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By J. E. Nesset, L. S. Urbanoski, J. R. Goode

"The benefits and advantages of pre-competitive, collaborative industry/university research are not always well appreciated. This paper presents the case study of a current collaborative project between CAMIRO-Metallurgical Processing Division and McGill University that is investigating the understanding and prevention of sphalerite activation in lead and copper-lead flotation circuits. The benefits of the research findings to the sponsors can be maximized by an approach which links the researchers themselves with the sponsors at frequent, interactive project review sessions. Some examples of the findings and their application to industry are also presented along with a general update on CAMIRO-MPD.INTRODUCTIONThe history of Canadian efforts in the area of collaborative pre-competitive research is not long when compared to Australia (AMIRA) and Britain (MIRO). AMIRA (Australian Mineral Industry Research Association) began over 40 years ago and has had a well recognized role in bringing together industrial sponsors and researchers to fund a large variety of very significant development projects in that country, The total AMIRA funding effort for mineral processing work currently exceeds some $Aus 40 million with new projects valued at about $Aus 12 million initiated each year. This high level of commitment by industry has contributed to establishing Australian researchers and their facilities as among the best in the world.Canadian companies have traditionally funded much of their R & D in-house with extensive facilities and large funding commitments. The past 2 decades have seen most of these facilities disappear. The current situation is one in which only the largest integrated metal and mining companies have retained their own R & D groups (e.g. INCO, Falconbridge, Noranda). Industry-funded research at universities was primarily through individual efforts by the mining companies and rarely included collaboration with other mining companies, equipment or chemical suppliers, or engineering firms."

Jan 1, 2001

By J. E. Carrasco, J. D. Stinnette, R. A. Alvarez

"Chuquicamata Underground Mine is one of the main projects for the Chilean government copper company (CODELCO). Underground mine project has been under construction since 2013 and presents a solution for the lower production levels of the open pit and prolongs the life of the mine for the next 40 years. Currently, around 2000 workers operate in the mine daily. Dozens of trucks and heavy machines drives through all main routes and access in the mine. As a mine under construction not all the infrastructure necessary to operate safely in the mine has been completed. Risk of a truck or fixed facility fire is always a challenge to keep under control. One important part of fire simulation relays on what we can do prevent a fire and what can be done with the existing infrastructure to control a declared fire and start evacuation plans. This study has been made as a feasible emergency plan to implement, in this case, of a mine under construction, were limited resources are available. Several fire scenarios have been made to support all the emergency plan strategy and a detailed step by step procedure indicates what the elements of a fire emergency plan and risk analysis are.INTRODUCTIONThe main objective of this study is to describe the importance of fire risk analyses (FRAs) and different methods to be used before commencing fire simulation and methodology steps utilized for a fire emergency plan strategy (EPS) at the Chuquicamata underground mine. It also describes how to classify zones which are going to be affected by fumes and gases propagation derived from the exact location of a fire event. Fire simulation study is helpful to determine the impact on a ventilation system with the main purpose of providing relevant information to complement emergency plans and stablished control techniques in ventilation design and its operation. Most fire simulation studies only concentrates in simulation techniques on itself. But what is the next following step in developing an emergency plan? How can we evaluate, classify and treat risky areas? This study is focused mainly in the phases before and after a fire simulation process. Phases corresponds to a good FRA and how output data can be used for an EPS."

Jan 1, 2019

By Mehdi Razavi

Scope of the Study The possibility and risk associated with mining two stopes at the same time The influence of Creighton Fault on the stability and dilution The effect of irregular shape of stope walls on overall stope stability and ore dilution The support requirements for proposed mining plan

Oct 1, 2010

By Rimas Pakalnis

This paper describes a focus of work presently being conducted at the Rock Mechanics Research Group at the University of British Columbia. The underhand method under consolidated fill ensures a high recovery under an engineered back that is comprised of cemented rock fill and/or cemented paste fill. This method of mining is generally necessary either due to a weak rock mass comprising the immediate back and/or high induced back stresses. A major concern in the design of sill mats is the loading and strengths associated with the overlying sill mat. This paper reviews past practice coupled with present observations and measurements from over ten(10) mines throughout North America. It outlines areas of concern in terms of design requirements.

Apr 1, 2005

By P. T. Craddock, H. V. Paliwal, L. K. Gurjar

The Indian cultural heritage of mining, smelting and the use of minerals and metals dates back to ancient times. Although the exact date of the commencement of such activities in India is not certain, Indians are known to have been familiar with gold, silver, copper, tin and lead and to a lesser extent with iron at least since the Vedic period (Table 1).

Jan 1, 1999

By Michael Cooper, Eric Konigsmann, A. Moerman

"A paste backfill plant and underground piping distribution system was commissioned at the Brunswick Mine in June, 1998. Concentrator tailings, composed mainly of pyrite and lesser amounts of silicate minerals with a P80 of 37um (45 YO-20 pm), are pumped to the backfill plant. The backfill plant uses conventional thickening and disc filtering to dewater the solids, which are then mixed with binder in twin screw mixers. The paste is discharged through a gob hopper and one of three boreholes by gravity. Approximately 65% of the concentrator tailings will be placed underground at full production. The remaining thickened tailings will be pumped to an existing impoundment area. Application of paste technology will completely replace the use of cemented rock fill in the mine by the end of 1998.The design capacity of the paste backfill plant is a total of 360 dmtph of cemented paste through two parallel production lines. The plant is highly instrumented and controlled via a hybrid Programmable Logic Controller (PLC-5) and Fisher ProVox Distributed Control System that is in communication with the property information highway. Video and audio signals from the underground system are carried to the surface plant via a leaky feeder communications/fiber optic system.The underground distribution system consists of a network of 200mm diameter boreholes and piping. There are approximately 3.5km of boreholes and 5.5km of piping in the system. To minimize pressures, the greatest piping length from any borehole is approximately 400m with all piping being open-ended. There are no valves in the entire paste distribution system.Construction of the plant, including installation of piping to and from the plant and preparation of the underground distribution system, was completed in less than one year from the time of management approval for the $M 22.3 project."

Jan 1, 1999

By R. E. Barbosa

Seepage forces generated during tunnel excavation affect the ground response and may cause severe instability problems, including total ground collapse and flooding into the tunnel. This paper presents a new closed-form analytical solution, for stresses and displacements around a cylindrical tunnel excavated in a porous water-bearing elasto-plastic material, which includes the effects of seepage forces. The analysis is carried out in terms of effective stresses and pore water pressures. The solution shows that seepage forces may have a major effect on the effective stresses around the tunnel, on the extent of the plastic zone, on the radial displacements, and on the tunnel support requirements. The conditions for development of a ?flowing ground? condition at the tunnel face have been identified. The paper presents a procedure for the hydromechanical ground-support interaction analysis, to determine the excavation induced inflow and the pressures acting on the lining, throughout the progressive driving of the tunnel, including the effective pressures exerted by the ground and the pressures generated by the water.

May 1, 2009

By D. A. Cormode

"INTRODUCTIONPine Point Mines, operated by Cominco Ltd., is located approximately 55 miles east of Hay River, N.W.T. by the southern shore of Great Slave Lake.The milling operation commenced in the fall of 1965 at a design capacity of 5,000 tpd. An addition which came on stream late in 1968 raised the nominal capacity to 8,000 tpd. Currently the milling rate is 11,000 tpd.The lead and zinc sulphides occur in dolomite host rock. Typical feed grades at present are 2% lead, 5.5% zinc and 5 % iron. When dolomite is present even in relatively minor amounts in the zinc concentrate, it presents serious treatment problems and causes inefficient operation of electrolytic zinc refineries.By 1972, it had become apparent that magnesium rejection in the form of dolomite was deteriorating because of increased plant throughput of less amenable ore. This paper will briefly outline the Pine Point zinc flotation circuit and will discuss the two phase program for reducing the magnesium level in the zinc concentrate. The program included changes and alterations to the flotation circuit and the construction of an acid leaching plant."

Jan 1, 1977

By A. Lewis, J. Zachwieja, M. Widell, P. Zhou, W. W. Geissler, M. Svensson, A. Movahedi, H. Nordberg

Flotation collectors for sulfide minerals has been traditionally based on xanthate, thiophosphate, thiophosphinate and thiocarbamate, all derived from sulfur chemistry. Tecflote™ is a new family of patented collectors based on nitrile chemistry which can supplement or replace thiol collectors, depending on the ore types. A steep grade-recovery curve typical of Tecflote™ collectors was observed when using Tecflote™ as the main collector for the rougher and cleaner steps allowing a better recovery compared to current thiol collectors while maintaining the desired grade. Additional recovery increase has also been observed by the addition of scavenger steps using Tecflote™ collector in combination with current thiol-based collector. The selectivity seen in the lab is transferred to full scale trial and is clearly seen in the rough flotation where the increase in the rough concentrate grade of 5% after pumping Tecflote S11 directly into the tank cell. The mechanisms for Tecflote’s selectivity towards sulfides are currently under investigation and will be discussed. Results of TOF-SIMS analysis will be presented, demonstrating the collector’s selective affinity to different mineral surfaces in flotation. INTRODUCTION The history of collectors used today started in 1882 when Zeise first made xanthates. It was first used in flotation in 1925 – Cornelius Keller’s first patent (Fuerstenau, Jameson, Yoon, 2007). Between 1928 and 1930 American Cyanamid filed 7 patents for dithiophosphate, including flotation and chemical synthesis of the reagent, the first of which was filed by Christmann in 1928 (Christmann, 1933). Synthesize of thionocarbamates for mineral flotation was filed in 1954, by Dow Chemical Company (Harris, 1954). Now that the head grades have been declining over the last decades the need to find more selective collectors to extract difficult and complex ores has pushed the industry to look at different chemistries. Thiol collectors standard to the industry rely on the sulfur in the collector molecule to bond to the mineral surface. The electronic property of this group is modified by the adjacent chemical groups, such as additional S, P or N have the effect of changing the selectivity of the collector (Wills & Finch, 2016). In the case of xanthate the length of the hydrophobic group also has an effect on the selectivity with some minerals such that the ethyl xanthate is more selective against pyrite and pyrrhotite than the long chain xanthates (Wills & Finch, 2016).

Jan 1, 2019

By Grant J. Goddard

"The Iron Ore Company of Canada (IOC) has been in operation for over 30 years. Today, and in the future, technology and its application will play an ever more critical role in the company’s business success.The Carol Mining and Concentrating (CMC) division of IOC is energetically applying technology today to enhance performance and results, and is aggressively exploring opportunities to apply technology to support improved business results in the future.A critical area of focus is the application of technology to maintenance management performance. CMC has taken a “back to basics” approach to the fundamentals of maintenance management in 1995 and 1996. In parallel, the mine is aggressively implementing its Vision 2000 maintenance integration plan. This plan is targeted at levering the energies applied to sound maintenance management fundamentals as the company moves to a fully condition based maintenance approach.This paper discusses some of the strategies, key technologies and objectives of theVision 2000 maintenance integration plan at the mining operations of IOC."

Jan 1, 1996

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 H. M. Lewis

The current status of the international zinc market is summarized, and a supply /demand outlook is presented for the next five years. A number of technical problems facing the industry are outlined. Introduction ZINC has sometimes been called the unknown metal. Considering that on a world basis it ranks third among non-ferrous metals in production and consumption, zinc retains a certain modesty. It has no distinctive colour like copper, lacks the low density of aluminum or magnesium and is not always easy to identify as a product. The 'spangle' of galvanized steel is probably zinc's most distinguishing feature. The purpose of this article is to develop an over-all review of zinc. Starting with the current position of the metal, the major factors that will shape its future will be described so that an assessment of the outlook for zinc can be made.

Jan 1, 1978

By J. A. McLennan, J. M. Ortiz

Nickel laterite deposits are typically formed from tropically weathered mafic-to-ultramafic complexes. The resulting nickel concentration is found within soil horizons and is mineable with regular dozer units. At the time of mining, digging elevations are needed at selective mining units (SMUs) or representative dozer regions (RDRs). Moreover, for mine planning, the costs due to dilution and lost ore require mining elevations to be specified. A conditional simulation approach is used to calculate “optimum” RDR mining elevations. Multiple realizations of the ore base surface are simulated. For a single bottom surface realization, dilution and lost ore costs are calculated over the entire vertical extent of each RDR. The optimum mining elevation is the elevation where the lowest summed cost of “accepting dilution” and “wasting ore” occurs. The reported RDR dilution is the cost of mining the volume of waste located below the bottom surface and above the optimum mining elevation. The reported RDR lost ore is the cost of not mining the volume of ore above the bottom surface and below the optimum mining elevation. For all ore bottom surface realizations, optimum RDR mining elevations and their associated dilution and lost ore costs are calculated and compiled to represent production uncertainty.

Jan 1, 2006

By Jiwen Zhang

Abstract Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

By Jiwen Zhang

Due to the blocking nature at the crusher station, straightforward application of queuing theory cannot give realistic results on the performance of a shovel-truck-crusher system. A new queuing network-based model has been developed in which, the crusher station is formulated into an open queuing network and the whole shovel-truck-crusher system into a closed queuing network with the crusher station as a special server. To fully account for the influence of blocking, Monte Carlo simulation is first used to obtain the performance parameters of the open queuing network for the crusher station. The closed queuing network for the entire system is solved by applying the Extended Summation Method (ESUM), in which the crusher server is described by the simulation results. The model has been applied to the Yuanbaoshan open-pit coal mine to analyze its shovel-truck-crusher system and to improve its efficiency. Results indicate that the blocking at the crusher is an important factor affecting the crusher output and in turn the efficiency of the whole system, and prove that the model can realistically describe the behavior of such systems.

Oct 1, 2009

A series of field and laboratory evaluations were conducted in order to characterize the effects of a Mann+Hummel SMF-AR® diesel particulate filter (DPF) system on the aerosols and criteria gases emitted by diesel engines. This system, with a durable sintered metal filter media and available active regeneration via an on-board electrical heater, has been considered for retrofitting diesel engines used in light- and medium-duty underground mining applications. Two DPF systems were installed on a forklift and locomotive from the underground mining fleet of the Vale?s Creighton Mine and evaluated over a 1,500-hour trial. This evaluation was complemented with field and laboratory emissions tests. The field tests were performed on the vehicles while at the Creighton Mine surface shop. During those tests, the emissions were assessed for the engines operated at hydraulic stall, high idle, and low idle conditions. The laboratory tests were executed at the diesel engine emissions laboratory at the National Institute for Occupational Safety and Health (NIOSH), here the DPF removed from the forklift was further evaluated at four steady-state engine operating conditions as well as at transient conditions using a custom-designed duty cycle. Very similar methodologies were used during field and laboratory tests to measure concentrations of aerosols and criteria gases in the diesel exhaust, both upstream and downstream of the DPF system. The concentrations and size distributions of aerosols were measured using a fast mobility particle sizer spectrometer, in exhaust diluted by a partial flow dilution system. The concentrations of CO2, CO, NO, and NO2 were measured in the raw exhaust using a Fourier transform infra-red spectrometer. Both field and laboratory emissions tests showed that the evaluated DPF systems were very effective in reducing aerosol emissions from all tested engines, and for all test conditions. The systems were found to have minor effects on gaseous emissions from those engines. The findings from this study should help the mining industry to better understand the benefits and challenges of using DPF systems to control the exposure of underground miners to diesel aerosols.

Aug 1, 2013

By T. Holmes

Investigations reveal that the throughput difference between a perfect production day and the average is often on the order of 40%, and that bulk solids handling system deficiencies are the largest (>50%) class of lost opportunities. Root causes for underperformance of elements in material handling systems can often be traced back to the detailed design and even study-stage oversights. To reduce or eliminate bulk solids handling problems in an existing system requires an analysis of troublesome handling equipment – for example, a concentrate transfer chute that experiences plugging, poor flow to the furnace, unacceptable dust generation, and spillage. These problems often lead to significant maintenance costs related to downtime and personnel time. Understanding the cause and cost of flow issues is the first step in troubleshooting the problem. Next, measuring the material’s flow properties is critical to providing design data required to develop a comprehensive scientific solution. In the case of a new installation, the design data is required to properly design the system right first time and prevent flow problems from occurring so that the new equipment works correctly from start-up. This paper highlights the cost of material handling problems and discusses the best approach to evaluate material handling system deficiencies. A case study is given of how Anglo American's operation in Barro Alto Brazil enjoyed a 5-month payback from a bulk solid transfer chute debottleneck project. INTRODUCTION When operating a plant or designing a greenfield or brownfield operation, the intent is to have perfect production days (PPD) each and every day. Money is made by moving material through the plant in a controlled manner to produce the desired product. Mining operations and copper concentration processes are at the most basic level a practice in bulk solids handling (BSH). Unfortunately, many of the project planning steps are overlooked, particularly related to BSH. Investigations reveal that the throughput difference between a PPD and the actual average is often on the order of 40%, and that BSH system deficiencies are the largest (>50%) class of lost opportunities (Wellwood, 2017). Root causes for underperformance of elements in material handling systems can often be traced back to the detailed design and even study-stage oversights. BSH issues are essentially baked into the fabricated plant and left to operations to accept the deficiencies and deal with them for the life of the mine. These deficiencies then become part of the normal operation of the mine and plant.

Jan 1, 2019

By H. Pempel, J. Markowski, P. Ay

"Metal-coated thermoplastic parts find more and more functional and aesthetic applications in the interior and exterior of cars. The vapor-deposited or electroplated coatings are usually composed of a plurality of nickel- and chromium-containing layers, which are applied to copper-containing carrier layers on the polymers. Previously, recycling processes are mainly focussed at the recovery or thermal utilization of the plastics. Targeted and selective recycling of the metallic coatings is usually not carried out. Together with several SME, BTU developed a process, in which a complete and separate recovery of all components in high purity is possible with biotechnological methods. The bioleaching is carried out with iron and sulfur-oxidizing bacteria, especially Acidithiobacillus ferrooxidans. The copper-containing layers are dissolved in the solution; chromium- and nickel-containing particles are precipitated as solids. After the bioleaching, a mechanical separation of the individual metal-containing components and their separate workup are carried out. End-products are metallic copper, a nickel- and chromium-containing solid and the cleaned plastics. The bioleaching ensures a high purity of the end products. Through the use of bacteria, which are also found in nature, the process is environmentally friendly. Compared to chemical leaching using inorganic acids, considerably shorter leaching times can be achieved. In addition to the optimization of the leaching process, the R/D-project also includes the development and testing of the apparatus technology.INTRODUCTION The material complexity of many end-user products has increased in recent years, especially in the fields of electrical appliances, vehicle technology and medical technology. However, the demands on functionality, safety, comfort and energy efficiency still play a greater role in product design as factors such as sustainability and usability. For example, if a car still holds more than 70% of steel in the 1980s, a vehicle nowadays includes a larger proportion of a variety of difficultly separable plastics and composite materials, as well as complex metal composites. This relates in particular to composites made from such different materials as metals and plastics. The processing and recovery of the components of those complex material mixtures is difficult for recycling companies."

Jan 1, 2017

By L. Hanschar, C. Bwalya, E. Mokola, K. Musonda, A. Makayi

This paper describes the installation, commissioning and operation of porous plugs featuring nitrogen gas purging in both Anode Furnaces at the Kansanshi Copper Smelter (KCS), a greenfield copper smelter which commenced operation in March 2015. The decision to install porous plugs was taken in November 2016 and the facilities were successfully commissioned on both anode furnaces in October 2017. The project was successful and has demonstrated the following process improvements: 12.2% reduction in main burner fuel consumption Larger average charge size, due to fewer accretions; 17 minute decrease in average refining cycle times Improvements in slag skimming operations Improved casting rates INTRODUCTION Porous plugs The application of porous plug technology in copper smelter anode furnaces is well established around the world. Vukovic and Gamweger (2017) and Wallner (2004) noted that the stirring and mixing action induced by the injection of inert nitrogen gas into the molten copper via porous plugs has potential benefits in the following areas: Homogenization of the temperature and composition of the molten copper resulting in Reduced fuel consumption Less tendency to overheat slag (reduced risk of refractory attack) Less slag produced with a lower degree of oxidation (lower rate of refractory wear) Less tendency for buildups to form Improved environmental performance (produce low sulphur blister at Peirce Smith converters) Elimination of buildups inside the furnace and potential for larger charges per cycle Reduced processing times and potential for shorter cycle times More efficient skimming of anode slag Shorter skimming time Less copper carry over to Peirce Smith converters Very little slag remaining in the furnace (reduced potential for buildups to form)

Jan 1, 2019

By A. R. House, G. W. Shepherd

Newmont USA Limited owns and operates the Phoenix Mine near Battle Mountain, Nevada, USA. The existing milling facility has operated since 2006 (House, 2010). Following the startup of the milling operation, and coupled with the upswing in the copper market, Newmont realized that Phoenix had no process option to treat transition and oxide copper ores. This meant that potentially revenue generating ore would be mined as waste. With no system in place to treat the transition and oxide copper, work began to determine the most feasible approach. After evaluating multiple options, the flow sheet was set for a runof- mine (ROM) heap leach pad and solvent extraction/ electrowinning plant (L-SX/EW). This paper will discuss the eight years of successes and challenges with developing the copper L-SX/EW plant and achieving commercial production of copper cathode.

Jan 1, 2014