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By E. Rosseland

Glencore Nikkelverk is operating its Chlorine Leach Process in Kristiansand, Norway, producing nickel, copper and cobalt metals by electrowinning. The copper tankhouse, with an annual capacity of 40 000 tons, is based on traditional technology with copper starting sheets and cast lead anodes. Due to the integration of this copper sulphate process in a nickel chloride refinery, operating conditions are unique. In recent years, operating costs have escalated, and health, safety and environment are top priorities. Test work on a new copper process involving permanent cathodes was therefore initiated in 2007, and a pilot plant was started up in 2012. The objective was to introduce innovative technologies and tailor these to be robust in the Nikkelverk process, to form a basis for a new sustainable copper tankhouse with a high degree of automation. Key learnings from more than 10 years of R&D work is presented, focusing on cathode materials and copper metal deposition including product quality, robotic stripping, coated titanium anodes, electrode contacts and alignment, electrode current monitoring with Hatch HELM tracker technology and acid mist capture using cell hoods with off-gas scrubbing. The new copper tankhouse project was approved in December 2018, and commissioning is planned in 2022. INTRODUCTION The Kristiansand nickel refinery was started up in 1910, processing nickel-copper matte originating from Norwegian mines. It was the first industrial plant in the world to produce nickel by electrolysis using the Hybinette electrorefining process. After roasting to burn off sulphur in the matte, copper was leached and recovered as cathodes by electrowinning with lead anodes. In the first years, the copper cathodes were fire- refined and cast into ingots for sale (Thonstad Sandvik, 2004). The Nikkelverk refinery was acquired by Falconbridge Ltd. in 1929, and since then matte from Sudbury, Canada has been the main feed source. The Hybinette process was in operation until 1975 when conversion to the newly developed Chlorine Leach Process was started (Stensholt, Zachariasen, & Lund, 1986). In this process still used today, nickel and part of the copper in the matte is leached using chlorine gas generated on dimensionally stable anodes in the nickel and cobalt electrowinning tankhouses, as illustrated in Figure 1. The presence of dissolved copper ions in the strong chloride leach solution is essential for effective chlorine absorption and nickel dissolution. To improve copper-nickel separation, slurry from the atmospheric leach is pumped to autoclaves and then to cementation tanks for precipitation of copper as copper sulphide, which is collected in filter presses. The leach residue, also containing the precious metals, goes through a 3-stage wash to remove chlorides before being introduced as a slurry to fluid-bed roasters for sulphur removal. The resulting calcine is then leached in spent electrolyte from the copper electrowinning tankhouse, to dissolve most of the copper and also some nickel, cobalt and other elements. After separation of the leach residue, elements like Bi, Te, As and Ag are removed from the strong copper sulphate solution by reaction with metallic copper in three columns in series filled with cut copper cathodes. The purified solution then passes polishing filters before being mixed with spent electrolyte and returned to the electrowinning cells.

Jan 1, 2019

By C. S. Lord

"The Regal Silver mine is 5 miles north-northwest of Albert canyon; a station on the main line of the Canadian Pacific railway; 21 miles east of Revelstoke; British Columbia.Development, commenced in 1918, comprises more than 8,000 feet of workings from six adits, one of which extends into the Regal Silver property from the adjacent Snowflake ground. Production has been limited to a little tungsten concentrate recovered recently from a few r..undred tons of ore treated in a small underground mill. The property has received some attention as a possible source of tin. The deposits are large quartz veins containing irregular sulphide bodies. Ore minerals normally make up less than 1 per cent of the veins and include pyrite, galena, sphalerite, scheelite, and stannite. The veins are approximately parallel with the bedding of the enclosing graphitic, siliceous to calcareous, slates and argillites. These strata are of Precambrian age, strike about northwest, and dip northeast. No other rocks are known in the vicinity of the workings . Granitic rocks, intrusive into t'he sediments, outcrop 4 miles to the southwest and 7 miles to the northeast and may underlie the property at no great depth."

Jan 1, 1954

By Kamran Esmaieli

Open Pit Mining Through Underground Voids: Challenges Main Challenges/Hazards: Unexpected collapse of the pit floor and/or pit walls; The loss of equipment and/or people into underground voids; Loss of explosives from blast holes that broken through into the underground voids. How to address these challenges? An important step that must be integrated into mine planning and design is the accurate detection and delineation of underground voids. (i.e. probe drilling, Geophysical techniques, laser scanning,?); Leaving a pillar of adequate thickness between the working bench and the underground voids; Backfilling the underground voids from surface using vertical or inclined raises; Monitoring the working locations (pit floor and pit slopes) to detect movements.

May 1, 2013

By Y. Lizotte

"This paper examines the application of blasthole sloping to narrow vein mining in Canada, for ore deposits where widths are less than two metres. While the technique has now been utilized for more than ten years, it remains in the experimental stage and on-site testing is necessary for its adoption at new mining operations or in differ¬ent geological settings. It is intrinsically a safer method than other narrow vein methods in current use.The investigation describes the main operating parameters for mines recently surveyed. The criteria for method applicability are defined and the problems encountered are studied. It is concluded that blasthole sloping for narrow vein mining is a viable modern method which promises to gain popularity and that emerging fragmentation technology and blasting research can be used to further increase applicability of the stoping method."

Jan 1, 1991

By Marc C. Betournay, John E. Udd

"In this study, the authors investigated the stabilities of slopes cut predominantly into Trenton limestone in a large quarry in the Montreal region. Analyses of the bench and pit walls indicated that small-scale toppling, ravelling, and wedge failures are the most likely modes of instabilities. Because most of the joints dip steeply, however, the conclusion was made that relatively high walls could probably be justified.The field investigations were supplemented with the determinations of the shearing strengths of artificial discontinuities that were cut into samples of the limestone. The properties of a fine-grained limestone were found to be influenced very much by the magnitudes of the loads that were applied, while the properties of a crystalline limestone were found to be much less, or not load-dependent.The study is one of a number that are being conducted in this area.IntroductionExtensive quarrying has been done in the sedimentary strata of the Montreal area for a very long time. By any standards, it can be said that the Island of Montreal is a major mining area. At present, approximately 20 quarries are being operated in, or near, the city of Montreal.In addition to the millions of tons of limestone that are removed each year, a large number of excavations for foundations are cut into the sedimentary rocks.To date, however, very little information has been published concerning the engineering properties of the local geological materials. No mention is made of this aspect in the references which are presently available.Because of this lack of information, the senior author has initiated a study in which the strength properties of most of the rock types, and of the natural discontinuities contained in these, would be investigated. To date, the results of one other investigation have been published and other work is in process. It is hoped that the end result will be a comprehensive knowledge of the important strength properties of all of the rocks in the entire region."

Jan 1, 1983

By Kenta Suzuki, Toshiya Anami, Daisuke Shimosaka

"In an Al-Mn alloy heat exchanger fin stock, the effect of annealing conditions for as-cast and 0.1%Zr addition on recrystallization behavior is investigated using metallurgical analysis. Refinement of post-brazed recrystallized grains in fin stocks with Zr addition are suppressed for long-time annealing. In 0.1%Zr fin stocks, there was a decrease in the number of fine a-Al(Mn,Fe)Si dispersoids for pinning of sub grain and grain boundary. In addition, relatively homogeneous distribution of Al3Zr dispersoids was observed with increasing annealing time in as-cast. Homogeneous distribution of Al3Zr dispersoids can have a major effect on pinning of sub grain and grain boundary during brazing heat treatment. The homogenous distribution of fine dispersoids prior to brazing heat treatment is effective in causing the suppression of refinement of post-brazed recrystallized grain structure in aluminum alloy fin stocks.INTRODUCTIONAl-Mn based alloys are widely used as fin stocks in automotive heat exchangers because of their superior mechanical properties, braze ability, sagging and so on. In particular, coarsening of recrystallized grain structure is beneficial to avoid erosion, and achieve excellent sagging resistance (Lee, Yoon, Kim & Jung, 2002). For resisting grain coarsening, the alloys should contain a dense and homogeneous distribution of fine dispersoids to retarder crystallization (Humphyreys& Hatherly, 2004). It has been demonstrated that addition of Zr to Al-Mn alloys can shift recrystallization to higher temperatures because of the distribution of fine Al3Zr dispersoids in matrix(Pokoba, Cieslar& Lacaze,2012). According to Tohma, Asanoand Takeuchi (1987), coarsely recrystallized grain structure was obtained in 3003alloy with Zr addition after heat treatment. However, fine Al3Zr dispersoids are usually heterogeneously distributed because of segregation during casting and low diffusion rate of Zr in aluminum. Therefore, a homogeneous distribution of Al3Zr dispersoids can be achieved through long-time precipitation annealing(Jia, Hu, Forbord& Solberg, 2008)."

Jan 1, 2018

By B. M. Das, F. Claridge, V. K. Garga

Coal, as well as a large part of other minerals in Canada, is produced by surface mining methods. This has resulted in short and long-term accumulation of waste rock in dumps. Two main problems arise from the flow of water through these dumps: stability of dumps and the impact on stream flows. In recent years, a number of mines have started placing waste rock in valleys for general disposal or far constructing mine access road ways. All these have created challenges in the following areas: effective design of dumps and flow-through dams; stability monitoring of the structures; environmental impacts downstream by way of increased amount of fines in suspension, sedimentation, and toxic substances; and long-term status of flow and flood. Similar situations also exist in many civil engineering structures. This paper discusses the status of rock drains and the immediate and future research needs.

Jan 1, 1990

By V. Casaletto, L. Widdifield

"Equipment capable of higher production requires more sophisticated maintenance programs. Reduction in fleet size through use of modern technology requires higher utilization and greater availability.Caterpillar's maintenance control system program will display the capabilities of computer technology in a maintenance environment. Utilizing such resources will provide increased availability, lower inventory requirements, fewer last minute disasters, and lower cost per ton for maintenance. High production from premium quality equipment can only be realized by good planning and care, executed by maintenance and operating personnel acting cooperatively.IntroductionAccurate information is the key to accurate decision making. In today' s competitive industry, mines' teeter on the brink between profit and loss. Their survival will be predicated on their ability to retrieve, analyze, and formulate accurate information regarding the operating costs of mobile equipment. This paper deals with the impact of managing equipment operating costs and introduces a computerized control system designed for monitoring and controlling these costs.Caterpillar has produced several computerized modelling programs designed at taking the guesswork out of equipment selection and management. The most basic of these is Equipment Investment Analysis (E.LA.). This model compares two or more alternatives over the projected life of the machine. It deals with comparisons in the owning and operating costs of equipment, as well as, their productivity over a specified period of time.In order for a computer model to be credible as a decision making tool, it must be simple to use and the results measurable and accountable . Caterpillar has introduced several computer models to assist the industry in selecting and managing an equipment fleet. These programs allow the user to predict and monitor the operating costs and production capability of mobile equipment. They are often used in the machine selection process to select equipment which best suits a mine's long-term cost per tonne objectives. After the optimum selection is made, Caterpillar's Maintenance Control System provides an efficient management tool to monitor and verify the data used in the selection model."

Jan 1, 1992

By R. E. Molnar, P. A. Riveros, V. M. McNamara

"This paper describes some recent research done at CANMET in the areas of ion exchange and A VR (Acidification- Volatilization Reneutralization), as applied to the recovery of gold and cyanide, respectively. It also discusses the ways in which these two technologies may be combined in order to minimize the environmental impact of gold milling operations and optimize reagent usage. IntroductionGold milling operations can essentially be divided into those that carry out a liquid/solid separation after leaching and those that recover gold directly from a leach pulp. The former produce a barren solution which may contain considerable amounts of cyanide, either free or cornplexed with metals. The latter produce a similar solution but this is now part of a slurry rather than a clear stream. Due to its toxicity, any excess cyanide must be destroyed before the effluent is discharged into the environment. Ideally, this should be (and sometimes is) accomplished by natural degradation. However, in many cases natural degradation alone cannot remove the last traces of rnetallocyanide compounds from the effluent and , as a result, most Canadian gold producers utilize a supplementary chemical oxidation system. This not only increases the operating costs, but concerns have also arisen in recent years about the formation of ammonia as a result of the chemical oxidation of cyanide (via CN--CNO--HCNO-NH3) ·"

Jan 1, 1993

By A. Mukherjee, C. Kelly, B. Markovich, G. E. Agar, G. E. Robertson, F. Khan, B. Shea

"Laboratory batch flotation tests were performed on a sample of bulk slow cooled converter matte (Cu:Ni = I) to optimize the time in each of the separation stages. Numerical simulations were carried out to estimate a continuous circuit material balance for the conditions selected. An experimental simulation of a continuous circuit (locked cycle test) readily came to steady state and there was reasonable agreement between the numerical and experimental results. The use of nitrogen as the flotation gas and the addition of collector to the grinding mill minimized the oxidation of chalcocite, which has previously resulted in increasing circulating loads, and led to a stable circuit with very low weights in the recycle streams.IntroductionINCO Limited developed a flotation process for separating the components of copper-nickel matte [Sproule, Harcourt and Rose 1945; Sproule, Harcourt and Renzoni 1960] in 1945 to replace the Orford process and continues to use the flotation process in almost the original mode to this day. Initially the matte processed was the result of smelting a nickel concentrate that analyzed about 12% nickel and 2% copper and all of the recycle material that was generated in the smelting process. The matte generated analyzed about 25% copper and 53% nickel, roughly 2: 1 nickel to copper. This matte was blown in Pierce-Smith converters to be sulfur deficient in order to produce a metallic phase that collected the precious metals contained in the smelter feed [Wilson and Stratton-Crawley 1991]. This process continued with little change until 1994 when the separation of chalcopyrite from pentlandite in the Copper Cliff mill was discontinued after 63 years of operation. As a consequence of the elimination of the primary separation of chalcopyrite from pentlandite in the milling process a bulk concentrate was produced for smelting. Bulk concentrate smelting came into practice in 1994 as part of the initiative to meet government legislation that restricted the emission of sulfur dioxide to the atmosphere. Previously, the copper concentrate was smelted in an INCO oxygen flash furnace which resulted in the capture of a high strength sulfur dioxide stream from which liquid sulfur dioxide was produced. Nickel concentrate was smelted in reverberatory furnaces that produced low strength sulfur dioxide gases which were difficult to treat. The action taken by INCO to meet the environmental constraints was to smelt a bulk concentrate in oxygen flash furnaces which would produce gases suitable for the production of liquid sulfur dioxide and another stream that was high enough in sulfur dioxide to be readily converted to sulfuric acid [Bell et al 1990]. The end result of this decision was that all the copper-nickel separation would be done in the matte separation plant."

Jan 1, 1996

By P. M. STILES

Acquired in 1957, the limestone quarry of Ideal Basic Industries on Texada Island north of Vancouver has become a major supplier of high purity limestone and construction stone. Crushed limestone products are shipped by barge to various destinations along the B.C. and northern U.S. coasts.

Jan 1, 1984

By Barry James

"This paper discusses past and current energy use patterns in the mining and manufacturing sectors of the industrial minerals industry. Information is presented on the primary energy input types as purchased by the industry, the quality and form of the energy actually required by the various production processes, and the residual form of this energy, either embodied in the product or rejected in gaseous and liquid waste heat streams. With the continuing concerns about the availability of energy combined with the rapidly increasing cost of energy as a production input, the reduction of energy usage through improved efficiency will undoubtedly be an increasing priority for the industry during the 1980s. Reduced energy consumption through investment to improve energy efficiency appears to be advantageous from both the corporate and national perspectives.IntroductionEnergy, like labour and materials, is one of the basic production input s to the various mining, processing and manufacturing production stages in the industrial minerals industry. Energy costs, as a percentage of total production costs, have been well above the average for industry in Canada, accounting for more than 50 cents out of every dollar in the most extreme cases. Consequently, energy has always been a relatively important management concern in the industrial minerals industry.The energy supply and price situation in Canada and internationally has been changing rapidly since 1973, following a long period characterized by declining real energy prices and an abundance and wide choice of energy supplies. It is generally accepted that energy prices will continue to increase rapidly, and that there will be uncertainties about the long-term continuity of supply of some energy types. In essence, a period of relative stability has been replaced by a period of relative uncertainty. In such a changing situation, a reassessment of the role of energy as a production input is appropriate.The following sections outline some of the effects of the changing energy scene on the industrial minerals industry. These effects are dealt with primarily in terms of energy costs, because, in most circumstances, a change in the cost of energy as a production input is the end result of both energy price and energy supply changes."

Jan 1, 1981

By T. B. Armstrong

"The energy situation is extremely fragile and there is a critical need for energy conservation in the short term and development of new technology in the long term. To keep tabs on energy flow, separate electrical metering is being installed in major industries: The first step reduces demand through peak load control; the second reduces the waste of energy by monitoring energy used per unit of production. IntroductionThe current energy situation is best described as being extremely fragile. The supply of hydrocarbons is being exhausted, while energy needs remain the same in the industrialized nations and are increasing in the Third World.The petroleum era is expected to come to an end in this century, as there will no longer be enough. Gas, coal and electricity will replace some oil as it becomes scarcer during the transitional period before new sources are gradually developed.There is a critical need for energy conservation in the short term. Conservation will, to a great extent be justified by savings, as it will be less expensive to recover energy that is being wasted than to acquire additional energy.The gradual development of new technology is expected to increase energy self-sufficiency in the long term. New energy sources are attracting a growing interest and are becoming more economically feasible and marketable. These rediscovered energy sources include peat, wood, solar, domestic waste and windmills.The sudden increase in energy prices has forced users to look at the way energy is used and find ways to save it. Major industries have found that using separate meters for each department spurs energy responsibility. Energy trim programs now rank in importance with profitability, productivity and with quality.Energy has become such a crucial cost element that better data are essential for planning. Data acquisition varies with plant size and number of utilities. Meters can be read manually or monitored by computerized energy management systems.The relationship of electrical energy input and production levels for a typical uranium mine will be used to demonstrate two steps to energy management. The first step reduces demand through peak load control; the second reduces the waste of energy by monitoring energy used per unit of production.The direct benefit of saving energy is the money saved."

Jan 1, 1980

By Steve Scott

Outline of Talk Seafloor Massive Sulfides (SMS) and Seafloor Sedimentary Sulfides (SSS) Ocean mining of SMS (Nautilus Minerals) Environmental issues Summary

May 1, 2013

By E. P. Wiechrnann, C. M. Castro, G. A. Vidal, F. A. Muñoz

Different authors and publications indicate that Optibar Segmented Intercell Bars cause a remarkable distortion in the distribution of the current in a cell group. However, these results were based in inaccurate computer based models and do not represent the technology. During the last trimester of 2010, a 92 cells circuit from Barrick Zaldívar EW plant was implemented with Optibar Segmented Intercell Bars. The technology was incorporated progressively without disrupting the plant production. Depending on operational conditions, this led to a 2 to 4% current efficiency increase and 3 to 5% specific energy consumption reduction. By October 2011, 40,000 tons of copper will be produced with the technology.

Jan 1, 2011

By P. Reyes

The start up and operational optimization of the No. 3 Oxygen Plant at the Caletones Copper Smelter of the Codelco - Chile El Teniente Division is summarized. In addition, the economic impact of such optimization on the production cost of oxygen and others aspects associated to the operational robustness as well is detailed.

Jan 1, 2007

By H. Warren Newcomen, Dennis C. Martin

"This paper describes the investigation of a large, progressive slope failure on the southeast wall of the east pit at Highmont Mine, British Columbia Geotechnical investigation s consisted of geological and structural mapping, assessment of blasthole drilling records, review of rock core information, slope movement monitoring and back analysis of various possible failure modes. Climate records and mining history were also assessed to determine their relationship to slope movement .Analysis of movement monitoring records and geotechnical information indicates that the failure is deep seated. The upper portion of the failure surf ace occurs along clay filled discontinuities. The lower portion of the failure surf ace appears to occur through the highly altered rock mass. High groundwater pressures and mining at the toe of the slope are documented to have had a major influence on stability at various times during the failure. Stability analyses results are presented and possible remedial measures are discussed.IntroductionHighmont Mine is located near Logan Lake in the Highland Valley approximately 50 km southwest of Karnloops, British Columbia (Fig. I). Mining of the porphyry copper and molydenum ore bodies began in 1980. In May, 1983, when mining in the east pit had progressed to a depth of about 60 m (200 feet) , a failure (designated the Southeast Failure) began to develop in the southeast corner of the east pit. Subsequent mining to a depth of 110m (360 feet) was accompanied by frequent and substantial slope movements involving between 500000 and I 000 000 m3 of rock . The slope was monitored extensively to assess short-term movement trends for operational safety. Geological mapping, core logging and rock mechanics testing were used in conjunction with the long-term monitoring information to determine the failure mechanism, conduct stability analyses, assess the effects of instability on pit design and enable design and installation of remedial measures."

Jan 1, 1988

By Tibor Horvath

Dust abatement is possible on bulk materials, whether conveyed or stockpiled. Minimum (ppm) quantities of chemical additives can efficiently and rapidly control dust of conveyed substrates with no effect on floatation chemistry. Top coating of large surface areas can control surface dust and wind erosion. Environmental and toxicity impact must be considered in any treatment, especially on areas with percolation runoff, leachates, or limited containment. The most effective dust control is preventing release of substrate fines rather than trapping and removing air borne dust. Techniques to prevent release of fines from conveyed substrates will be discussed. Dust control dynamics are a very complex combination of solid phase physical and chemical interactions between the substrate and the fines. ?Smart Technology? products permit dust abatement of stockpiled substrates and tailing fields with no environmental impact. Using ?Smart Technology?, the dust abatement products remain active and can re-seal damaged areas. Efficient, low environmental and toxicity impact, dust control will be demonstrated through case studies where these principals have been applied.

Oct 1, 2010

By T. Yalcin

"This paper describes a study carried out to determine the behaviour of Cu-Ni mill tailings during natural and flocculated sedimentations. Settling rates were examined under various conditions through standard laboratory batch settling tests. Flocculation was found to improve the sedimentation process significantly, but its effectiveness depended on several factors such as the pulp density of feed, the type and dosage of flocculating reagent, the pH of pulp, the intensity of mixing flocculant with tailings sand the use of stirring during compaction.It is shown that. for a sedimentation process taking place under given conditions, underflow pulp density (P) and sedimentation time (t) are related by the expression P = k.tn, where k and n are constants. A procedure is described for the use of this expression in thickener size estimations. IntroductionOften a considerable proportion of the mill feed is disposed as tailing, because the valuable mineral recovered usually forms a small fraction of the ore. Moreover, wet concentration processes result in liquid wastes that are several times more voluminous than the ore itself. Thus the handling and disposal of these wastes become an important cost item in most milling operations. The principal unit process employed in tailing disposal is solid-liquid separation which is traditionally carried out by gravity sedimentation in thickeners or tailing dams. Direct disposal of tailings into tailing dams is common practice where sufficiently large areas of land are available but it frequently becomes more economical or practical to densify the tailings in a thickener beforehand.Successful thickener operation depends essentially on correct thickener size which is in turn governed by the sedimentation characteristics of the tailings handled. Flocculation can aid the sedimentation process and bring about significant savings in thickener size, but its effective use requires a detailed study to identify the optimum conditions of application."

Jan 1, 1988

By Yve Fourmanoit

"This paper discusses the exploitation of shallow underground deposits in a very altered geological environment. The methods, their adaptation to local conditions, their evolution, dilution control and recovery of mineral reserves will all be dealt with.The recovery of the B zone crown pillar under 40 m of till that was originally saturated with water, is of particular interest.Future underground development and production start-up of the A-2 zone, organization of mining operations, mechanical services, group incentives and safety practices will also be given.IntroductionThe underground deposit of B zone is not very deep. A 300 m shaft provides access to the mine. In addition , exploitation sublevels are developed every 20 m and are linked by a service ramp. The overburden located on top of the deposit is 40 m thick and is composed of a very dense till.A detailed work plan was initiated to permit mining under the overburden. To do so, it was imperative that efficient methods be developed. At a time when an accident at the Belmoral Mine shook the mining world , it was a task to convince provincial authorities that it was safe.While B zone was being mined , development began in the A-2 zone deposit which has recently been put into production (Figs. 1 and 2).The intention of this paper is to provide an outline of the mining method s and their particular aspects. To do so, some of the mine services are described and a brief outline of the under ground department is provided."

Jan 1, 1990