in connection with the copper deposits of Quebec will recall that on many properties the sulphide bodies occur as replacements of fault breccias or tuff breccias, and exhibit a pronounced distaste for the more massive lavas. At the same time the rocks around the ore-bodies are profundly altered, first by addition of silica and sericite, later by conversion of these minerals into chlorite. It has been known for some years that at the Amulet and Waite-Ackerman Montgomery mines these conditions do not prevail. At both mines the ore-bodies are replacements of massive lavas, and at the Amulet they are associated with a very peculiar rock christened ?spotted dog&apos;, or &apos;dalmatianite&apos;. Accordingly, when in 1929 the writer had the opportunity to make a further examination of these properties, two problems presented themselves for solution. The first was to determine, if possible, the conditions under which massive lava, rather than breccia, is replaced by the sulphide masses; the second, to find out the exact nature of dalmatianite and its relations to the sulphide bodies. The first of these problems is believed to have been solved; the second has been found very complex, and will require further work before it is satisfactorily settled.

Jan 1, 1930

By C. R. Whittemore

Introduction The technical library in the service of industry is gradually becoming a well recognized and important part of all progressive industrial organizations. The larger mining, metallurgical, and chemical firms of Canada are establishing extensive reference libraries in connection with their research and operating departments in order that the members of the organization may keep abreast of the rapidly developing fields of engineering in which they are interested. It is the purpose of this paper to point out the usefulness of such a department in any industrial organization, to give a general outline of a system for filing and dispensing information, and to outline briefly the literature to be consulted and the procedure to be adopted in instigating a literature search. The technical library falls under the classification known as &apos;Special Libraries&apos;, and is quite different from the general library in that it is a storehouse of facts and owes its value to the ready presentation of information required for each specific case, and in a form most ready for use. The library brings all the available information relative to the interests of the corporation from without the plant to the organization within, and also keep in touch with each department of the organization.

Jan 1, 1930

By R. L. Veenstra

This paper explores the connection between the stresses observed and the failure mechanisms present in the modelled cemented paste backfill. In order to look at this connection, the authors have used a previously developed model to conduct a sensitivity analysis of the model?s strength and permeability input parameters. The results from the sensitivity analysis were then compared to determine what causes modelled stresses and failure mechanisms to vary. Increased insight into the behaviour of the modelled paste will help clarify how paste behaves in the field.

Aug 1, 2013