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By M. Aushouri, S. H. Mansouri, N. Aminizadeh

A thermo-chemical model of the Peirce-Smith copper converter has been developed to predict the molten temperature. The primary assumption of the model was that all matte, slag and gaseous phases in the converter were in thermal and chemical equilibrium. In this model, the matte components were considered only as copper, iron and sulfur elements. In the slag making stage, all the reacted iron was converted to fayalite. The reaction rate of iron and oxygen in this stage was considered to be constant. The converter temperature was calculated by heat balance over time. The model was validated by a detailed comparison with measured industrial data. A good agreement was obtained. The converter temperature depends on process parameters such as oxygen efficiency and molten emissivity.

Jan 1, 2007

THE Michipicoten area, one of numerous iron-bearing "Archean" segments in the Shield, contains two main types of iron formation, a normal Keewatin-type, consisting of interbanded chert, siliceous magnetite and jasper, and, gradational to this, a carbonate-sulphide type which contains large de-posits of siderite and pyrite. The carbonate-sulphide type of iron formation bears a direct and intimate relationship to the volcanic development of the area; it there-by affords some insight into genetic problems of Archeanron formation in general. The purpose of this pa-per is to summarize the geological setting of Michipicoten iron formations and to briefly review genetic aspects of recent work in the area. GENERAL GEOLOGY in largely by assorted volcanics and sediments of the Michipicoten series and younger, regional granite masses. (Fig. 1). The Michipicoten series comprises a thick assemblage of mixed flows and pyroclastics together with elastic sediments and banded iron formations. The volcanics belong to the Andesite-Rhyolite Association, and characters-

Jan 1, 1961

By Z. Jun, L. Kerning

Jinlong copper smelter and refinery, originally designed for 100,000tpa primary copper and started up in 1997, has been expanding its capacity on the basis of operational optimization and by modifying its facilities. Currently it is producing 210,000tpa primary copper, and the new phase of expansion project with a target capacity of 350,000tpa primary copper is ongoing. This paper reviews problems and improvements made with operation and equipment in the past years. Recent plant operation is briefly described. The expansion projects completed are summarized and the ongoing expansion project is present.

Jan 1, 2007

By J. J. Denny

The purpose of this paper is to present, briefly, an outline of Canadian practice in the milling of gold-bearing ores- not, however, including those auriferous ores which are mined and milled primarily for their content of some other metal. It is not the writer's intention to offer technical data, nor to discuss any particular phase of the metallurgy, but rather to give a general résumé of past and present methods. As it is only within recent years that gold milling has assumed prominence in Canada, much of the technology is modern, and detailed articles describing the practice adopted in the several mining districts, and recording the various changes and innovations that have been made from time to time, are to be found in the Transactions of the Canadian Institute of Mining and Metallurgy, and in the mining journals. Prior to the year 1860, any gold that had been produced in Canada had come from placer operations in British Columbia, but ' during that year lode gold was discovered in Nova Scotia, in quartz veins, and in several localities mines were opened and small mills of very simple character were erected to treat the ore. These plants, equipped with stamps, or arrastre, were only effective in recovering the free gold. Concentration and chlorination were introduced in an endeavour to save the gold occurring in intimate association with metallic minerals, but, due to various circumstances, gold mining and milling did not progress in Nova Scotia.

Jan 1, 1930

By J. Tuominen

Outokumpu Direct-to-Blister Flash Smelting is currently in operation in two smelters, a third one is under construction and a fourth one is in the design phase. The two smelters in operation are the Glogow 2 smelter of KGHM Polska Miedz S.A. in Poland and the Olympic Dam smelter of BHP Billiton in Australia. The Outokumpu Direct-to-Blister smelter of Konkola Copper Mines Plc. in Zambia is under construction and the new smelter of Glogow 1 is under design and waiting for final go-ahead decision. Additionally, the Garfield smelter of Kennecott Utah Copper Corp. makes blister copper out of matte in a Flash Converting furnace. A similar operation is under construction for Y anggu Xiangguang Copper Co. in China. The slag cleaning process, which is needed to clean the slag of the Direct-to-Blister Flash Smelting Furnace, has different requirements depending on the feed to the flash furnace. These differences are discussed in the paper. The differences between the processes and slag produced are discussed as well as the metallurgical requirements for slag cleaning. The Direct-to-Blister process, where the blister copper is produced directly from concentrate in one step, requires at least a partial treatment of the slag in an electric slag cleaning furnace. The existing impurities determine the specific requirements of the actual cleaning process. The different processes are discussed in the paper. The newest developments of Outokumpu Technology Oy for electric slag cleaning furnace design are presented as well as the characteristics which the furnace shape gives to the process.

Jan 1, 2007

By C. Fortin

The subject of gold flotation has been reviewed extensively in a number of publications. The focus in most of these reviews has been on the theories of gold flotation as well as the physical and chemical effects that may impact the efficacy of the gold flotation process. It is evident that the current status of gold flotation chemistry as it is being applied in industry has not been addressed widely. It is the intent of this paper to review current gold flotation practice and how these applications tie in with the current understanding of the chemistry of gold flotation.

Jan 1, 2011

By M. Pearson, J. Irvine, L. Mercer, P. Lauzon

Severe service ball valve performance has a direct impact on the mechanical availability of high pressure oxidation and leach plants. The primary function of these valves is to isolate the autoclave for maintenance. Valve failure has historically contributed significantly to the maintenance downtime of these process plants. An understanding of the root causes of valve failures is the first step in increasing the reliability of the severe service ball valves. A rigorous failure analysis practice has been developed by Hatch for investigating refractory failures in furnaces and kilns based on Kepner-Tregoe methodology. The method has also been modified for valve failure analysis. From a root-cause failure tree analysis of each of the valve components, a list of all potential valve failure mechanisms was developed for ranking and evaluation, along with recommendations for further valve development. The purpose of this paper is to present the reader with the modified Kepner-Tregoe method and examples of this analysis.

Jan 1, 2004

By J. M. Mwase

The platinum group metal (PGM) industry is currently reliant on the crush-mill-float-smelt-refine route to process PGM ores. However, there are many instances where this route would not be feasible. An alternative process route has been developed which involves heap bioleaching to extract base metals followed by heap reclamation and a water wash step, leading into heap cyanide leaching to extract precious metals. This process was evaluated through test work on samples of Platreef ore using laboratory scale columns. After 304 days 75% Ni and 93% Cu were extracted in the bioleach experiment at 65°C, and after 60 days 58% Pt, 99% Pd and 90% Au in the follow-up cyanide leach experiment at 50°C. A preliminary process flow sheet has been developed around this. Analysis via a mineral liberation analyser showed that the remaining Pt was in the form of the mineral sperrylite, which appeared to be slow leaching in cyanide in comparison to the other mineral types. Analysis of cyanide effluent solution showed high levels of thiocyanate, which present an environmental risk for disposal and high consumption of cyanide. Further studies to develop the process for commercial application in the South African PGM industry are outlined.

Jan 1, 2014

By M. Fafard, M. Dupuis, P. Goulet, J. Bédard

Start-up of a Hall-Heroult cell is a delicate task that can affect pot performance and pot life. Modem practices for high amperage cells involve preheating the lining before the molten electrolyte is poured in. Different preheating methods and heat-up schedules are used throughout the industry, and the optimum between a short start-up and damage minimization to the cell is elusive. Direct electrical coke-bed preheating is one of the most common techniques. This practice typically results in a non-uniform surface temperature distribution and can generate detrimental thermal gradients in the cathode blocks. Numerical modeling is an invaluable tool to study this complex problem and can help improve the preheating procedures. The modeling of the mechanical response of the lining is critical to detect risks of cathode block cracking or the development of gaps where liquids could leak into. Taking into account the baking of ramming paste, the quasi-brittle nature of carbon and the contact interfaces between different materials are examples of key elements to consider. A finite element slice model of a cell was built and simulations of different electrical preheating scenarios were performed using the inhouse code FESh++ to demonstrate what can be learned through thermo-chemomechanical modeling. The potential industrial application of the model is discussed.

Jan 1, 2006

By Paul B. Batten

Shutdown is a generic term for what may be called an Outage, Turn Around (TAR) or Overhaul etc. Running a plant shutdown well has always been key to the financial contribution of a mine. However, something important has changed. The post pandemic reality is that it is harder to retain workers and many of those near retirement just didn’t come back to work. This is creating a shortage of experienced people and a workforce that changes employers easily. We are seeing the impact of this manifested in the erosion of established maintenance and supply chain processes that now struggle to yield the plant runtime that could once be taken for granted. The scope, cost and duration of a shutdown varies widely depending on the nature of the work and the equipment being renewed. The PM of an electric shovel might require a week of downtime and cost $100,000. A gold plant may need to go down for 3 days when its time to change mill liners and cost $500,000. A turnaround in a refinery can take more than a month and cost multi millions. Despite the huge differences.

Jan 1, 2023

By Xiaoqiong Wang, Daobing Wang, Fanbao Meng, Jianbo Wang, Hongkui Ge

"Shale gas has become an important unconventional oil and gas resources. Its effective development relies on comprehensive and accurate understanding of shale gas reservoirs. Rock mechanical properties is one of the important components of reservoir evaluation. Two adjacent black shale samples, which are cored from the depth of 1145 meters in Chongqing, southwest China, are subjected to acoustic emission(AE) test under uniaxial stress and compared with coarse grained granite. The results of synchronous AE, stress-strain and ultrasonic velocity experiments show that shale has weak anisotropy. Compared with granite sample, two shale samples are similar, but their strength, velocity and brittleness are quite different, indicating that shale has strong microscopic heterogeneity. TOC, XRD, SEM microstructure analysis show that total organic content, mineral composition and natural fractures are the main impacting factors for mechanical heterogeneity. INTRODUCTIONShale gas is a typical low-grade marginal resource, which is characterized by ultra-low matrix permeability and small single well control volume. In order to enable commerical development, complex hydraulic-fracture networks must be created in the shale to allow gas to escape from the micro/nano-pores and natural fractures where it is trapped in the rock (C. Clark et al.,2013; Ge et al., 2013). The development of shale gas requires accurate evaluation methodologies to evaluate shale reservoir properties and predict production. (Jarvie et al., 2007). Rock mechanical properties are an important part of the reservoir evaluation. It is significant for efficient drilling, completion and hydraulic fracturing to understand mechanical behavior of shale gas play (John, 2011; Wei, 2013).Rock mechanical properties mainly include heterogeneity, anisotropy, brittleness and acoustic emission activity (Lockner et al., 1992; Jerome et al., 2009; He et al., 2010; Liang et al., 2012). Shale mechanical properties are evaluated from laboratory tests following a complex workflow that covers tasks from sampling to testing (Md. Aminul Islam et al., 2013). It is common to include various experimental methods such as stress-strain curves, ultrasonic velocity and acoustic emission when evaluating the mechanical properties (Rao et al., 2006). Because of the presence of organic-rich matter, mineral composition orientation and natural fractures, shale tends to have strong anisotropy and heterogeneity (Deng et al., 2004; Wang et al., 2013; Hathon et al., 2013)."

Jan 1, 2015

By Nehad Elsafty

It is always necessary to expand existing buildings, so that they could meet the growing societal needs. Compared with demolishing them and then constructing new ones, the expansion of existing buildings could not only reduce project cost, but also save the use of energy and raw materials in projects. Therefore, it is widely adopted in most under-developed countries. However, the expansion of existing buildings is not an easy task. It has been involved with a lot of issues in defining the scope of work, planning landscape, managing construction activities, etc. This paper investigates the potential challenges in expanding existing buildings. The project of expanding the Al-Agoza Hospital, one of the biggest and oldest hospitals in Cairo, Egypt, is selected as a case study. In the case study, the project documents have been carefully reviewed. The project engineers and the health-care professionals working in the hospital have been interviewed. This way, the point of views from the owner, the architect/engineer, and the contractor have been taken into account. Several lessons are learned through the discussion with these people. The results from this paper are expected to provide pieces of useful advice and suggestion for the expansion of existing buildings in the future.

Aug 1, 2013

By S. W. Marcuson

In the late 1960's concerns about the natural environment reached high levels within North America and provided activists with suitable platforms for exerting influence over the general public and politicians. In response a host of regulatory mechanisms were developed, statutes, voluntary measures, land grants, codes of practices etc. Emerging environmental awareness from the era provided impetus for rapid technological change that encompassed all industries, especially the base metal business. The resulting clean up impacted all aspects of copper production, dealing with issues such as waste disposal, water and air quality with specific impact on emissions of sulfur dioxide and particulate. This paper provides a perspective of these changes reviewing the macro-economic impact of environmental movement in mining with its specific implications to the copper smelting industry. The fundamental challenges that were faced by the old, but capital-intensive North American plants and the approaches taken to deal with the changing times are reviewed with special emphasis on the conceptual approach to smelter S02 abatement and different paths taken in the USA and Canada. The role of economics, sustainable R&D and presence of technical infrastructure that facilitated the change process is elucidated, and speculations are made about the future state of pyrometallurgy and the natural environment. Cu2007 -

Jan 1, 2007

By T. Verdel, Y. Gunzburger

Rockfalls are major and essentially unpredictable sources of danger, particularly along transportation routes (roads and railways). Thus, the assessment of their probability of occurrence is a major challenge for risk management. From a qualitative perspective, it is known that rockfalls occur mainly during periods of rain, snowmelt, or freeze-thaw. Nevertheless, from a quantitative perspective, these generally assumed correlations between rockfalls and their possible meteorological triggering events are often difficult to identify because i) rockfalls are too rare for the use of classical statistical analysis techniques and ii) all intensities of triggering factors do not have the same probability. In this study, we propose a new approach to investigate the correlation of rockfalls with rain, freezing periods, and strong temperature variations. This approach is tested on three French rockfall databases, the first of which exhibits an outstandingly high frequency of rockfalls (approximately 950 events over 11 years), whereas the other two databases are more typical (approximately 140 events over 11 years). These databases come from (1) the national highway RN1 on La Réunion Island, (2) a railway in the Bourgogne-Franche Comté region, and (3) a railway in the Auvergne region. Whereas a basic correlation analysis is only able to highlight an already obvious correlation in the case of the “rich” database, the newly suggested method appears to detect correlations even in the “poor” ones. Indeed, the use of this method confirms the positive correlation between rainfalls and rockfalls on La Réunion Island database. This method highlights a correlation between cumulative rainfalls and rockfalls in the Bourgogne region, and it detects a correlation between the daily minimum temperature and rockfalls in the Auvergne region. This new approach is easy to use and also serves to determine the conditional probability of rockfall function of a given meteorological factor. This approach will help to optimize risk management in the studied areas based on their meteorological conditions. Nevertheless, even if some rockfalls are correlated to meteorological factors, other seems to occur independently of these factors, which highlights the unpredictability of rockfall hazard.

Jan 1, 2015

By Maurice Lauzon

"Aerial surveys of the open pits have been conducted regularly at Lake Asbestos of Quebec, Ltd. -a subsidiary of American Smelting and Re-fining Company -since 1958. Ground controls are supplied by Lake Asbestos, and a topographic map of the pits at a scale of 1 in. to 50 ft., with 2-foot contour intervals, is obtained by aerial photography. The information from the topographic map is then transferred by the Lake Asbestos engineering staff to sections from which the volumes removed are calculated. Considering the size and complexity of the operation, this system has proved to be the cheapest, fastest and most accurate way of determining the quantities of rock and overburden removed. More than 11,000,000 tons of ore and waste are mined each year in three different pits. Further-more, the nature, shape and extent of the orebodies make it necessary to mine on many (up to eight) benches of a pit during a single year. In addition, there are sections of the pits where it is impossible or un-safe to survey the crest of some benches by standard ground methods. For these reasons, the tonnages obtained by truck count are checked and adjusted by aerial survey. These surveys are now taking place every six months. With this system, it is possible for a two-man surveying crew to look after all field work in the mine area."

Jan 1, 1967

Electric Vehicle Controllers Ltd. ?EVC started in 1981 ?Underground electric locomotive drive systems ?Developed tandem load sharing system and radio ELOS controls ?Locomotive autonomy systems ?Entered space technology development in 1999 with NORCAT to develop Mars drill for CSA ?Commercial distributor for drilling systems, lunar physical simulants, electric mobility systems and lunar mining technologies

May 1, 2009

"A method is described for determining the viability of hard rock orebody extraction by block caving. Using a very limited amount of geotechnical data, the procedure enhances Laubscher’s empirical stability graph method by using the complex structural modelling system (ChaSM) to assess cavability and block cave tonnages.IntroductionIn considering the selection of suitable mining methods, block caving has gained popularity over other extraction systems in recent years (Butcher, 1999). This has been ascribed to the fact that block caving is the lowest cost per ton mining method, with orebodies that were in the past considered unsuitable for caving, now being successfully mined. However, even though all orebodies will cave, a problem exists in the evaluation of economic viability — it is necessary to be able to predict both when the orebody will cave and what will be the sizes of the initial ore fragments (and the associated tonnages) that report to the drawpoints. This problem is compounded by the fact that, during the scoping study phase of a project, only limited geotechnical data may exist on which to base an assessment of whether block caving is viable or not. Empirical and numerical methods of cavability assessment do not account for the full effects of geological discontinuity trace lengths, nor for the stress regime. Those require significant geotechnical data to be available. The result is that uncertainty may exist as to whether block caving is an economic option. This uncertainty is complicated by the fact that limited experience exists with the caving of more competent orebodies.This paper describes a method for assessing cavability, and for predicting the size of initial ore fragments and the tonnages reporting to block cave drawpoints, using only the level of data normally available during a scoping study. Fragment size and tonnages are assessed by identifying potentially unstable blocks and wedges in the undercut back using statistical joint data. The effects of lateral confining stresses are accounted for by comparing the in situ stress orientations with the joint orientations. To evaluate the accuracy of the method, a back analysis exercise was conducted to predict cavability and initial tonnage for a mine in which the actual behaviour is known. The method is then applied to cavability and tonnage predictions for a hard rock orebody."

Jan 1, 2002

By C. Doyle, J. Brennan, C. Díaz, J. Hrepic, K. Cushnie

"In 1991/1992, INCO undertook a successful R&D program aimed at extending the lining lives of the top blown rotary converters (TBRCs)at its Copper Cliff Nickel Refinery (CCNR) and the electric furnace at INMETCO. At the laboratory scale, this effort was divided into three phases. In the first part, mineralogical work was performed on six refractories that were either currently being used to line these vessels or were considered suitable alternatives. In the second part, this mineralogical knowledge was used to help determine the compositions of slags that would not corrode the bricks at the operating temperature (1600°C) of the above furnaces. Finally, several important properties of the six refractories were measured to complete their evaluation as candidate linings. This paper reports the results of all three phases of the laboratory scale R&D work.The mineralogical work showed that rebonded fused grain magnesite-chrome (RFG-MC) bricks consist principally of periclase with minor amounts of free chromite and trace quantities of silicates monticellite and sometimes olivine. The bricks are principally held together by periclase-periclase direct bonding. Of note, the bulk of the chromite exists as exsolved precipitated blebs within the periclase grains. These likely redissolve at high temperature.Slags on the periclase liquidus coexist stably with these refractories. Examples are presented using CaO-MgO-Al2O3-SiO2 slags at~1600°C.Finally, the two refractories manufactured using close to 100% fused grain material generally outperformed the others in terms of physical properties and certainly were superior in their resistance to slag penetration damage."

Jan 1, 1997

By B. A. Monkman

"IntroductionONE OF :THE most effective methods by which the construction industry is combatting mounting building costs is by making increased use of lightweight materials, thus reducing the dead load to be carried •by structures. This applies to non-metallic materials as well as to metallic ones, and particular attention has been given to developing lightweight aggregates for use in concrete.The use of lightweight aggregates is not new and, in fact, dates back to the Roman Empire, when pumice was used in the walls and domes of the Roman buildings. More recently, and up to a decade or so ago, the demand for these aggregates was met from deposits of volcanic cinders, pumice, scoria, etc., and from the by-products of blast furnaces and coal burning boilers. However, these sources of supply are no longer sufficient to meet the demand, for transportation costs pretty well restrict the use of the natural lightweight aggregates to the western cordillera regions where the deposits of these materials occur, and the use of expanded slag aggregates to the areas neighbouring the plants where slags are produced. As for cinders, the supply has been greatly reduced by the conversion of industry to fuel oil, natural gas, and powdered coal, and the large stockpiles which existed previously have been pretty well exhausted.Industry's approach to the problem of a decreasing supply, in the face of an increasing demand, has been characteristically direct. The solution has been to construct plants whose sole .purpose is to produce economically an acceptable light-weight aggregate from materials close at hand."

Jan 1, 1955

"IntroductionIn the 1970s, environmental concerns and associated liabilities were a new and unknown aspect of corporate risk. Today, social concerns and the associated conflicts that they can generate constitute a rapidly expanding aspect of risk. Although not a new phenomena — the Bougainville copper mine was forced into closure in 1988 — social risk has emerged as considerably more important, and increasingly visible, in the last few years. Social risk is now an aspect of all mining activities which needs to be calculated into project assessments, and to be managed throughout the life of a project. While social risk has a number of aspects at the corporate level, such as company image and shareholder relations, at the level of the individual project, its primary component is social acceptability, and the principal tool for managing it is the Social Licence to Operate.Social Risk in Latin AmericaThroughout Latin America there are newly modernized mineral codes and economic systems introduced over the last ten years which, together with new environmental legislation, look very much like regulations in developed countries. To the corporations, the existence of these instruments means that the risks from the environmental issues associated with the project are known; they are legislated, defined, quantifiable and hence manageable.It seems ironic that, just when comprehensive regulations for the environmental management of mining have been put in place throughout Latin America, there arise an increasing number of challenges to mining activities. For, in spite of the apparent guarantees provided by these new legislative reforms, communities in Latin America today are more frequently standing up and taking exception to the presence of mining companies, or the ways in which the companies are conducting themselves. The viability of projects becomes threatened because they are considered socially unacceptable, a phenomenon that we describe as social risk. These challenges are less about opposing mining activities than many people would think. Rather, they are based on an increasing desire on the part of the local population to have some measure of control over their own future, and to participate in the development process from the earliest stages."

Jan 1, 2000