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By Tim Robinson, Michael S. Moats, William G. Davenport, Andreas Filzwieser, Andreas Siegmund, Shijie Wang

This survey continues the long tradition of providing a snapshot of operating data from industrial electrorefineries. It is a supplement to previous surveys that were performed in 1987, 1991, 1995, 1999, 2001, 2003, 2007, 2010, 2013 and 2016. Analyses of current data and historical trends are presented. Examples of innovations to reduce costs, improve productivity, and improve quality are provided. In general, refineries continue to increase productivity while treating anodes with more impurities. INTRODUCTION This manuscript analyzes global survey data provided by operating copper electrorefineries. This paper continues a series of surveys of copper refining tankhouses that started in 1987 (Schloen, 1987, 1991; Schloen & Davemport, 1995; Davenport et al., 1999; Robinson et al., 2003; Moats et al., 2007, 2013, 2016). In this installment, data collected from 2015 and 2018 will be presented and analyzed. The 2015 survey data were presented at Copper 2016 in Kobe, Japan. This survey will continue the analysis of previous data to illustrate long term trends in copper electrorefining, which were originally presented at the Davenport Symposium in October, 2014 (Moats, Robinson, & Wang, 2014). Refineries who supplied surveys are listed in Table 1. Cathode production data from 2015 and 2017/18 (from surveys presented in 2016 and 2019) are provided to indicate which plants provided surveys and when. This manuscript presents operating data for ~6.5 million tonnes of copper production, which represents 30–35% of the world’s copper electrorefining production. The detailed survey results are available upon request from the corresponding author.

Jan 1, 2019

By Jeffrey D. Eisenman

FRP is a proven material for the solvent extraction processes of copper production. There is a history of successful applications of FRP piping and equipment in hydrometallurgical processing. The performance of FRP equipment has not always been consistent, but at no fault of the material. Its non-metal attributes and behavior vary from those of more typical materials of construction, such as steel and alloys. FRP is a mainstay material in many areas of solvent extraction and electrowinning and yet not well understood by all. We will discuss the critical concerns, which are key to reliable performance of FRP systems. This paper will include discussion of key elements, which are fundamental to reliable FRP piping design and considered best practices. Essential design and construction considerations to maximize reliable service life of FRP equipment, such as thickeners and process vessels, used in copper extraction and processing, will be discussed. Additionally, we will expose potential pitfalls and share lessons learned from previous copper processing plant projects, which can aid and impact other copper processing projects to ensure best system performance and reliability. INTRODUCTION The corrosion resistant attributes of fiberglass reinforced plastics (FRP) make it an attractive and cost effective material of construction in corrosive service applications that are found in copper processing. FRP is used all over the processing plant in seawater, brine and sulfuric acid services where the corrosive nature of these services would challenge most ferrous materials and coatings. FRP is a fully customizable material to meet the specific needs of each service and process. FRP piping and equipment can be found throughout the hydrometallurgical process, in the acid plant, desalination, leaching processes, solvent extraction and electrowinning to name a few. Beyond its superior corrosion resistant characteristics, FRP can be made abrasion resistant by introducing particulate additives into the resin, such as silicon carbide and alumina oxide. Because many of these services have combustible organic elements in the flow streams with accompanying safety concerns, the linings can be made conductive with carbon fibers to dissipate static charges that might collect on the surface of the equipment otherwise. Further, FRP can be made flame retardant as well, where flammability may be of concern.

Jan 1, 2019

By Chelto. D. Smith

With the pressure on mine and metallurgical managers to take accountability for responsible corporate governance in their operational area, it is no longer acceptable to rely on central departments in the organization to manage safety, health and environmental impacts of the company?s processes. Environmental impacts exist because of the production or mining process. Some of the inputs to the process are natural resources and some of the outputs of the process are the inputs to the environmental control equipment, plant and the environment itself. Environmental management therefore needs to be incorporated in production management to effectively control and reduce the impacts. Many aspects of environmental management are identical to production management and the systems to manage them will likewise be very similar. By examining key components of these two management systems a decision can be made whether environmental management and production management are structurally similar and can be integrated into a combined IT solution.

May 1, 2009

By M J. Daniel

Comminution is the science of size reduction of brittle materials. It is integral to mineral extraction and is one of the most energy intensive processes in the mining industry. There are a number of tests used to quantify the strength of ore, which are then used to size the AG / SAG mill in circuit design. The calculated energy utilized for breakage in these devices is based on the assumptions that the materials treated are of average shape and that the processing equipment is designed to break the ore as efficiently as possible under the given operating conditions. In drop weight tests, it was found that shape significantly influences the measured rock strength. Controlled experiments with variations in blends of rock shape show that mill throughput increases with the addition of weaker shaped rocks.

Jan 1, 2012

In terms of throughput, product size and power draw, grindcurves provide a measure of the response of the mill performance to changes in mill operating parameters – usually mill filling. Since presenting the principle in 2006, grindcurves have been applied to a wide variety of AG and SAG mills. Mill response has been carefully measured for variations in: mill fillings from 15% to 40%; throughput by a factor of two; power by 50%; feed blends; liner profile; and mill speed from 65% to 80%. The outcomes of this extensive program of work are presented as the measured grindcurves. How they have enhanced our understanding of mill operation and how they may be applied to practical daily mill control is discussed. It is proposed that this technique provides a viable and valuable mill control tool that may find extensive application in the industry.

Jan 1, 2012

By S. M. Bulatovic, D. M. Wyslouzil

"This paper presents the results of a study of the effect of flowsheet configurations on metallurgical results and describes a general method for developing and optimizing flowsheets used in the treatment of massive sulphide ores. The flowsheet configuration can have a significant effect on recovery and selectivity between valuable minerals and gangue minerals. Placing of intermediate products within the flowsheet, positioning of various pretreatment units, such as conditioners or regrinding mills, and the ability of the flowsheet to cope with wide swings in the feed grade and composition are the major parameters that determine the optimum flowsheet configuration. The complexity of the flowsheet is largely a function of the ore itself and of the number of final, marketable products that have to be recovered from the ore. INTRODUCTIONTechnological ExpansionThe trend of past decades has been towards larger equipment and a better understanding of the chemistry of the flotation process. Despite appreciable progress in these areas little attention was given to the study of the actual configuration of the flowsheet, although the arrangement of the flotation equipment significantly affects the overall performance of the circuit."

Jan 1, 1989

By M. Takebayashi, K. Takenaka, S. Matsubara, T. Yoneyama

The cathode production of Toyo Smelter and Refinery, owned by Sumitomo Metal Mining Co., Ltd. reached 450,000 tons per year in 2016 with three tank houses. Niihama tank house commenced operations in 1919 with conventional sheet cathode technology. Approximately 100 years of operation experience and the technical development enabled that the current density of Niihama tank house and the Toyo tank house #1 increased to 320 A/m2. These operation techniques were utilized at the Toyo tank house #2 which started in 2005, and its current density reached up to 350 A/m2 with permanent cathode technology. In order to achieve high current efficiency under condition of 350 A/m2 operation at Toyo tank house #2, continued efforts had been made to verticality of anodes and permanent cathodes. To improve verticality of anodes and cathodes, reduction of short circuit ratio by changing the shape of the anode, optimizing the anode pressing machine and off-line process for rectifying the distortion of permanent cathodes was carried out. In addition, concentration control of electrolyte and expansion of Ni removing ability from the electrolyte prevented passivation. Finally, more than 96% of the current efficiency was stably confirmed. INTRODUCTION Today, Toyo Smelter and Refinery of Sumitomo Metal Mining operates three tank houses in Japan, namely, Toyo tank house #1, Toyo tank house #2, and Niihama tank house with a total capacity of 450,000 metric tons of copper cathodes. Figure 1 shows the trend of cathode copper production and the current density at three tank houses over the last 10 years. Cathode production by Toyo Smelter and Refinery reached 450,000 tons per year in 2016 with three tank houses.

Jan 1, 2019

By A. R. Kinkel JR.

"The Buffalo Ankerite mine is in the southern part of the Porcupine gold district of northern Ontario. The mine has a history of exploration and development reaching back to 1911, and has been operated continuously since 1932. From 1932 to 1942 a total of 510,874 oz. gold was produced from the mine. In 1941 the production was 71,654 oz. from 448,621 tons of ore.With few exceptions, the ore-bearing veins did not crop out. They were discovered during the prospecting of the prominent outcrops of barren or low-grade quartz-carbonate breccia near the veins.GEOLOGICAL SETTINGThe Porcupine gold district lies in an area of folded and sheared Precambrian lavas, sediments, and intrusives. The Buffalo Ankerite mine is in the southern part of a large fold. The structure appears to be a continuation of the Vipond cross anticline and accompanying syncline described in earlier papers (1, 2). The orebodies lie along both flanks of the synclinal part of the fold, and are known as the north and south vein systems, respectively. No mineable veins have been found on the axis of the syncline (Fig. 1).The rocks found in the mine area are pillow lava, dacite, conglomerate, quartz porphyry, tuff, and fragmental lava. The tuff and fragmental lava are now largely altered to chlorite schist. Productive veins have been found only in pillow lava, dacite, and conglomerate, but a minor amount of gold occurs in some of the quartz porphyry. The Porcupine Creek fault, a zone of intense shearing over 1,000 feet in width, lies immediately south of the mine. A spur fault branches to the northwest from the Porcupine Creek fault, separating the north from the south vein systems ( Fig. 1) ."

Jan 1, 1954

By M. Uszko

Methane drainage and ventilation methods of methane hazard mitigation are used in the coal mines of Kompania Weglowa S.A. Over 22% of methane released during mining activities is captured by methane drainage systems and transported to the surface. In this article we present development plans for utilization of methane captured and transported to the surface by methane drainage systems. The results of research on the possibility of economic utilization of methane concentrated in ventilation air that leaves the mine through fan diffusers are also described.

Aug 1, 2013

By Yongqiang Liu

Background For refractory gold ores with high carbonate contents ! Acid pressure oxidation ! High acid consumption (if low sulfur content) ! Low oxidation efficiency due to CO2 in autoclave ! Problems with slimy precipitates (gypsum, etc.) ! Alkaline pressure oxidation ! Difficulty in fixing arsenic ! Low gold dissolution due to iron hydroxides/oxides coating ! High reagent costs Summary ! Carbonate and sulfide minerals had similar floatability across the pH range tested (5 - 12) using sodium oleate as a collector; ! Thioglycollic acid or citric acid depressed the flotation of pyrite but could not depress chalcopyrite when used alone; ! Combination of thioglycollic acid and citric acid had a much stronger depressive effect, and the mixture depressed chalcopyrite as well as pyrite between pH 8 and 11 without affecting the flotation of calcite and dolomite; ! Calcite could be separated from chalcopyrite and pyrite; dolomite could be separated from pyrite but not from chalcopyrite under the tested conditions.

Apr 1, 2005

By H. Wilhelm, W. I. van Drunick

The Anglogold Ashanti (AGA) Navachab single stage SAG mill has provided an excellent setting for incremental optimization. Over the past decades, several interventions have resulted in marked improvements in specific performance; including steel ball scat removal, re-design of the mill lifters, replacement the pebble crusher and cyclone cluster, as well as the use of a vibrating screen in place of a discharge trommel. Recent initiatives now include an operating fine DMS circuit, studies on pre-crushing of the ROM feed and also fine-screening as an alternative to hydrocyclone classification. The current optimized state of the Navachab mill allows it to operate at approximately 20% higher efficiency when compared to mills of similar shell dimensions in gold mining, treating similar ore. This paper describes the systematic improvement of the SAG circuit to its current state.

Jan 1, 2012

By Michael Davies

Mined Material Management Meeting or Missing the Mark? o you agree that we have the technology to consistently design robust M3 facilities? ?YES your experience do these M3 facilities perform as expected during operations? ?USUALLY hat can be done to improve performance, e.g. better communications between project and operating teams, discontinuity between design and operational input by designers, others? ?UNDERSTANDINGWHY THINGS GO WRONG an we identify the key characteristics of ?good M3 facilities?, i.e. ones that are performing well? Can we identify ?good M3 facilities?, i.e. ones that perform well and can be held up as examples? ?WITHOUT QUESTION?? your opinion, for what reason do they not perform as expected? ?NO SINGLE REASON??..

May 1, 2010

By David Morley

This paper considers the ideal truck-excavator combination, defined as the combination resulting in the lowest direct unit cost, in consideration of multiple haul scenarios characterized by different haul distances, material and equipment availability. Through the application of Monte Carlo simulation, selected for its unique ability to handle the uncertainty of activity durations, the ?four to six passes? loading rule is shown to not correlate with the selection of the minimum cost fleet. Additionally, through the results of the simulation it is determined that the haul truck capacity has a greater effect on the overall efficiency of the system than does the excavator capacity. As a result, in order to arrive at efficient operations, the entire earthmoving system must be viewed as whole, namely, considering haulers together with excavators, as opposed to the popular method of first selecting a loading unit and then selecting a hauler obeying the ?four to six passes? loading rule. Furthermore, truck utilization and excavator utilization exhibit an inverse relationship and neither directly correlates with the overall efficiency of the earthmoving operation. The following conclusions are drawn: first, with limited financial resources, it is more valuable to increase hauling unit size before increasing loading unit size and second, predefined rules or generalizations, not based on evidence, potentially eliminate optimal truck excavator combinations from being considered.

Aug 1, 2013

By Craig Ford

Inmet Mining is committed to implementing the highest corporate responsibility standards in its mining operations worldwide. Inmet is 100% owner of Minera Panama, a world-class copper project that is currently in the feasibility phase in north-central Panama. Panama has limited experience with modern mining, limited mining capacity, and the project context involves significant social, environmental and political complexity. The Project area is remote with recent in-migration of latino and indigenous people, informal and small-scale mining, local subsistence populations and considerable biodiversity value, coupled with a complex jurisdictional setting. In short, it is increasingly the kind of project mining companies are taking on because the easy projects have already been developed. With such challenging conditions, anticipating and managing social risks is critical to effective project management. To this end, between August 2007 and the third quarter of 2009 Inmet seconded Monkey Forest Consulting Ltd to the project to assist Minera Panama in building and implementing an effective, early phase external relations strategy. The team was also tasked to find and develop a locally based team that could sustain success through project development and into operations. Today?s presentation was created by Inmet and Monkey Forest and describes some of the lessons learned in implementing an effective early phase process for managing social issues.

May 1, 2010

By Chan-ho Park

As the building has recently become bigger, higher, and freeform, a technology called BIM(Building Information Modeling), which is a key technology that integrates construction and IT(Information Technology), has been rapidly introduced and expanded. Because BIM technology offers various benefits, countries that introduced BIM early has been actively promoted. However, misperceptions of BIM are prevalent in countries such as South Korea that have adopted it relatively late, with lack of awareness of its fundamental purposes. Under these circumstances, transparent and quantitative performance assessment needs to be executed in order to eliminate the misperceptions, and to explain and revitalize the BIM introduction. These quantitative performance measure KPI (Key Performance Indicators) to be measured should be prioritized. As derive performance indicators in terms of the four types (financial, customer, internal processes, learning and growth), and performance management systems, Uses the BSC to seek a balance between short-term financial goals, values and the value of long-term goals. Uses the BSC(Balanced Scorecards) to derive performance indicators in terms of the four types (financial, customer, internal processes, learning and growth), and performance management systems, seeking a balance between the value of short-term financial objectives and the value of long-term objectives. Through this, the KPI (Key Performance Indicators) which is used for measuring the effect of the BIM will be generated and also the method that can determine whether the generated KPI figures are objectively inter-connected will be suggested as well.

Aug 1, 2013

By Chin J. Chang

Powder metallurgy (P/M) technique is known for its capability of producing near-net-shape parts. Its specific characteristics have resulted in low cost and eliminated of many secondary machining. However, more and more P/M parts do require additional operations to fulfil their complex geometric features and surface roughness. Many of the machining factors that influence the machinability of cast and wrought steel parts, such as cutting speed, feedrate, coolant, tool geometry and shape, are also considered in the machining of P/M components. The special feature in P/M structure is the porosity that can decrease the machinability and shorten the tool life. Different variables have been considered in the machinability of P/M materials. Densities and the free machining additive manganese sulphide (MnS), are the two main factors of material composition, which dominate the P/M machining performance. Machining process is the main method that generates the desired working surface of machining components. This paper will discuss the metallurgical structure of the powder metallurgy components, their physical properties and possible issues when encountering machining operation. Turning operation has been tested in this investigation to show the relationship between the cutting speed, federate, cutting forces and chip formation. This investigation also discusses how the free machining additive, manganese sulphide, affects the P/M structure and machinability in order to understand how the metallurgical structure can affect the machining operation and, how to obtain the optimised surface results.

May 1, 2001

By André Chagnon, Héroux. Yvon

"Résumé - Cette étude porte sur l'altération de la matière organique et des argiles dans les boues carbonatés dévoniennes du facies ""F' de la Formation de Pine Point et ses équivalents stratigraphiques la Formation d'Evie et l'unité bitumineuse de la base de la Fonnation de Hom River. La matière organique se compose principalement de bituré solide et de quelques fragments de fossiles (organaclastes). La majorité des échantillons ne renfement que de l'illite et des inter-stratifiées illite/smectite.Si on compare les températures d'homogénéisation (Th = 100°C) des inclusions fluides de la sphalérite et des dolomites associées a la minéralisation aux températures estimées à partir de la réflectance de la collinite (84°C à 117°C), l'on ne peut pas conclure à la présence d'une anomalie thermique dans le district minier de Pine Point. De plus, la réflectance des organoclastes n'est pas plus élevée dans le district minier de Pine Point que dans les localités plus éloignées des gites. L'analyse des minéraux argileux conduit à la même conclusion: aucune anomalie thermique n'est décelable dans les unités échantillonnées à l'intérieur du district minier de Pine Point quelque soit l'indicateur utilisé.La kaolinite et la matière organique altérée, affichant des valeurs anomales de sa réflectance, se trouve essentiellement en présence de soufre et de sulfures. Cela suggère une origine authigène de la kaolinite et une altération de la matière organique reliées au phénomènes de minéralisation.Abstract - The alteration of organic matter and clays is studied in the Devonian Pine Point Formation carbonate muds, ""F"" facies, and its lateral equivalents the Evie Formation and the bituminous unit at the base of the Hom River Formation. The organic matter is mainly composed of solid bitumen with few fossil fragments (organoclasts). Most samples contain only illite and mixed layer illite/smectite.If we compare the Th (100°C) from fluid inclusions of sphalerite and dolomites associated with mineralization to the temperatures calculated from the reflectance (Ro) of the collinite (84°C to 117°C), we cannot detect a thermal anomaly in the Pine Point mining district. This result is based on the reflectance values of organoclasts from the mining district that are not higher than those reflectance values measured on organic matter (OM) away from the ore deposit. A similar conclusion is reached from the clay study: none of the parameters used allow us to identify a thermal anomaly in the samples from the mining district.The kaolinite and the altered OM showing anomalous Ro values mainly occur with sulfides and sulfur. This association suggests an authigenic origin for the kaolinite and an alteration of the OM due to the mineralization events."

Jan 1, 1994

By W. Melnyk, L Pokhilenko, J. A. McDonald, A. Hall

The Camsell Lake property comprises 270 000 acres located about 240 kilometres northeast of Yellowknife in the Northwest Territories. Kimberlite has been located in two areas of the property:

Jan 1, 2001

By F. R. Archibald

IN a recent paper on Roasting of Beattie Concentrate (1), the importance of controlling the temperature, and the sulphur dioxide concentration was pointed out. It is the purpose of the present paper to present further information by which the most satisfactory conditions for roasting are more specifically defined. Incidentally, a method of illustration is developed for representing roasting curves on a three-dimensional diagram. The primary purpose of this investigation, as in the case of the earlier work, was the search for information that would be of practical value in improving plant operation and gold recovery. For this reason, emphasis is laid on the regulation of essential variables and on definition of their optimum values and limits for maximum gold recovery in the subsequent cyanidation process. Good roasting is considered at least as much an art as it is a science, and, in this light, theoretical consideration of the nature and sequence of the chemical reactions involved is of secondary importance. The presentation which follows includes a series of graphical illustrations, an interpretation of the graphs, some theoretical considerations, and a description of laboratory technique.

Jan 1, 1940

By L Thompson, R C. West, T S. Kho

In 1978, the Outotec direct to blister flash (DBF) smelting process was commercialized with the commissioning of the Glogow 2 smelting facility in Poland. Since then four further DBF facilities have been constructed, two at Olympic Dam, one in Zambia and most recently one at Glogow 1 in Poland. The DBF smelting process differs considerably from conventional smelting process in both chemistry and unit operations, presenting opportunities for flowsheet capital and operating cost savings particularly when the concentrate copper grade is high. WorleyParsons has amassed considerable expertise in the Direct to Blister process and in this paper the process is compared to the modern two stage Double Flash process. The processes are modeled, and the key operating parameters, consumables and production metrics are directly compared. Subsequent flowsheets, key equipment lists and capital costs are also presented for comparison and discussion. The results show the range of concentrates which are most economically treated by the DBF process relative to those best treated in conventional processes along with those concentrates which could be treated by either process. INTRODUCTION The Outotec Direct to Blister (DBF) process was developed and installed at Glogow in 1978 (Czernecki et al., 2006). Currently there are a total of five DBFs built on three sites: Glogow No.2, Olympic Dam No.1, Olympic Dam No.2, KCM Zambia and Glogow No.1, being the most recently constructed. The DBF process was the first flash furnace process to produce blister copper and paved the way for the subsequent development of the flash converter and other continuous converting processes. Today four flash converters are in operation taking the total number of flash furnaces producing blister copper to eight. In all DBF operations it is the unique ore and concentrate composition which made selection of the DBF process the most attractive. In all cases, the concentrate is relatively high in copper but low in iron because chalcopyrite is not the major constituent. When considering smelting options for high copper, low iron concentrates a key question is then often asked, “At what point does it become economic to switch from two stage smelting and converting process to the DBF process?”

Jan 1, 2019