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By A. Mellek, M. Pischtschan, M. Perrucci

ABB has received an order for one of the most challenging mill drive projects in its history. With one SAG mill and one ball mill to be added at an iron ore mine in Sweden, the customer’s plant managers wanted to have the most efficient solution for driving their mills but had the budget limitations typically faced by the majority of mining companies during periods of market downturn. To find the best balance between cost of acquisition and highest performance throughout the lifetime of the plant, ABB was selected to deploy a synchronized bypass solution, in which only one drive system is used for two different mills in series. However, being one of the first grinding mills in the world with such a solution was not the only challenge the ABB team faced: The inclusion of some mill application functions - e.g., frozen charge protection, automatic positioning and creeping mode - brought the demands on the engineers to another level. With only one frequency converter and one mill application controller available, the configuration logic and interlocks had to be meticulously designed and thoroughly tested to ensure a smooth and safe startup. The solution offers a footprint reduction and more operator flexibility at a reduced investment as each mill can be run in both directions, and wear on the mechanical components can be greatly reduced due to ABB’s premium ring-geared mill drive (RMD). This paper will describe the details of the project, the configuration developed and the tests performed to guarantee correct software functionality. Mill startup is scheduled for January 2016.

Jan 1, 2016

By J. Zachwieja

As part of a general review on study of surfactant blinding agents to improve gold recovery during cyanide leaching of carbonaceous gold ores, processes of CIL and RIL leaching using surfactants were investigated. When refractory ores were treated by surfactants, CIL and RIL leaching processes yielded significant improvement on gold recovery. This paper will discuss and compare the laboratory results from two different leaching processes on preg-robbing ores, as well as, illustrate the difference of potential fouling of the blinding agents on activated carbon and resins.

Jan 1, 2015

By C. A. Biley

"A dedicated iron removal stage was installed at Anglo American Platinum’s Rustenburg Base Metals Refiners (RBMR) during an expansion project which began execution in 2010. The Pressure Iron Removal (PIR) process aims to precipitate iron from a nickel leach solution under medium temperature (145 °C) oxidative conditions using caustic for neutralisation. Since commissioning, the process has been robust in removing iron from the refinery but has shown significant variability in the residues produced. These residues, which are typically comprised of ferrihydrite, hematite or natrojarosite, have varying iron contents and different physical properties which have implications for their filtration and ultimate removal from the refinery. Since over 95% of nickel plated at RBMR passes through the PIR section, volumetric constraints caused by poor filtration performance directly influence nickel production and stabilisation of this process remains central to the continued ramp-up of the refinery to full nameplate capacity. This paper details the development of the PIR process and the journey from concept to implementation. Recent laboratory and plant scale tests have highlighted the importance of the initial phase formed in the autoclave for the ultimate residue requiring filtration and how the feed acid concentration is a critical control parameter. On this basis, a new caustic dosing philosophy was implemented which improved pH control in the autoclave. Further optimisation of the PIR process is on-going.INTRODUCTIONIn 2010, an expansion of Rustenburg Base Metal Refiners (RBMR) to increase nickel production from 21 to 33 ktpa began execution. The management of iron was pivotal in the ultimate configuration in the new circuit and one of the primary differences from the original circuit was the addition of a dedicated iron removal stage: Pressure Iron Removal (PIR). A significant drive for this new unit operation was to facilitate the separation of iron from other leach residues. Not only did this result in a significant decrease in the amount of leach residue but, without the constraints associated with iron precipitation during leaching, has permitted more aggressive leaching conditions and, correspondingly, greater throughput and efficiencies.However, as with many commercial implementations of even mature technologies, the journey from development to implementation has presented challenges for the continued ramp-up of the refinery to full nameplate capacity. Specifically, since all nickel bearing leach solution must pass through the PIR section prior to the nickel purification and recovery circuit, throughput difficulties in the PIR section can directly impact supply of feed to the nickel tank house. Since commissioning, the PIR autoclave has effectively removed iron from the refinery, but has shown significant variation in the solids phases produced in the autoclave. This variation presents difficulties for the filtration of the discharge slurry and represents a key throughput limitation which periodically impacts production. Additionally, the increasing production rates associated with the ramp-up of the refinery have resulted in a significant increase in the required volumetric throughput through the PIR process. This has placed even greater emphasis on improving the stability of the solid phase produced in the autoclave, ultimately targeting an easily filterable residue with high iron content."

Jan 1, 2016

By M. Cossette, V. H. Tran

"How can the durability of asphalt pavement be doubled without increasing highway budgets? Asphalt containing asbestos can provide the desired performance with additional costs being made up by longer life. The addition of a low percentage of asbestos to an asphalt mix permits a higher asphalt content without any consequent loss in stability. It is mainly the higher asphalt content that provides improved performance and durability, although the fibrous reinforcement plays a key role in preventing the propagation of micro-fissures. As well, several international studies show that, thanks to the latest production techniques, no environmental hazards need be incurred.RésuméComment doubler la durée des chaussées d'asphalte sans augmenter les budgets de voirie? L’asphalte contenant de l'amiante peut offrir les performances souhaitées et l'augmentation des couts initiaux peut être rapidement compensée par une durée prolongée. L’addition d'une faible teneur en amiante courte il l'enrobe de bitume permet des teneurs en bitume plus élevées sans subir une perte de stabilité en conséquence. C'est principalement la teneur accrue en bitume qui assure un améliorations propriétés physiques et une augmentation des performances mécaniques, ainsi qu'on prolongement de la durée. Cependant, le renforcement fibreux joue un rôle clef en prévenant la propagation éventuelles micro-fissures. Les nouvelles techniques évitent tous risques environnementaux"

Jan 1, 1991

By Kosta Fytas, Nour-Eddine Chaouai

"Selection of the appropriate kriging plan during indicator kriging estimations is of a paramount importance to the precision of ore reserve estimation. However, very little is known on the sensitivy of indicator kriging results when changing the kriging plan parameters (mainly search distance and number of samples). This paper evaluates the effect of the search distance and number of samples on indicator kriging results using a gold deposit as a case study.IntroductionBlock estimation using kriging is based on the autocorrelation function (variogram) on one hand and on the kriging plan on the other. As far as the variogram is concerned it is more or less subjectively adjusted and this is reflected on its parameters (range, sill, nugget effect and anisotropy). The effect of a poor estimation of these parameters on the kriging variance of ordinary kriging has been proven very important (Brooker, 1986). Choosing a kriging plan is generally a difficult matter depending on the estimation type (global or local). Generally there is not a unique kriging plan be cause there is not a unique structural analysis (variogram). There are no rules or dogmas in choosing a kriging plan but it is rather a function of the sampling pattern (David, 1982).Structural analysis requires the hypothesis of quasistationarity but very often either the data available within the zone of quasi-stationarity are too many so that the search distance is reduced during kriging or the data are too few to satisfy a stationary kriging system (Journel and Huijbregts 1978). As a rule, the larger the neighbourhood, the more precise the estimates should be , but for large neighbourhoods the hypothesis of stationarity does not always hold (Rivoirard 1987; Armstrong and Champigny 1989)."

Jan 1, 1991

By T. P. Johnson, A. Vathavooran

"Conventional mining operations can produce a wide range of wastes containing gold and other precious metals but which are less suitable for processing by traditional methods. There are also types of ore that do not fit easily into a traditional processing flowsheet, e.g. because the refractory nature of their minerology or the combination of valuable metals is less suitable for traditional processes. Nevertheless, these potential sources of valuable metals remain unexploited resources that have attracted growing interest in the metals and mining industries over recent years. The challenge is therefore to develop and use alternative processing methods that have the flexibility of operation to cope with a wide variety of material types and tonnages, whilst providing high recoveries for valuable metals. Tetronics’ DC plasma smelting technology achieves industry-leading recovery rates for precious metals from a wide range of input materials and initial precious metal concentrations, whilst generating an inert slag-based material as a by-product (even when starting from a hazardous waste input material), approved within the EU for use in construction applications. This paper describes how this technology can be used as a key part of an overall process for the recovery of precious metals from these interesting materials.INTRODUCTION The extraction of gold from its ores by various forms of cyanide leaching has been practised by the mining industry for over a century (Minerals Council of Australia, 2005) and it remains the primary extraction method in a wide range of mining operations. The ability of cyanide to extract gold efficiently and quickly from lower grade ores without extensive additional processing, coupled with well-known methods to recycle the cyanide for re-use within the process mean it is often both the most economically preferable and environmentally acceptable method for recovering gold. As a result, 88% of all gold produced from mines in the USA in 2014 was recovered via leaching of open heaps or dumps (UGGS, 2016). Nevertheless, there are occasions where certain combinations of mineralogy and other circumstances reduce the effectiveness of cyanidation techniques, so that ever more elaborate additional processing steps are required, with inevitable increases in operating costs (Swash, 1988). In these circumstances, which are likely to be more common in future as ore qualities diminish, other methods of extraction may offer better alternatives. Whilst much less commonly used for Au extraction at present, pyrometallurgical methods are amongst the longest-established of these alternative approaches and merit serious consideration in such cases."

Jan 1, 2017

By A. Khan, C. Ciriello, W. Oliveira

"The purpose of this paper is to demonstrate the value of Operational Readiness (OR) in the successful delivery of capital projects. OR can be captured using several technical and practical definitions:• To ensure that the capital project being delivered is capable of an effective start up, ramp-up as planned and a sustainable productive operation.• To function as intended when started, with the appropriate people able to run it.• To increase the value in delivering the product/service through established systems, processes and procedures, while simultaneously minimize risk to both the project and the business.Historically, mining and metallurgical capital projects concentrate efforts on cost and scheduling during the implementation and design phases. The completion and subsequent handover of the operational unit is the main objective.When reviewing the mining and metallurgical industry’s capital projects, it seems many poor results and errors in terms of project design and ramp-up are self-inflicted, with the project neglecting to account for key aspects of the future operational plant. Interestingly, if the problems for the future plant occur during project implementation, they can be prevented during the project phase. It is required to connect the operational knowledge with the project in order to ensure an effective start up and operation.The benefits of OR will be shown to be applicable not only to mining capital projects but also to sustaining and business transformation projects. The paper also includes industrial examples showing both proper and improper use of OR techniques.The paper will cover 3 main areas of Operational Readiness: the OR model, OR related risk elements (i.e., risks associated specifically with the improper execution of OR) and conclude with OR specific case studies."

Jan 1, 2016

By Donald Roberts

"Parameters f or design and development of an emergency hoist system (Fig. I) were submitted to Timberland Equipment Limited of Woodstock, Ontario by the Potash Corporation of Saskatchewan Mining Limited.The unit is the first of its kind in Canada. Not only does it comply with the province of Saskatchewan's mining regulations, but has the added advantage of being completely mobile and self-contained.As well as being useful in the mining industry, the mobile hoist unit could be used in other emergency situations such as rescuing people trapped in wells.JustificationRevisions to the Mines Regulations under Section 13 of the Occupational Health and Safety Act, 1977, of the Province of Saskatchewan stipulate as follows:"" Section 410 .04(4) The Mine Employer shall make adequate provision at every mine where any worker is hoisted in a shaft not equipped with a manway to enable an y such worker trapped in a conveyance in the shaft to be rescued . "" It was not possible to equip the shafts at PCS Mining' s Divisions with "" manways"" and therefore an alternative was required.BackgroundThe Potash Corporation of Saskatchewan Mining Limited, a subsidiary of the Potash Corporation of Saskatchewan, operates four potash mines. Of these, three, Cory, Rocanville and Lanigan Divisions are wholly owned while the fourth, Allan Division, is 40% owned by Kidd Creek Mines Ltd., but managed by PCS Mining. The four underground operations all have a service and production shaft.From 1979 to 1981 the PCS Mining Division, along with Central Canada Potash, were developing an idea to use the existing ground-mounted timberland hoist at Lanigan as an emergency hoist. This hoist was used in the past for rope-up work at both Rocanville and Lanigan and other potash mine s. The Department of Labour at this time had concerns about the time it would take to load, t ran sport and re-install the hoist on a foundation when needed for an emergency. Weight and size made this particular unit very cumbersome for transporting.In addition, the speed at which this hoist operates is too slow for rescue work. When the Department of Labour expressed concern that this unit would be unsuitable for these rea sons, a search for a suitable unit was initiated.The project responsibility for procuring an emergency hoist for the Potash Corporation of Saskatchewan Mining Limited was assigned to the author, a shaft/ hoist specialist a t PCS Mining."

Jan 1, 1986

By C. Schlumberger

INTRODUCTION The object of the present paper is to discuss, from a geological point of view, the practical results obtained by the authors with the method of the 'resistivity map of the subsoil' in the study of various mining problems. Some of the studies described date from 1920, 1922, and 1923. They are, therefore, quite old, at least as far as geophysical research is concerned (1). Others, on the contrary, are very recent (2). We shall deal only very briefly with the theoretical and technical sides of the processes employed. This paper has, essentially, a practical purpose, and it has seemed unnecessary to enter into a detailed discussion of the methods. Such a discussion cannot be presented without introducing ,quite. Complex considerations both of mathematics and experimental physics, which interest only the geophysicist: whose work is highly specialized.

Jan 1, 1931

By Xiaoqi Sun

"Rare earth elements (REEs) have a series of specific properties making them invaluable in products including lighting, electronics and magnetism. The elements have been used in many commercial products, for example, turbines, electric vehicles, batteries, lighting, computers, cell phones and lasers. Heavy REEs are attracting the interests of scientists from many countries, and these elements have become critical to develop high-tech materials. Ion-adsorbed rare earth deposits were first discovered in China. The minerals are also called weathered crust elution-deposited rare earths. The particular types of deposits are distributed throughout southern China. The ion-adsorbed deposits are rich in medium and heavy REEs, accounting for more than 80% of the world’s total medium and heavy REEs production. However, the separation of heavy REEs from ion-adsorbed deposit is difficult owing to their similar chemical properties. The conventional separating technologies have caused serious pollution. A novel extraction strategy has been developed in this laboratory and is presented herein.INTRODUCTIONThe unique properties of rare earth elements (REEs) render them important in high-strength magnets, lighting phosphors, polishing compounds, and ceramics. Especially for applications that take advantage of the f-orbital electrons, substitutions outside the REE family are often difficult to impossible (Nassar, Du, & Graedel, 2015). Extracting and separating individual elements from mined ore is not easy, requiring lengthy operations to separate them, and this results in high costs and adverse effects on the environment. The low concentration of REE in the earth’s crust makes economic exploitation difficult (de Boer & Lammertsma, 2013) and the sustainability of the REEs separation industry has aroused considerable attention (McLellan, Corder, Golev, & Ali, 2014). To eliminate protons and break the dimmers in organic phosphonic acids or carboxylic acids, the saponification of acidic extractants by acid-base neutralization reactions are widely used in industrial REEs separation (Sun, Luo, & Dai, 2012a). The saponification procedure contributes to increased extractability and selectivity of acidic extractants to a considerable extent. The common industrial saponification mechanisms and technological processes are shown in Figure 1 and include ammonium saponification (saponified by NH3·H2O), sodium saponification (saponified by NaOH), calcium saponification (saponified by Ca(OH)2), and magnesium saponification (saponified by MgO). These inevitably result in wastewaters containing NH4 +, Na+, Ca2+ or Mg2+ because of the cation-exchange extraction mechanisms (Xiao, Long, Huang, Feng, Cui, & Wang, 2013; Song, Fu, Wang, Liu, Zhou, & Li, 2014; Sun & Waters, 2014)."

Jan 1, 2016

By G. T. Lapidus, A. Garcés, O. J. Restrepo

"Colombian nickel laterites have historically been processed by pyrometallurgy. However, due to the depletion in ore grades, alternative processes are required. Hydrometallurgical processes, such as pressure acid leaching, have been proposed as alternatives to extract nickel from deposits with suitable characteristics. Such a leaching process requires high concentrations of acid to achieve acceptable extractions, and is not selective. In this study, an alternative aqueous alkaline glycine system has been employed to evaluate the leaching behaviour of a Colombian nickel laterite which contains 1.15% Ni, 0.12% Co and 41.1% Fe. Additionally, the effect of the addition of chloride ions, the use of a reducing agent and the application of a pre-treatment to improve the extraction of nickel were evaluated. Extractions of 4.63% Ni, 42.16% Co and 0.33% Fe were obtained using a 1M solution of glycine at pH 9. In addition, an increase in nickel extraction from 4.63% to 25.68% was achieved by applying a pre-treatment to the sample. The results show that even though nickel dissolution was much slower than in acid leaching, it was selective over other metals such as iron, proving the proposed method to have potential as a process for the extraction of nickel from Colombian laterites.INTRODUCTION Before 2010, most of the industrial operations used pyrometallurgical processes for the extraction of nickel, mainly in saprolitic regions of deposits, with greater contents of the metal. Nevertheless, due to the gradual depletion of such deposits, different hydrometallurgical processes have been studied as alternatives to process those nickel laterites with low grade and those which present problems of refractoriness due to the presence of acid consuming materials (McDonald & Whittington, 2008; Oxley & Barcza, 2013; Wang et al., 2012). However, such leaching processes require high concentrations of acid to achieve acceptable extractions and they are not selective. Facing lateritic nickel ore deposits containing high levels of acid consuming materials, an alkaline leaching medium becomes an advantageous alternative over acidic media, due to the increase in selectivity and decreased corrosiveness and reagent consumption (Tanda, Eksteen, & Oraby, 2017). Unlike conventional acidic reagents used for metal recovery, alkaline reagents can selectively dissolve the desired metal, leaving in the solid residue other elements such as iron, magnesium and aluminum, which are problematic in subsequent stages of metals separation and recovery. Furthermore, there are no serious corrosion problems associated with alkaline leaching, even at higher reagent concentrations, or at elevated temperature and pressure (Ntumba Malenga, Mulaba-Bafubiandi, & Nheta, 2015)."

Jan 1, 2017

By Hammenm R., J. Hammen, C. Hammen

"The production of salable Rare Earth Element (REE) products necessitates a sequence of chemical separation steps between the mine and market commodities. The effectiveness of the chemical separations that purify REE salts is critical to the success of the producer, as the purity of REE salt products affects their market price. This is due to the fact that impurities in REE salts, even at low levels, can be deleterious to the function and usability of the end product. The purification of REE by removal of low levels of contaminant has been referred to as "product polishing". The technologies commonly in use for product polishing, solvent extraction (SX) and ion exchange (IEX) are challenged by the availability of separation chemistries to separate the contaminant from the desired REE salt. In simple terms, if a product specification is 99.9% purity, the SX or IEX separation reagents need to have at least a 999:1 selectivity ratio. Significant testing has been carried out on the use of solid phase extraction (SPE) columns to extract low-level impurities such as aluminum or zinc from REE product streams. The SPE columns are nano-composite materials that have rapid equilibration kinetics with the solutes being processed by the columns. The SPE matrices have been modified with chelating ion exchange ligands that bind the contaminating ion with great selectivity in residence times of a few seconds. Thus, REE streams with 1 to 2% of contaminating aluminum ions, have been polished to >99.99% purity. In this paper, results are presented on the removal of aluminum impurity from a didymium (neodymium+praseodymium) product stream using SPE technology. The selection of the SPE medium and the process steps to treat the feed solution for aluminum removal and ultimate stripping and recycle of the solid phase extractant are discussed."

Jan 1, 2014

By Minoru Fujita, Ian M. Johnson

"A helicopter-borne geophysical survey was flown in 1978 over selected areas on Kyushu Island, Japan. The principal sensors were a moving source electro-magnetic system and a magnetometer. Maps of apparent resistivity were generated from the EM data. Based on the resistivity signature of known deposits within the survey areas, targets were selected for ground follow-up. Drilling of one such target in late 1980 resulted in the discovery of a gold deposit from which full production will begin in the summer of 1985. The deposit contains a minimum 120 tonnes (3.86 million ounces) of recoverable gold and is the largest in Japanese history. The deposit is in a geological setting previously unsuspected of hosting precious metal deposits. The case history suggests a preferred exploration strategy which might be employed in other similar geological environments.IntroductionThe Hishikari area is located some forty-five kilometres north of Kagoshima city, Kagoshima Prefecture, Kyushu Island, Japan (Fig. I). The area and its environs is one with a number of gold deposits which have been worked with varying results since the late 1800s. The large st deposit in terms of recovered gold is the Ohkuchi (or Oguchi) Mine (Fig . 2) which was recently closed due to exhaustion of reserves. The Ohkuchi Mine started production in 1896. A total of 22.2 tonnes (714 ,000 ounces) of gold, with an average ore grade of 13.6 grams/tonne (0.39 ounces/ton), was extracted over the Life of the mine.In an attempt to discover new deposits , the Metal Mining Agency of Japan (MMAJ) carried out a regional geologic mapping program of the area between 1975 and 1977. This was followed by a helicopter-borne electromagnetic and magnetic survey. The airborne survey was flown by Scintrex and the compiled results presented to MMAJ in early 1979."

Jan 1, 1985

By Douglas W. Reeve, Hoc Nghia Tran, David Barham

"In kraft pulp mills, the spent pulping liquor is concentrated and used as fuel in the recovery boiler. Extensive deposits are formed in the upper section of the boiler due to the very high ash content of the fuel and the volatite nature of the ash. Deposits are composed of Na2S04, Na2C03 NaCI, some potassium salts and reduced sulphur compounds. Chloride and potassium salts are enriched in the deposits compared to the smelt due to their greater volatility.Severe corrosion of the superheater tubes in a recovery boiler has been traced to three factors: a non-uniform temperature profile in the flue gas, relatively high operating steam temperatures and high chIoride and potassium concentrations in the fireside deposits.The role of chIoride and potassium in superheater corrosion has been explained by increased Iiquid phase in deposits. Together with corrosion studies, this information has shown that kraft recovery boiler superheater corrosion due to the chloride and potassium enriched deposits can be avoided by proper boiler operation and by judicious superheater and furnace design.IntroductionThis investigation of recovery boiler superheater corrosion was initiated by the discovery of severe corrosion of the final stage superheater in a Canadian closed cycle kraft pulp mill(1,2). Metal wastage leading to tube failure was believed to be due to three major causes : the relatively high operating steam temperatures, the uneven distribution of flue gas temperature across the boiler which created a "" hot spot"" and the high chloride and potassium concentrations in the superheater fire side deposit. The mill responded to the problem by i) lowering the superheater steam temperature from 475°C to 380°C, ii) minimizing the chloride content in the spent pulping liquor, by controlling the NaCI input with recovered bleach plant effluent, and iii) changing metallurgy of a portion of the bottom section of the final stage superheater platens from ferritic steel T-22 (2.25% Cr, 1% Mo) to austenitic steel Incoloy 800H (21% Cr, 32% Ni, 46% Fe, 1.5% Mn, 1% Si, 0.6% Al) (Fig. 1). Details of the superheater corrosion experienced in the closed cycle mil! have been reported in previous papers(l ·2,) ."

Jan 1, 1984

By J. Karonen, M. Tiihonen, J. Guentner, L. Haavanlammi, Outotec GmbH, E. Kolehmainen

"Rare earth elements have obtained significant attention during the last few years due to predicted increase in their demand. Several projects worldwide are at pre-feasibility or feasibility stage aiming to commence production. Deposits of rare earth elements are typically complex and multi-metallic of nature. This means that production processes are often also complex and therefore, various metallurgical unit processes are needed. Outotec’s equipment and technology portfolio is very comprehensive and includes hydrometallurgical and pyrometallurgical apparatus and processes applicable to the efficient exploitation of rare earth deposits. Outotec has gained useful experience relevant to the processing of rare earths through several assignments including those for Alkane Resources Ltd. (Dubbo Zirconia Project), Greenland Minerals and Energy Ltd (Kvanefjeld Project), Frontier Rare Earths Limited (Zandkopsdrift project), Tantalus Rare Earths AG (Madagascar), Quest Rare Metals (Strange Lake project) and Orbite Aluminae Inc. (HPA project). The hydrometallurgical test work of two process flowsheets is presented in the paper. A roasting or acid baking step is common to several proposed rare earth projects. In the past, rotary kilns have been used, but Outotec has developed a new process concept to handle the rare earth material in fluid bed reactors. The basis for this development is long experience in fluid bed technology of Outotec in Germany. One advantage of fluid bed roasting is the higher throughput per unit. In combination with the roasting and baking, Outotec offers the gas cleaning and acid plant and provides a complete and closed concept.INTRODUCTIONRecovery of rare earth elements (REE) has obtained significant attention during recent years. It has been estimated that their demand will be boosted because of their need in many technology areas. REE can be utilized in magnets, batteries, displays, catalysts, optical devices etc. (Jordens, Cheng, & Waters, 2013; Zhang & Edwards, 2013). The production of REE is focused in China, which means that production outside of China is very scarce. However, there are multiple active development projects worldwide working towards production of REE containing products outside of China (Chen, 2011)."

Jan 1, 2016

By Hooman Askari-Nasab

Open pit mine plans define the complex strategy of displacement of ore and waste over the mine life. The objective of the mine plan is to maximize the future cash flows within the technical and physical constraints. Various mixed integer linear programming (MILP) formulations have been used for production scheduling of open pit mines. In the MILP formulation the slope constraints guarantee that all the overlying blocks are mined prior to mining a given block. Traditionally, the slope constraints have been modeled with cone templates representing the required wall slopes of the open pit mine. The overall pit slopes constructed by these templates are a function of the width and height of the geological block model. Therefore, the overall slopes are fixed in one bearing. This paper presents a general MILP model for open pit mine scheduling with variable slopes constraints. The methodology utilizes a directed graph to capture the precedence of extraction of blocks and pit slopes in different bearings. Depth-first-search algorithm was used to traverse the graph for constructing the slope constraints in the MILP problem. TOMLAB/CPLEX was used as the implementation platform to efficiently integrate the mathematical solver package CPLEX with MATLAB. A case study on intermediate scheduling of an iron ore mine over twelve periods was carried out to validate the models.

Oct 1, 2009

By Henrik Saxén, Mikko Helle

The operation of hot stoves used for preheating the blast in the ironmaking blast furnace has a strong effect on the consumption of reductants, economic performance of and CO2 emissions from the steelmaking site. Generally, it is recommended to maintain as high blast temperature as possible, because this minimizes the rate of reductants in the blast furnace. The blast temperature is affected in a complex way by the time periods of heating and cooling of the stoves, and by the amount of gas combusted in the stoves. Furthermore, as the hot stoves show degraded performance with age, it is a non-trivial task to select optimal operation parameters for the stoves. The paper addresses this computationally by applying a one-dimensional heat-transfer model of the hot stoves for optimization of the performance of the system. The complexity and strong coupling of the decision variables is demonstrated by numerical examples, where the blast temperature is maximized under different constraints.

Jan 1, 2015

By E. V. Konopleva, H. J. McQueen

Steels in high variety have been providing strength and ductility for more than a century mainly through complex heat treatments following hot shaping. The economical and sustainable goal was a steel with the two operations combined through applying knowledge of dislocations and strengthening mechanisms aided by new mechanical and microstructural techniques. Primary hot reversing-mill rolling produced static recrystallization (SRX) between every pass to significantly finer grain size. Hot torsion showed that with lay-on temperature and rate of reduction suited to gradual precipitation of minor additions of Nb, the austenite grains would become highly pancaked; the existence of very fine subgrains along the grain boundaries (GB) could be deduced from tests on stainless austenite. The HSLA strip had to be water-jet cooled immediately to prevent SRX at austenite GB and ensuring complete transformation to ferrite avoiding grain growth after coiling. Confirmation on old mills and successful product led to the design of more flexible mills for wider range of compositions and products. A significant one was auto bumpers that reduced crash damage. More crack-resisting compositions were developed for strip welding into line pipe for arctic oil transport. Lower metal consumption and easier fabrication has resulted in more sustainable welded bridging.

Jan 1, 2015

By D. Shen, J. Cheung

Variable reactance arc control by the SPLC (Smart Predictive Line Controller) has been installed at many different mining sites and steel processing plants around the world. Since its first installation 18 years ago, many advances have been made to both the technology, and to its integration with furnace processes and plant operations. The SPLC has helped to improve electric arc furnace stability by reducing electrode movement while maintaining flat line arc power. Stable furnace operation at higher average power increases productivity. This paper summarizes the progression of electro-technology at Hatch since the 1970s, including fixed and variable reactance, digital electrode regulation, and fast variable speed hydraulics for Soderberg electrode, as demonstrated and benchmarked through projects and lessons learned over the years.

Jan 1, 2015

By M. Okada

Consumption of refined copper in Asia, especially in China and India, has soared, and the copper price is at its historic height. New smelters and refineries have been built in the region with state-of-the-art technology to meet the unprecedented demands. Supply of copper concentrate, on the other hand, has fallen short of the growing demand for concentrate by the smelters and refineries with expanded production capacities. The shortage of copper concentrate is attributable to the delay in the mining development, caused by the prolonged price slump of before 2005. The mismatch between supply of concentrate and smelting and refining capacities may cause disorderly movement of copper price, and hamper the sound development of the industry. The recent high copper price may prompt substitution with alternate materials. With electrical and thermal conductivity and workability, copper is one of the most customer-friendly materials. It is regrettable for both customers and suppliers if the high copper price would become an impediment to promoting copper use. Some outdated and environmentally unfriendly facilities still operate. In view of recent lower-grade copper concentrate with higher sulfur content, these facilities must reform their equipment to environmental-responsive one. The current level of per capita consumption of refined copper in Asia shows that the demand of copper will further grow. It is necessary to realize stable supply of refined copper and stable copper price, to help developing countries including China and India to economically take off. Hence, it is essential that the development of the copper industry be accompanied by environmentally friendly facilities, and harmoniously increased capacities between mining and smelting and refining.

Jan 1, 2007