Search Documents

By B. Burger, T. Bester, S. Deonarain, L. S. Schultz

"This paper details the process followed to raise drill and equip a 6.1 metre diameter vertical service shaft at Glencore’s Mindola Deeps project in Kitwe, Copperbelt Province, Zambia. The project scope comprises a shaft collar, bulk air intake, a pre-sink to -90 metres and raise drilling the shaft from surface to a final depth of 1,892 metres underground, in four separate lifts of approximately 475 metres each. Equipping of the shaft steelwork, headframe erection and commissioning the shaft for hoisting. In addition, the scope included the development of a decline down from 5430’ level underground to the new shaft position on 6205’ level. This paper will provide some insight into the successes and challenges encountered during execution of the shaft works to date and provide some learnings for future projects of a similar nature. INTRODUCTION The Mindola Mine is situated to the west of the city of Kitwe in the Copperbelt Province of the Republic of Zambia (Figure 1). The mine is owned and operated by Mopani Copper Mines Plc (MCM), whose shareholders are Glencore AG (73.1%), First Quantum (17.9%) and ZCCM Holdings Plc (10%).Productivity at the Mindola mine has been adversely affected because of significant ventilation and ore re-handling challenges, which are caused by the dilapidated infrastructure, and design of the existing vertical and sub vertical shaft system. In the circumstances, it was apparent that it was necessary to sink a new vertical shaft that would increase the volume of fresh air down the mine, improving the underground working environment and the current hoisting restrictions, resulting in an increase in productivity and efficiency. Because there were two existing levels ideally situated and perpendicular to one another and because a third level was in close proximity to that perpendicular and because the mine required a ramp down to shaft bottom in any event, consideration was given to raise drilling the shaft as opposed to using conventional blind sinking methodologies."

Jan 1, 2019

By E. You

Kennecott Utah Copper Refinery and Outokumpu Technology have developed a wireless Electrolytic Cell Monitor (CellSensor) system to monitor cell voltage and temperature. The system is based on a robust self-organizing and self-healing wireless network with a very reliable redundant structure. The microprocessor controlled CellSensor device operates off a small amount of energy harvested from the cell bus and requires no external power source. The radio works in the 2.4 GHz international ISM band using robust Spread Spectrum technology. The CellSensor does not require end user calibration of either the voltage or temperature sensors and accuracy is superior to previous systems. The on-board computation power allows digital filtering of the cell voltage signal which results in very high quality data. The system requires much less maintenance than conventional hardwired systems and is intrinsically safer since no high voltage isolation is required. The advanced diagnostic functions allow the device to determine if the bus tap contact is degrading. The CellSensor can also be used for monitoring electrowinning (EW) cells for a variety of metals. CellSensor have been tested for over two years at the Kennecott Utah Copper and Boliden Harjavalta Pori refineries. The CellSensor system is now commercially available through Outokumpu Technology.

Jan 1, 2007

By J. Day, Matthew X. Yao, Lijue Xue

Hardfacing overlays are commonly applied on the shroud Z-section of turbine blades for enhanced wear resistance. Among various processes that are used to apply the hardfacing overlays, the plasma transferred arc (PTA) welding process offers several advantages including lower heat input, less base material dilution, rapid process time, and reduced operating cost associated with the capability to apply materials in the powder form. The development of a robust PTA process is crucial for overlay performance and repeatability, particularly in the aerospace industry where a quality intensive manufacturing environment prevails. For this reason, the Taguchi method of experimental design was selected to develop a test plan. A 4-factor 3-level (L9) orthogonal array (OA) was used in the experiment. The L9 OA allows for a more detailed (3 level) investigation of critical process parameters, namely plasma gas flow rate, traverse speed, powder feed rate, and arc current. Two hardfacing materials, Stellite 694 and Tribaloy T-800, both Co-based wear resistant alloys, were investigated by deposition onto a cast IN738 Ni-based superalloy substrate. Performance measurements of the hardfacing deposits included deposit hardness, substrate hardness, deposit density (porosity), degree of cracking/inclusions, and a quantified visual inspection. The procedure resulted in optimized PTA hardfacing parameters for both Stellite 694 and Tribaloy T-800 on IN738 turbine blade material.

Jan 1, 2004

By A. E. Gillis

"Some or all of the following benefits can be expected following application of automatic control to a grinding circuit:1. Maintenance of Optimum Mill Load Level2. Improved Uniformity of Grind3. Increased Productivity4. Decreased Power Costs per Unit of Product5, Reduced Ball Wear per Unit of Product6. Reduced Labour Costs per Unit of Product7. Reduced Operator SupervisionTo establish an indication of the benefits that could be expected through automation of the grinding circuit at East Malartic Mines Ltd. it was agreed that the Department of Mines and Milltronics Limited should jointly conduct a survey of the existing grinding circuit and operation.Aside from establishing feasibility, an important purpose of this survey was to determine costs of a suggested control system that East Malartic Mines Ltd. management might be in a position to assess the economics of the proposal and justification of the investment.The survey involved the taking of sound recordings of rod and ball mills during manual operations, locating circuit bottlenecks, establishing time constants and determining the number and location of sensors for good automatic control."

Jan 1, 1966

By Rodney Trevor Jones, Arthur Robert Barnes

Anglovaal Minerals acquired the Nkana slag dump from Zambia Consolidated Copper mines (ZCCM) in 1998 and embarked on an ambitious project to pioneer the recovery of cobalt from slag using DC smelting technology. Anglovaal Research Laboratories performed initial pioneering smelting tests in a 250 kW DC furnace over a 3-year period before engaging Mintek for three piloting campaigns at the 1.5 MW level. Mintek had previously developed a reductive smelting process, patented in 1995, using a DC arc furnace for the recovery of cobalt from slags. The results of the pilot-plant test campaigns were used as the basis for engineering the commercial 40 MW operation installed at Chambishi Metals plc in Zambia in 2001. This paper traces the development of understanding of the metallurgical fundamentals ultimately used to predict furnace performance, reviews some of the extreme technical challenges faced, how solutions were identified and highlights some of the critical issues identified during piloting and how these impacted both positively and negatively on the final commercial operation.

Jan 1, 2011

By S. Demetrio

China has a traditional segment of Copper Smelters with its own Chinese technology, typically small in size from 20.000 to 50.000 tCu/a, and they are responsible for the processing and production of more than 600,000 tonnes of blister copper per year. For occidental experts, like one of the authors, it is not so easy to believe that they are profitable, because the size and the use of old Blast Furnaces, but they are with simple and effective production lines. The authors are convinced that China has a good alternative to improve theses old copper production lines with small innovative changes in its process arrangement, jumping to higher level technology, more efficient in production, productivity and cost, assuring copper as a raw material for the country and its high speed development. The key to improve that the traditional Chinese Copper Smelter is white metal as an extra raw material as a first step doubling the copper production from raw materials and the complete replacement of concentrates by white metal (WM) in a second step increasing it four times or more as the final goal. It is not so difficult nor expensive to make it happen, but there are a couple of questions for implementing this innovation in the copper smelter industry: 1 - Will the old fashioned mentality be open to this new direction for China being the biggest copper consumer on one side, and the biggest copper Primary Producers on the other hand? and 2 - Will they be open to follow this "win-win" strategic way for both ends of the copper market? We don't know if anybody will take up the challenge to improve it but our responsibility as a consulting expert and a university professor is to put the alternative on table for others to decide whether to implement it.

Jan 1, 2007

By M. B. McClenaghan, O. P. Lavin, Ian Nichol

"Exploration in most areas of Canada has to contend with problems posed by glacial overburden. In many areas exploration for gold has been based on the sampling of tills, frequently by deep overburden drilling, and analyses of heavy mineral concentrates. Notwithstanding the significant role that till geochemistry has played in the discovery of some important gold deposits over the last few years, increased appreciation of the nature of the glacial history and stratigraphy and the character of gold within till has led to the recognition of a number of ways whereby the effectiveness of exploration can be improved upon.In order for till geochemistry to be useful in exploration, a number of conditions must be fulfilled, including:1. mineralization, or alteration halo related to mineralization, subcropping at the bedrock/overburden interface;2. glacial erosion and dispersal of a recognizable signature of mineralization into the glacial sediments;3. preservation of glacial sediments containing this geochemical component (trace metal or mineral) at positions subsequently selected for sampling (normally drill sites);4. correct identification of specific till units and associated ice movement history;5. collection of adequately large and representative samples;6. appropriate sample preparation and processing;7. appropriate geochemical analyses; and8. correct data processing and interpretation.While we have no control over the first two geological conditions, and only limited control over till availability, we can control the quality and thoroughness of sampling, sample identification, sample preparation, analysis and interpretation. In particular attention needs to be focussed on obtaining a large enough sample to be adequately representative, an unbiased sample must be collected, together with appropriate sample processing, analysis, data processing and interpretation. It is considered that by modifying or extending existing approaches to gold exploration the chances of exploration success can be increased. In particular, analyses of both the heavy mineral and minus 63 µ m fractions of till is recommended because gold in till may occur in different size fractions."

Jan 1, 1992

By J. Xie

In underground coal mining, the potential for an outburst of coal and gas is considered to be one of the major hazards. As such, considerable emphasis is given to understanding and preventing such events. A number of indices are used in the prediction of the outburst in a coal mine. The main indices include initial gas desorption rate, gas pressure, gas content, coal strength, gas flowrate from a borehole drilled in a coal seam, and combinations of the above. Some of these indices are considered to be inadequate, inappropriate or impractical for some coal seam conditions, such as those with soft and friable coal. The Huainan Mining Group (Huainan) in China and the Commonwealth Scientific and Industrial Research Organisation (CSIRO) in Australia have been jointly developing gas content based technologies to predict the risk of the outbursts. One of the major progressive achievements is a new method for determination of outburst gas content threshold values. The method utilizes empirical analyses, numerical modeling, and seam-specific knowledge . This paper describes the method and its application for the #11 Seam at Guqiao mine, Huainan.

Aug 1, 2013

By F. Flores

With the World Summit for Sustainable Development planned for 2002 in mind, nine of the world's largest mining companies decided to initiate a project to examine the role of the minerals sector in contributing to sustainable development, and how that contribution could be increased ? the Mining, Minerals and Sustainable Development Project (MMSD). This project assumed from the start that sustainable development could provide a useful framework to guide the minerals sector which main goal was integrating economic activity with environmental integrity, social concerns, and effective governance systems. The broad steps of MMSD project strategy can be grouped into four major categories: increase understanding of sustainable development; create organizational-level policies and management systems for implementing the principles of sustainable development; collaborate with others with common interests to take joint steps towards sustainable development, and; increase our ability to work towards sustainable development at the local, national, and global levels. In opinion of the article's author, to go ahead with the MMSD strategy and achieving the sustainable development objectives, it is necessary to consider the concept of self-organization, fundamental of the emergent new scientific paradigm, and the consequent epistemology and values that conform a supporting culture for sustainable development.

Jan 1, 2007

By P. B. Marchant

"Based on laboratory and pilot scale continuous biooxidation of complex sulphide concentrates, commercial processing design and scaleup considerations are discussed. Capital and operating cost estimates for commercial biohydrometallurgical operations are summarized and potential applications of biotechnology are discussed. Biooxidation as an oxidative pretreatment alternative to enhance precious metals extraction from refractory sulphide concentrates in stirred tank reactors has received considerable attention recently due mainly to advances in the practical applicability of the process. Biooxidation of sulphides is certainly not a new process, however, application and control in large scale hydrometallurgical operations to treat refractory sulphides remains conceptual and the limited data available is restricted to relatively small laboratory and pilot scale operations. It is the intent of this paper to indicate scaleup and plant scale process design considerations for commercial bioleach circuits, based on recent operating experiences with laboratory and pilot scale continuous bioleach systems. An indication of the expected range of applications will be presented parameters for optimization will be discussed."

Jan 1, 1986

By C. Bazin, D. Hodouin, M. Ounpuu

Sensors are now available in mineral processing circuits to monitor pulp flowrate and density, as well as ore characteristics and other process variables. The amount of information provided by these instruments is considerable but in many cases poorly exploited. This paper gives the results of the application of time series analysis techniques to signals generated by the sensors installed on an industrial Pb dezincing flotation circuit in New-Brunswick. Autocorrelation and cross correlation functions appear to be interesting tools for a preliminary circuit analysis, however the calibration of single input single output discrete transfer functions using collected sensors signals leads to conflicting results. For this reason a phenomenological approach, based on the kinetic and transport properties of the flotation process, is also considered. It has several advantages over the empirical transfer function modelling but also limitations in its applicability to industrial processes. A combination of the transfer function and kinetic modelling approches appears to be a promising avenue for better process modelling and control.

Jan 1, 1985

By N. Shi, T. G. Joseph

ABSTRACT A revised equilibrium approach to evaluate dipper-ground interactions during the dig cycle of ultra-class mining shovels operating in soft unblasted uniform ground conditions is presented. A review of previous approaches, leading to an outline of the modifications and ground condition considerations, is made in support of the reasoning and basis for the derivation presented. An analytical solution is provided to the scenario of a cable shovel dipper digging in soft ground material such as oil sands.

Jan 1, 2012

By Julian V. Simela

Conventional methods of underground surveying use theodolites/total stations and 3D laser scanners to obtain information about the underground environment. Current methods of geo-referencing these instruments to a mine reference system include triangulation, trilateration and resection. However, despite technological advancements, surveying procedures have remained slow, laborious and relatively unchanged during the last half-century. Recent innovations in the robotics community have shown that automated mapping of underground mining tunnels can be undertaken using 2D/3D laser scanners. These techniques have the potential to, in turn, improve upon current underground surveying and mapping methods. Automating surveying and mapping using current surveying tools without changing the setting up procedures or removing current constraints, or even changing the type of equipment used, does not change the status quo. The problem of moving from a static, tripod based surveying and mapping system to an unconstrained mobile surveying and mapping system is the subject of this paper. A current challenge for automated mapping is the ability to automatically geo-reference a mobile mapping system to a mine reference system. For a mobile mapping system that uses a horizontally mounted 2D laser scanner to gather data of the underground environment, the challenge of determining its position and orientation within the mine environment is magnified even more. This paper introduces Mobile Automated Scanner Triangulateration (MAST), a technique under development at Queen?s that is designed to geo-reference a mobile mapping system to a mine reference system for the purposes of underground mine surveying. MAST quickly and automatically determines scanner 2D position and orientation (azimuth) in a mine reference frame by using minimal human input.

Aug 1, 2013

By M. Xiao Bo

In recent years, there has been a heightened interest in the hydrometallurgical processing of sulfide ores and concentrates (especially copper sulfide ores and concentrates) mostly in the USA and Chile. Currently, hydrometallurgical operations account for about 30% of the primary copper production. In the present research, the leaching phenomena of IOCG (iron-oxide hosted copper-gold) ores and concentrates were studied. The IOCG ore, which is characterized as having a predominant amount of magnetite with fine chalcopyrite, is currently the center of attention for new copper resources. Heap leaching of IOCG ore is desirable because of its low cost. However, the leaching characteristics of the ores and concentrates and the mechanisms of copper leaching require investigation. This study defines the factors, which affect the leaching operation, such as the ORP, pH and oxidizing agents. Based on these results, the optimal leaching conditions are provided for pilot column leaching test and ultimately, commercial operations.

Jan 1, 2007

By J. Fixter, P. Prangnell, Z. Pinter, E. Eimer, B. Chehab

"High deposition rate Wire and Arc Additive Manufacture (WAAM) can provide benefits to the aerospace industry, including a reduction in lead time, reduced material waste and, through higher solidification rates, refinement of the as-built microstructure relative to a cast material. However, candidate 2xxx series high strength alloys for this process normally require a solution treatment, which is problematic for large near-net-shape components, and age hardening to achieve maximum mechanical properties. With each layer being subject to multiple thermal cycles, exploiting the thermal conditions in the WAAM process to avoid post-build solution treatment is therefore of interest. A solutionisation model has been developed for the WAAM process, based on diffusion controlled dissolution using DICTRA, which was validated through thermal simulations combined with 2D and 3D image analysis. The model has subsequently been used to simulate the solutionisation behavior during a typical WAAM thermal cycle and to explore what could theoretically be achieved by, for example, refining the starting microstructure.INTRODUCTION There is currently great interest in exploiting additive manufacturing (AM) in the aerospace sector due to several benefits it can potentially provide; including reduced material waste, shorter product lead times and greater design freedom (Herzog, Seyda, Wycisk, & Emmelmann, 2016). However, with aluminium alloys the material properties obtained are generally inferior to those of conventional high-strength wrought products; therefore more research is required to explore the potential for exploiting the unique process conditions in AM to improve the as-deposited microstructure. A range of AM techniques are now available (Debroy et al., 2018), which differ in terms of the feedstock type and power source and it is necessary to match the appropriate technology to a particular application. This generally requires a compromise between the build rate and shape resolution. Wire and plasma-arc additive manufacturing involves using an electric arc to melt wire onto a substrate, and fabricates a part by building up overlapping layers of deposited weld beads (Addison et al., 2015; Williams et al., 2015). The benefits of this process over other AM methods are the much higher deposition rates (e.g. kg’s/hour) achievable and lower capital equipment costs relative to powder bed techniques, which makes it suitable for large scale applications. However, limitations include a lower part complexity, lower solidification rates and a greater need for post-process machining (Frazier, 2014)."

Jan 1, 2018

By G. Issid, J. McGinty, C. Lee, Y. Pepin

For more than a decade, Hatch has used process and logistics models to assist Rio Tinto Fer et Titane (RTFT) with capacity planning, debottlenecking, and optimization to help ensure design capability, capital effectiveness, and operational efficiency of the integrated production chain. Process models are used to optimize the physics-based aspects of the system, such as mass and energy balances, flow rates, yields, and equipment specifications. Dynamic logistics models are used to optimize how the various plant areas work together to achieve the desired ends and deal with such things as plant scheduling and synchronization strategies, sizing of buffers between processes, defining the required number of process and material handling units, and designing a plant layout that minimizes plant interferences and inefficiencies. The combined use of process models and logistics models enables the overall plant to be optimized from both a productivity and quality point of view, with each plant area working in harmony with one another to achieve targeted capacities and efficiencies. This paper describes the many benefits derived from such modeling efforts over the past 15 years for each of the major plant areas at RTFT: Beneficiation Plant, Smelter Plant, Steel Plant, UGS Plant, and Powder Plant (RTMP).

Jan 1, 2011

"With the plethora of cable bolts on the market, geotechnical engineers can be baffled by the differences in performance claims from the manufacturers but perhaps more importantly they are sometimes at a loss in making an optimal selection matching behaviour with a particular site condition. To this end a new testing methodology has been developed that can cater for the varying types of cable bolt behaviours. The methodology is based on the laboratory short encapsulation pull test (LSEPT) as recommended in the British Standard and overcomes several deficiencies such as cable rotation. Of most significance however, is its inability to measure the post-peak residual performance of high load transfer capacity cables and consequently, there is an inference that these cables may be susceptible to sudden anchorage failure with relatively little yield. This paper details the results of anchorage performance tests of a range of cable bolts and the differences in performance with rock strength and drill hole diameter.INTRODUCTIONA research project was undertaken to develop a new laboratory-scale test apparatus to study the axial performance of fully grouted cable bolts that are used in the Australian underground coal mining industry. Work by Thomas (2012) and others in recent years found there were a number of deficiencies in the testing methodologies making it difficult to determine and compare the performance of the dozen or more different types of cable bolts on the market. This has meant that geotechnical practioners have been hamstrung in optimizing the design of ground support systems in underground environments that are increasingly more arduous.A cable bolt is a flexible tendon consisting of a quantity of wound wires that are grouted in boreholes at defined distances between holes in order to provide ground reinforcement of excavations (Hutchinson & Diederichs, 1996). They were initially introduced into the underground hard rock mining industry in the 1960s (Thorne & Muller, 1964) and since the early 1970s have been brought to coal mining operations."

Jan 1, 2015

By M. P. Rennick, D. M. Burton

Abstract -The Murray Brook massive sulfide deposit, which was the first geochemical discovery in the Bathurst camp, is one of the largest sulfide deposits in the area. The massive sulfides are hosted by quartzose metasedimentary rocks in the lower part of the Ordovician Tetagouche Group. This thick succession of sedimentary rocks is overlain conformably by felsic volcanic rocks, and is structurally overlain by mafic volcanic rocks. The massive-sulfide body is polydeformed, but primary metal zoning is still discernable and may permit future exploitation of discrete lead-zinc and copper zones. Although it was discovered in 1956, the deposit was not developed unti11989, when Murray Brook Resources commenced processing of gossan containing precious metals. Recovery of gold, silver, and mercury is accomplished by indoor vat leaching on a year-round basis.

Jan 1, 1992

By S. N. Yu

Tele-operation manipulators applied in this paper are systems for the remote handling and management of pyroprocessing related facilities in an Argon cell of the KAERI (Korea Atomic Energy Research Institute). Generally, these kinds of systems are composed of a master-slave system and its peripherals installed along the wall of the cell, with the master transmitting the user?s own motion to the gripper directly. This study introduced various considerations and modifications to improve the remote handling performance. The analysis of an operator's ability using his/her own upper arm motion range while manipulating the MSM, and considerations of its manipulation margin and the related tool modifications are also included. Finally, the test results of several remote handling tasks are presented, and an adequate operation strategy for the tele-operation system of hot-cell type facilities is proposed.

Aug 1, 2013

By Z. Xie

Gas diffusion electrodes (GDEs) for high temperature polymer electrolyte fuel cells (PEFCs) have been prepared using ZrP-modified Nafion ionomer. The performances of these GDEs as cathodes and anodes were evaluated and compared with conventional Nafion ionomer GDEs using Nafion 112 as the PEM under elevated temperature and reduced relative humidity. ZrP-modified Nafion ionomer was incorporated into the catalyst layer to enhance water retention and/or increase the protonic conductivity. The fabrication of ZrP-GDEs was implemented by the ion exchange of Nafion solution with zirconyl chloride, followed by the impregnation of GDEs in H3PO4 solution. The composite electrolytes in the catalyst layer possessed a ZrP content of 20% by weight. GDEs were characterized by TGA, SEM, XRD, and CV. Scanning electron microscopy (SEM) indicated evenly distributed elemental Zr and P within the catalyst layer. Cyclic voltammetry shows a reduced electrochemically-active surface area when the ZrP is incorporated into GDEs. Polarization and impedance analyses indicate the cathode with ZrP-modified Nafion ionomer did not show an enhanced or decreased performance, compared with conventional Nafion ionomer GDEs under elevated temperature and decreased humidity. However, when GDEs with ZrP¬Nafion ionomer were used as the anode, an improved performance was observed. Preliminary experiments show that the anode is more sensitive to dehydration than the cathode under elevated temperature and/or low humidity. Improving the anode water retention capability will help to reduce losses at the anode. However, the incorporation of hygroscopic agents in the cathode catalyst layer is not essential because it is self-humidified by electrochemically-produced water even under elevated operating temperature and lower humidity.

Jan 1, 2005