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By T. Holmes, S. Davison

"The Special Standard Surge bin at Agrium’s Vanscoy Potash Operations (VPO) has been plagued with flow problems and wear, and corrosion issues for it’s entire working life. Investigation showed that the carbon steel construction, bin geometry, and resultant funnel-flow pattern were directly responsible for production losses and disproportionate maintenance and capital costs. Potash enters this bin at between 140°C and 165°C, but the stagnant potash outside the active flow channel was much cooler, allowing moisture to migrate toward the outer regions, which caused corrosion of the walls and reduced live capacity as the potash in this area hardened and built up on the walls over time.A 2013 inspection revealed holes and paper-thin areas in the lower cylinder wall sections and in the conical hopper. The only thing preventing major leaks and even a potentially catastrophic failure was the buildup of stagnant hardened product on the cone walls. It was concluded that the cone had reached the end of its life and required replacement. VPO’s original plan was to replace the cone in kind and repair the cylinder as necessary; however, a failure-mode and bin-performance investigation combined with a lifecycle- cost analysis indicated it would be better to redesign the hopper.For success in retrofit projects, it is essential at the design stage to consider the bulk solid flow properties and the operating environment involved. Because education in this area is not offered at a university level, engineers often do not fully appreciate the effects of the flow properties of bulk solids on bulk material handling equipment.Jenike & Johanson conducted flow properties tests on samples of potash and using the data, redesigned the bin and the feeder. After the modifications, VPO’s surge bin provides safer, more reliable operation with a much longer predicted working life. Using this retrofit as an example, we aim to provide a general understanding of bulk solids flow theory and highlight the importance of customizing the design to the appropriate flow properties in the cost effectiveness, reliability, and safety of a bulk material handling system."

Jan 1, 2016

By C. J. Newman, D. J. Kemp, R. M. Sweetin

"The smelter is described by area; feed preparation, continuous furnace line, gas handling and auxiliary systems, blister refining, Hazelett casting of thin anodes, and scrap remelting. Early smelter campaign data is presented and compared to design. Some modifications to the basic design of the furnaces and gas trains are indicated, with their respective impacts on improving smelter performance.Plant compactness, the use of jumbo tanks, and a highly automated electrode handling system are featured in the refinery description, with brief coverage of the liberator and slimes leaching sections. Early experience in refining thin regular Hazelett anodes, and submersible pump recovery of raw slimes are relayed, together with automatic stripping from titanium blanks.Refinery tonnages and operating parameters are given showing the relatively trouble-free attainment of refinery design performance.IntroductionPrevious papers and articles ( 1), (2) ,(3 ) have described the metallurgical facilities serving the copper-zinc-silver Kidd Creek orebody located near Timmins, Ontario. For convenience a brief review of their mid-1983 operating status is presented.The concentrator, originally designed for 9,000 short tons, was commissioned in late 1966. It can now comfortably process over 13,000 metric tonnes per day largely as a result of the addition of a fourth circuit in 1978."

Jan 1, 1984

By Willie van Niekerk

As mining projects get larger and more complex there is a need to examine the use of project management techniques developed for large construction projects in order to ensure completion of the project on time and budget. In recent years the construction/civil industry has sought new methods to ensure that multimillion dollar projects involving multiple contractors, working in an increasingly legislated work environment, are delivered to the clients satisfaction. The paper describes these methods, which range from program management to systems and tools to gather all project information such as schedule and cost, and relates how these can be applied to large international mining projects. The paper also describes the benefits that an independent project manager can bring to a client or owner?s team by setting up the relevant organization and controls together with the appropriate contract and procurement strategy.

May 1, 2009

By S. Kelebek, E. Yalcin

"Diethylenetriamine (DETA) and/or triethylenetetramine (TETA) are reagents that can generally be categorized under ""flotation modifiers"". These polyamines are known to be effective for the deactivation/depression of pyrrhotite that is present in Canadian nickel-copper sulphide ores in large quantities. Recent bench scale testing on some of these complex ores indicated that chalcopyrite flotation can also be adversely affected under certain conditions involving polyamines, which may be taken to be an evidence of their specific affinity towards chalcopyrite. In general, DETA shows no significant depressant action on chalcopyrite while TETA's promotion of hydrophilicity for this mineral has been observed even in the presence of xanthate. This prompted an investigation on thermodynamic equilibria involving these polyamines and copper ions. Results serve a useful purpose to identify conditions for deactivation phenomena. CuDETA2+ and CuTETA2+ chelates as products of sequestration have large predominance areas covering a wide range of redox and pH conditions, where copper xanthate species are not stable, especially in the presence of TETA."

Jan 1, 2009

By J. Ramirez-Castro, J. A. Finch

"Galena is the finest component of the product of a closed-circuit grind treating a lead-zinc ore, largely due to preferential recycling of this high-density mineral by the cyclone. For example, at the Pine Point Mines concentrator, for ~ 55% -200 mesh over-all, the galena will be close to 95% -200 mesh. This sliming of the lead can limit recovery, selectivity and dewatering. A proposed circuit modification to reduce the sliming is to incorporate a unit cell. A simulator was constructed to study the No. 3 grinding circuit at Pine Point modified by a unit cell on ball mill discharge (BMD).The simulator used a cumulative size basis rate-of-breakage with plug flow ball mill model, the parameters being obtained by laboratory grinding tests. Flotation and the cyclone models used a cumulative recovery/size matrix. The behaviour of each mineral, galena, sphalerite, pyrite and calcite/dolomite, was simulated. Simulation was adapted to a programmable calculator. A close fit to the existing circuit performance at two tonnages and mineral mixes was established.The simulator showed that the modified circuit could significantly coarsen the Pb grind, from 95% to —50% -200 mesh, depending on recovery, without substantially altering the size of the other minerals. The other principal findings were: compared to laboratory flotation tests on existing circuit BMD, the unit cell concentrate (CONC) will be coarser and markedly lower in grade; relatively low unit cell stage recoveries are desirable, because the cyclone scavenges the tail to give a circuit recovery which is higher than the unit cell stage recovery; unit cell stage recovery should not exceed the cyclone stage recovery, as the latter is the maximum circuit recovery; low unit cell stage recovery helps offset the disadvantage of the high flow at BMD; other high-density minerals will also be scavenged into the CONC, as illustrated by pyrite, making CONC quality difficult to maintain; density control of BMD flotation does not greatly alter feed density to the cyclone or ball mill.Possible plant metallurgy is forecast for a CONC diverted to final lead concentrate."

Jan 1, 1980

By Ju-hyung Ha

New automated curing system for mass concrete has been developed to improve the quality of concrete structure and to save construction time and cost. The principle of this system is the automated water circulation system of heated curing water. Applied curing water on the surface of mass concrete keeps the temperature difference between center and surface of the structure below the threshold of specification. Mock-up test and field application have been conducted to investigate the performance of this system. In the results, new automated curing system reduced the chance of thermal crack occurrence and improved quality of the concrete structure as well.

Aug 1, 2013

Of the many organic impurities present in Bayer liquor, sodium oxalate is known to have one of the most detrimental effects on the Bayer process. Because of its limited solubility, it will co-precipitate with gibbsite during the precipitation stage which results in many operational challenges for the refinery. Despite the importance of this phenomenon, the interaction mechanism between gibbsite and sodium oxalate is not well understood. In this study, the growth of sodium oxalate on three main morphologies (random agglomerates, prims and hexagons) of water-washed and caustic-washed gibbsite was observed under synthetic Bayer conditions using in situ optical microscopy. After a short induction period, oxalate started to nucleate on gibbsite crystals, and grew with a needle-shaped morphology which eventually developed into oxalate bundles. In addition, the results indicated that caustic washing was able to partly decompose gibbsite crystals and thus make the gibbsite surface rougher, which provides more potential sites for oxalate nucleation and growth. The growth rate of oxalate crystals on the basal (001) face of water-washed gibbsite was 1.33 µm/min determined by the time-lapse imaging of in situ optical microscope.

Jan 1, 2014

By V. Labiouse, F. Orellana

"Hollow cylinder samples can be tested for both the characterization of rock properties and the physical modelling at reduced scale of engineering applications. Particularly, this type of experimental setup can be used to simulate different stress conditions around underground openings, as already developed in the petroleum engineering field e.g. to study the instabilities around deep wellbores during either drilling or the oil production phase. Some authors have also used this technique to successfully characterize the damaged zone around underground openings in the tunneling engineering field looking for an efficient design of their support.This article presents a new hollow cylinder testing device developed at the Rock Mechanics Laboratory of the Ecole Polytechnique Fédérale de Lausanne (EPFL), Switzerland. It allows a full and independent control of the confining pressure and pore water pressure conditions at both the inner and outer boundaries of Thick-Walled Hollow Cylindrical samples. In order to mimicking a tunnel excavation in a porous rock mass, after initial recovery of the in-situ stress and pore water pressure, the hollow cylinders are subjected to a decrease in the internal confining pressure. Moreover, X-Ray Computed Tomography scans of the specimens are performed through the testing cell before and after the mechanical unloading to monitor the displacements undergone and the sample damage. The equipment, testing procedure and data analysis techniques are briefly presented in the paper.The good performance of the apparatus has already been checked on weak rock specimens, among others on Boom and Opalinus Clay samples. In many configurations, the mechanical unloading is found to induce a Damaged Zone (DZ) around the central hole. Its geometry and extent show a great similarity with in-situ observations around tunnels driven in the Boom and Opalinus Clay formations. Such similarities contribute to increase confidence in the understanding and modelling of the ongoing processes."

Jan 1, 2015

By Douglas R. Schmitt

In general, knowledge of the state of stress within the Antarctic lithosphere remains largely unconstrained due in part to Antarctica?s inaccessibility and because of the paucity of seismic focal mechanism solutions. As such, an important component of the ANDRILL project was to acquire new information on the stress directions and magnitudes within the upper crust. Extensive fracture mapping of the core and oriented ultrasonic televiewer logging were carried out to provide strong constraints on both stress orientations and the faulting regime. The first hydraulic fracturing stress determinations in Antarctica were also carried out to provide complimentary stress magnitudes. These measurements were accomplished using a wire-line transported hydraulic fracturing system consisting, essentially, of two synthetic polymer packers that were inflated to isolate the 1-m long pressurization interval. The tests were conducted at the end of the drilling and logging in a ~130-m section specially drilled below 1000 mbsf (nearly 1500 m from the rig floor) for hydraulic fractures. This zone was drilled primarily through competent, dense, and low permeability diamicts. The core fracture and televiewer logging information was used to site twenty separate measurements. Classic hydraulic fracturing pressurization records with unambiguous breakdown and fracture closure pressures were obtained in about half of the measurements. The remaining tests provided fracture propagation and closure pressures that are consistent with the classic breakdown curves, but they did not include a clear breakdown pressure and are indicative of the reopening of either natural or drilling induced fractures in the wellbore wall. The preliminary analysis of the results are in generally good agreement with the stress directions indicated by the core fracture logging and the stress regime suggested by the character of the drilling induced core fractures.

Jun 1, 2012

By O. G. Olvera, E. Asselin, D. Rival

Particle concentration distributions in a leaching tank have been estimated using a novel experimental approach that takes advantage of the galvanic interactions that occur between pyrite (FeS2) particles and a Pt electrode. The collision of FeS2 particles with Pt changes the open circuit potential measured with the electrode due to galvanic interactions. To discern particle collisions with the Pt electrode from experimental noise a simple analytical procedure was first adopted although the use of techniques involving frequency domain analysis is also briefly presented and discussed. Although this method is still under development, it is simple to implement and can yield valuable information regarding the hydrodynamic behavior of solid particles in stirred tanks in very short times. Finally, the advantages and drawbacks of the technique are discussed.

Jan 1, 2014

By A. Taylor

This paper considers mineral processing in zero gravity dry environments typical of asteroids or comets. The electro-dynamic separation technique using pneumatic flow systems is explored. Pneumatic delivery of solids is used because of extreme temperature changes and the possible scarcity of water. The present earth-based process and how it can be modified for these conditions is examined.

May 1, 2001

By G. Morin, F. Chiesa, B. Tougas, B. Duchesne, Jocelyn Baril, N. Giguère

"An aluminum A356 compressor impeller was sand cast using the Low Pressure technique. The casting was limited in size (170 mm in diameter, 1.2 kg in weight) and very intricate in shape thus making 3D mold printing particularly favorable; indeed, producing this part by the traditional pattern-core box route would involve mounting 12 cores inside the mold while stringent dimensional tolerances are required as the impeller blades are only 2 mm thick. Consequently the molds were produce on the X-One MFlex printer of Quebec Metallurgy Center - CMQ. A dozen castings were produced with different casting temperatures and filling times so that it was possible to assess under which conditions complete filling of the mold cavity would be achieved. Filling and solidification modeling allowed predicting misruns and metallurgical properties inside the A356 (AlSi7Mg04) casting.INTRODUCTION Recent advancements in additive manufacturing enable foundries to produce molds without the tooling (pattern and core boxes) necessary when conventional technology is used (Eyad, 2016). This is particularly advantageous when dealing with intricate shapes and/or when a limited number of parts must be produced within a few days rather than in 5 weeks. An additional advantage is gained when producing prototypes (Johnson, 2016) as changes are much less costly and time consuming when made on a numerical 3D drawing rather than on patterns and core boxes. 3D printing is normally economical for a small number of parts; however, if the part is not too big and very intricate in shape such as the part that will be studied in the present work, 3D printing can be economical even for an important number of castings to be produced. On the other hand, low pressure casting is a high integrity casting process in which the mold cavity is filled from the bottom via a transfer tube in which the liquid aluminum rises under the pressure applied at the surface of the melt as illustrated in Figure 1. The filling can thus be precisely controlled, eliminating the turbulence created when the mold is filled from the top (gravity casting). Also, the pressure applied on the melt during solidification results in excellent feeding of the casting when conditions of directional solidification are met. In the present work, the compressor impeller shown in Figure 2 will be sand cast by low pressure."

Jan 1, 2018

By T G. Callcott

Australian coking coals are either class 434<tlj534<2l, at Port Kembla, or 634<3> at Newcastle. The former yield good blast-furnace cokes; the latter yield poor ones. However, increases in conventional strength indices, by methods applicable with normal coking ovens, seem unlikely to be economically attractive. Characterization of the coals has enabled an "economic" blend to be developed in the Newcastle area, and this has affected mining, preparation and handling operations. Coking studies have led to a specification for the making of strong coke, especially from the high-volatile Newcastle coals. Continuous coking studies, developed from the efforts to make very strong coke, have taken two directions. Firstly, coking thin layers of coal on strands; secondly, coking, in various types of vessels, compacts of coals with or with-out the inclusion of non-coking coals, iron ores or other inert materials. Gas, "sand" and hot metal coking have been tested for use in compact coking. Particular attention has been paid to pellets of coal and ore. The probable industrial problems in adopting any of the ideas are presently being examined.

Jan 1, 1963

"In conjunction with Banick Mercur , Wright Engineers Limited designed the first multi-stage aqueous pressure oxidation system in an alkaline environment in North America. A three-stage slurry heating and slurry pressure let-down with heat recovery was an innovative approach to the problem of high energy cost with the low sulphur content of the ore. The design of this system required solving a number of problems associated with heating and pumping of slurries at pressures up to 3230 kPa and temperatures in excess of 220°C. Wright received an Award of Merit in October 1989, from the Canadian Consulting Engineering Awards Committee in the Process Category for its design of the Mercur pressure oxidation system.The Mercur Mine is located at the south end of the Oquirrh Mountains in Tooele County about 65 miles by road from Salt Lake City, Utah, U.S.A. The original mill was designed to process 5000 tpd of oxidized gold ore in a carbon-in-leach (CIL) circuit. A new ore treatment system was required to treat the substantial quantities of refractory ore reserves which could not be treated economically in the existing mill. The new pressure oxidation circuit makes the refractory ore amenable to gold recovery by oxidation of the sulphides contained in the ore .Wright Engineers Limited was commissioned by Barrick Mercur Gold Mine Ltd ., a wholly-owned subsidiary of American Barrick Resources, to design the pressure oxidation facility. This followed completion of a feasibility study by Wright which showed that the project was technically and economically viable.Work on the feasibility study began in 1986, detail design commenced in February 1987, and was completed in December 1987. Mechanical installation was completed in January 1988, and slurry feed began in February 1988. The plant has operated since June 1988 without major interruption . Wright was responsible for engineering, procurement and construction management for the addition of the 750 tpd pressure oxidation circuit to the existing mill and also had commissioning responsibility.Major unit processes involved in the pressure oxidation facility are ore thickening, three-stage slurry preheating, pressure oxidation and three-stage slurry cooling with heat recovery, stearn generation, propane and oxygen storage and a video graphic display process control system were included in the scope as process anciliaries.The pressure oxidation increases gold recovery from the refractory ore by conventional CIL from as low as 35% to more than 86070. A patent has been granted for the process."

Jan 1, 1989

By B. Holaday, H. McLaughlin

Orano Canada Inc. (Orano) operates the McClean Lake mill, located in the Athabasca Basin region of northern Saskatchewan. It processes high concentration uranium ore, delivered in slurry form from the Cameco Corporation operated Cigar Lake mine. After the ore slurry is leached at the McClean Lake mill, the leach residue solids are washed in a process known as counter-current decantation (CCD). This process uses six thickeners to facilitate counter-current washing of solids with diluted acid, flocculation and settling, as well as pumping the washed leach residue to the tailings neutralization circuit (TN), and the uranium laden aqueous to the solvent extraction circuit (SX). Challenges in settling the slurry in CCD started in early 2017. This is largely due to the variation in fines content of the slurry (D80≤75μm), and clay content. There are several changes that have allowed the mill to adapt to the evolving challenges of settling leached Cigar Lake leach residue. Flocculant selection and mixing, temperature effects, bed level management philosophy, and centre-well feed density are key parameters that have been explored as part of adapting to changes in Cigar Lake ore quality.

Jan 1, 2020

By Bryan Wilson

Background ?Nickel Rim South Mine started production ramp-up in Q2, 2009. ?The main dewatering pumps were put into use in August 2009. ?3 Feluwa?multisafe?positive displacement pumps ?1700m single lift pumping ?Reliability has been an issue due to the amount of slimes and fibers (from shotcrete) at the pumps. ?Critiqued internal dewatering system to solve some issues we were having with our sumps Findings 1.Much of the final dewatering system was not in place. a)Temporary pain. Difficult to say something is not working when the system was not yet in place as per design. b)Not enough capacity to handle slimes within the system. 2.Need to address issues with the final design: a)Ongoing costs: The end design has operating costs of $2.5 million b)Scoops in Sumps: The end design relies on scoops to be used for cleaning the sumps c)Slimes Recovery: The system mixes 3 different products in the sumps along with the fibers d)Pump repair costs: The existing Tsurumi pumps are too light duty for our slimes

Nov 1, 2011

By Brian E. Robertson

"This paper summarizes work carried out at the Dome Mine to mechanize the mining of narrow veins of less than 1.5 m in width by the introduction of new mining methods and specifically designed electric LHDs.Extensive mining trials have been conducted using sublevel blasthole, modified Avoca, and resuing mining methods. The introduction of the Microscoop and the Jarvis Clark remote, radio-controlled scooptram has increased mucking productivity.As a result of this work, additional narrow vein stopes are now being prepared for production. In the future, narrow vein stoping wil lprovide a greater percentage of the total mill tonnage.IntroductionThe Dome Mine, which is owned and operated by Dome Mines Limited, is located at Timmins, Ontario. Production has been continuous since 1910 and in 1984 was increased from 1814 to 2721 tonnes per day.At least six distinct ore types have been recognized at the mine. In general, these orebodies can be broadly categorized into wide and narrow deposits. The wide deposits are approximately lenticular in shape and vary in width from 10 m to 40 m. The narrow orebodies consist of quartz and quartzankerite veins ranging in width from a few centimetres to six metres. The average dip of the veins is 65 degrees.Since the I970s, mining activity has been largely concentrated in the wider orebodies using highly productive open sublevel blasthole and mechanized cut-and-fill stoping methods. With the demise of shrinkage stoping in 1975, investigations were initiated to develop new mining methods and introduce LHDs - truly designed for narrow orebodies. These investigations resulted in test trials of the sublevel blasthole, modified Avoca, and resuing mining methods. Consultations with equipment manufacturers and suppliers led to the development of the Jarvis Clark remote, radio-controlled electric scooptram and the introduction of the France Loader Microscoop."

Jan 1, 1986

By ManhKha Trinh, Neal Pyke

Dofasco was the first company to adopt oxygen steelmaking in North America in 1954, two years after the first LD vessel installed and operated successfully in Linz, Austria. Since then, Dofasco has investigated and implemented several strategies to maximize hot metal usage and minimize overall cost. Some key strategies -low hot metal silicon, combined blowing conversion, vacuum degassing tank upgrade and BOF slag carryover control - are discussed. Post combustion, scrap preheat, carbon injection trials along with current operating philosophies are described.

Jan 1, 2004

By Alf Hartling

"Most of the Paleozoic section of the Williston Basin is a thick accumulation of numerous carbonate to evaporite, shallowing upward, cyclic sequences. These sediments were deposited in broad epeiric seas, and the deposition of the evaporite facies marked the final stage of each cycle. Many of the sequences display a pervasive replacement dolomite in the uppermost portion of the carbonate units. This secondary dolomitization is, at least in part, an early diagenetic event, synchronous with evaporite deposition.The inception of evaporite precipitation resulted in the seepage of a dense, Mg-rich brine into the underlying sediment. The heavy brine moved down the gentle regional dip displacing the more normal marine interstitial pore fluid and dotomitized the primary calcitic sediments en route. The supply of Mg-ions decreased away from the source, and correspondingly, the degree of dolomitization decreased and larger crystals formed because of slower nucleation at fewer sites.The seepage refluxion of dolomitizing brines gave rise to the frequently observed textural variation of cryptocrys talline, impervious dolomite grading into a finely sucrosic, permeable dolomite down-dip. This diagenetic facies change provides the critical up-dip barrier for potential hydrocarbon reservoirs. The lateral pool boundaries are controlled by either structural relief or a similar diagenetic facies change. The reservoirs are capped by the tight evaporites.Hydrocarbon production is attained from diagenetic traps in the Mississippian Oungre Zone and the Ordovician Red River &apos;C&apos; Zone . Reservoir creation and the pooling mechanism are the result of dolomitization by the seepage refluxion of dense, Mg-rich brines beneath restricted, hypersaline lagoons. When formulating an exploration/ exploitation program for these oil prone horizons, it is essential to understand the complete geological history in order to establish where the reservoirs will be found and to define the areal extent of each accumulation."

Jan 1, 1984

By T. Krumins, L. Zunti, R. Frischmuth

Mercury is known to occur in sulphide-bearing refractory gold deposits in the form of sulphide minerals or elemental inclusions. These deposits typically require an oxidative pre-treatment process, such as pressure oxidation or roasting, to achieve economic gold recovery. However, these processes also have the potential to liberate mercury, a portion of which may then be released to the environment through gaseous emissions. Mercury emissions from mine processing operations have been of particular interest in recent years, as governments impose lower emission targets and organizations adopt better industry practices to reduce the environmental and health aspects of releasing mercury into the environment. This paper describes various mercury removal technologies with respect to pressure oxidation gas handling circuits, with a focus on key design variables and technology selection criteria.

Jan 1, 2014