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By Vilkul Yuri

Operation of the iron ore deposits of Krivbass which has been going for 130 years, has led to serious problems related to reaching great depths in open pit and underground mining. Extraction of the huge volume of rock mass (about 9 billion m3) resulted in mass violations of the natural state of the subsurface. At present most mining operations are carried out either by combined open pit and underground mining or by open pits in areas underworked by underground mining. Now the process of movement of the strata underworked by underground mines is not completed ? work fronts of open pits approach the areas of possible funnel, terrace and fissure formation, movement continue to develop. With deepening mining operations the remaining reserves are worked off under layers of incumbent rocks of > 900 m. Significant underground voids arise from mining "blind" deposits at large depths. Heaving of voids over the mined area lasts for decades; it may result in not only unpredictable time of funnel emerging and area development of movement synclines, but also the threat of air blows in mines. Forced caving of incumbent rocks as a way of controllable backfilling is difficult to achieve for economic and technical reasons. This is much more expensive and dangerous than stoping. Furthermore, the mining practice does not know examples of enormous volume backfilling under a km thick rock layer. Currently, RMI "KNU" is conducting research and pre-design work directed at creating a specialized pilot Geoinformation System (GIS) of continuous remote monitoring of rock mass in areas of underground voids influence in Krivbass area. Implementation of this system will enable to determine promptly in time and space the areas of the beyond cut off stress condition, to inform about possible occurrence of events that may result in accidents and to improve safety of mining along with other systems of forecasting and controlling the stress condition in rock mass. RMI "KNU", with a large number of professionals from many Ukraine?s leading mining research centers, has developed a research and design work program that includes the following principal stages: 1. Analyzing geomechanical conditions of combined mining of magnetite quartzite and rich ore deposits; determining mechanisms of moving of rock strata underworked by underground mining and places of hazardous area monitoring. 2. Investigating anthropogenic factor influence on the safe state level of rock strata underworked by underground mining (laboratory studies). 3. Developing processing techniques for continuous remote monitoring of rock mass in areas of underground cavity influence. 4. Modeling the state of rock mass based on results of pilot GIS hardware measurements. 5. Developing an expert diagnostics system for rock mass state in areas underground void influence. 6. Experimental investigation and testing the GIS, its improving for efficient application. After testing the pilot GIS it is supposed to be implemented at all mining enterprises as an integral part of iron ore mining and processing technology in the Krivbass area.

Aug 1, 2013

By Kamran Esmaieli

This paper investigates the behavior of ore pass walls under impact loads caused by material transiting through an ore pass. In particular it considers the influence of foliation in the rock mass surrounding an ore pass as both a triggering and accentuating cause of degradation. Based on empirical observations in several underground mines a numerical experiment was designed to understand the influence of rock mass foliation on impact-induced damage on ore pass walls. The distinct element method, and in particular the Particle Flow Code (PFC2D) was used to simulate three different rock masses surrounding an ore pass. Each simulated rock mass has similar properties but was defined by distinct dominant foliation (70o, 80o, 90o) along the foot wall. The numerical experiments investigated different scenarios whereby the walls were loaded by a projected rock fragment striking the foliated walls at a constant impact angle and velocity. The damage inflicted by the projectile rock fragment, on the foliated rock mass, was quantified using the number of impact-induced micro-cracks initiated on the ore pass wall. The results of the numerical analysis indicated that the presence of foliation resulted in greater damage zones in the surrounding rock mass. In addition, the extent of impact-induced damage to the ore pass wall increased as the angle of interception between the ore pass wall and the rock mass foliations decreases. This is in agreement with qualitative field observations.

Jun 1, 2012

By R. A. (Dick) McIvor

"It is important to ensure that the basic mine hoist plant design fundamentals are incorporated into any new mine hoist plant project before detailed design engineering is commenced. Some of the basic design fundamentals to be considered are: hoist rope fleet and flight angles for good hoist rope coiling, hoist rope harmonic frequency study to ensure that the hoist rope does not run at full speed at a rope resonance frequency, head frame and shaft clearance diagrams to establish the optimum positions for the loading and dumping of the shaft conveyances, access in the head frame and shaft collar for hoist rope and shaft conveyance installation and removal. Failure to consider the hoist plant fundamentals before detailed engineering commences will result in extra costs for hoist plant redesign or a significant increase in operating and maintenance costs for the mine due to increased hoist plant downtime to perform tasks and a lower mine operating efficiency. INTRODUCTION The mine hoisting plant is the most critical single line component in the operation of a shaft sinking operation or a permanent installation. Bad decisions in the design and selection of the hoist plant equipment can significantly add to the operating costs and up-time in the operation of the mine. Mine hoisting plant equipment installed costs represent approximately 5 to 8 percent of the capital cost of a new mine, yet price sometimes becomes the deciding factor for procuring the hoist plant components, sometimes selecting used equipment that may compromise the design and maintainability of the mine hoist plant. Mine downtime can cost upwards of $100,000 per hour and it will not take a very long time to eat up all the so-called savings on hoist plant equipment purchases. This paper will provide guidelines for the design, selection, installation and maintenance of mine hoist plant equipment with the objective to having the right mine hoist plant with the highest operational availability and best maintainability. PRELIMINARY DESIGN INFORMATION Before any engineering commences, the following information needs to be obtained to allow the preliminary sizing of the hoist plant equipment: • Shaft depth: The shaft depth will influence the hoist rope selection based on the material and personnel loads anticipated for the mine design. The shaft depth will also influence the maximum speed of the shaft conveyances. • Annual production: The desired annual production will influence the required payload sizing with allowances for maintenance and inspections of the hoist plant equipment."

Jan 1, 2019

By P. Su

Friction stir spot welding of a range of Mg-alloys is investigated (AZ91, AZ31, AM50 and AM60). The peak temperatures during friction stir spot welding of all Mg-alloys are close to their solidus temperatures. Also, the apparent material viscosity of Mg-alloy sheet is lower than that when Al-alloy sheet material is spot welded. This is important since it means that the widths of the stir zones forming during spot welding of Mg-alloy sheet are smaller than those when Al-alloy sheet is welded (when identical welding parameter settings are applied). These lower apparent viscosity values must be taken into account during numerical modeling of the Mg-alloy spot welding process. The efficiency of energy utilization is very low when Mg-alloy sheet is spot welded and is of the same order as that when fabricating Al-alloy sheet. The energy generation contributions of the rotating pin and the tool shoulder are investigated. When the spot welding operation is carried out without the application of a dwell period, the contribution made by the rotating pin vis-à-vis energy generation is around 66%. The contribution made by the tool shoulder increases to about 65% when a dwell period of four seconds is incorporated during the spot welding operation. This increase results from a longer contact time between the tool shoulder and material within the stir zone, The failure load during overlap shear testing increases when the bonded area and the energy input increase during spot welding. Sample failure initiates from unbonded regions and from discontinuities at the edge of the stir zone. The formation tendency of discontinuities is increased when Mg-Alloy sheet is spot welded because of the limited deformation characteristics of the base material at lower temperatures.

Jan 1, 2006

By R. Grau

"After commissioning and start-up of the first 500m3 TankCell® flotation cell in 2014, the over 300m3 mechanical flotation cells have earned their place in large-scale flotation operations. These 500 to 630m3 cells, designed for projects with large throughputs, are proven to provide savings in project capital and operational expenditure through savings in foot print, energy consumption, and less equipment to install and maintain. Addition to savings in different phases of a project, these cells provides operational flexibility and has shown improvements in metallurgical performance. In this paper a case study from Kevitsa TankCell® e500 installation and Buenavista del Cobre TankCell® e630 installations will be given.INTRODUCTION After development (Grönstrand and Bourke, 2008), characterization (Morales et al. 2009; Yanez et al. 2009; Grönstrand at al. 2009), validation (Elgueta et al. 2009; Coleman and Dixon, 2010), and more than 350 industrial installations of the Outotec TankCell® e300 flotation cell, the well proven energy efficient TankCell® product family introduced the TankCell® e500 forced-air flotation cell late June 2012 (Outotec.com, 2012). The introduction of the 500 m3 flotation cell followed by introduction of a 630 m3 flotation cell, TankCell® e630, in October 2014 (Outotec.com, 2014). These large flotation cells are designed for projects with high throughputs where the number of cells needed for operation with smaller equipment would become large. The benefits of this size of flotation cells comes from the lower capital expenditures due to lower equipment costs, savings in plant footprint, less installation work with less auxiliary equipment, lower energy consumption, and less units per installation resulting in less components, spare parts and maintenance.The first TankCell® e500 was commissioned and taken into operation in October 2014 at FQML Kevitsa Cu-Ni-PGE concentrator, nowadays owned by New Boliden. The first TankCell e630 was taken into operation in January 2018 at GrupoMexico’s Buenavista del Cobre Cu-Mo concentrator. The start-ups of the first TankCell® e500 and TankCell® e630 followed with test work where the hydrodynamic performances of the cells were characterized and metallurgical performance studied. The results of the TankCell® e500 test work were presented in detail by Mattsson et al (2015a; 2015b) and TankCell® e630 by Grau et al. 2018. In this paper the metallurgical improvements achieved with the large cell installations will be presented."

Jan 1, 2019

By F. J. Guevara

A two-dimensional mathematical model for fluid flow and heat transfer in a sixin- line electric smelting furnace was developed to study the effects of temperature on slag viscosity in both the liquid and mushy zones. The model focused on the fluid dynamics of the molten slag and the effects on the formation of a slag freeze layer on the hot face of the furnace wall. Previous experimental and mathematical work, carried out under Ra number of 109 and using a fluid with Pr number of 65, showed that it is possible to mathematically describe the freeze layer formation over a vertical wall using a fixed-grid model. The chemical composition of the slag was taken into account through its effect on the viscous activation energy as well the solidus and liquidus temperatures. The results show that the flow pattern is strongly modified in areas of high viscosity, in front of the cooling system and at the slag-matte and slag-calcine interfaces. The results are discussed in terms of heat flux over the refractories and their effects on cooling system design.

Jan 1, 2007

The Bluebell mine of The Consolidated Mining and Smelting Company of Canada Limited extends under Kootenay lake, in southern British Columbia, and water control underground has always been a major problem. This paper gives a brief history of the operation, and then de-scribes the methods used by Cominco to keep the combination of lake seepage, ground water and thermal spring water under control. The pumping arrangements are de-scribed in considerable detail, with illustrations to show the various stages of development, and the power supply sys-tem is outlined.

Jan 1, 1966

By M. H. ElMaghraby

This paper describes the development and validation of a strategy for vibration-based online detection of faults in a particular class of machinery commonly found in industry. This machinery is defined by two basic characteristics that preclude it from the application of standard online condition monitoring approaches. The first characteristic is that the machine is in a constant state of transient operation, thus making it difficult to differentiate between changes in transducer measurements that are due to variable duty and those that are due to machine malfunction or fault. The second characteristic is the fact that the machinery involves multiple sub systems that are subject to identical and simultaneous loading, operating environments and duty cycles. An example of such machinery is a system of multiple hydraulic pumps driving a common load. The monitoring strategy presented here employs an anomaly detection scheme together with methods of signal processing and feature extraction that exploit the parallel duty arrangements of this equipment. Preliminary data is collected from a pair or motor-gearbox assemblies used in a material haulage system in the mining industry. Testing and validation was performed on a mechatronic test bench with both healthy and faulted components. Experiments were carried out to investigate how various configurations of the system were able to detect different types of faults. The results indicate that this approach is effective and merits further investigation.

May 1, 2013

This work illustrates the potential of two welding processes for joining AA1100-16 vol.% B4C metal matrix composite: laser welding process using a 4 kW Nd:YAG laser and Friction Stir Welding. A comparison is made between these two welding techniques in terms of microstructure and mechanical properties of welded joints. A large amount of brittle needle-like phases, together with some residues of B4C particles were observed in the fusion zone of laser welded joints. The use of Ti filler can improve the microstructure and increase the joint efficiency from 63% to 75%. On the other hand, the friction stir welding process being a solid state welding technique is interesting as it avoids the formation of brittle intermetallic phases. In addition, the breakage of B4C particles and the grain refinement of the matrix were observed in the weld zone. Consequently, FSW joints show much better mechanical properties than laser welded joints. Up to 100% joint efficiency can be achieved by FSW for annealed AA1100-16 vol.% B4C materials.

Jan 1, 2011

By Ma Yuxin, Niu Fusheng, Yuan Zhitao, Bai Limei, Han Yuexin

"Using batch flotation experiment, contact angle measurement, particle size analysis, and scanning electron microscope (SEM), the influence and difference of pH value on the flotation rate of talc and chalcopyrite were investigate without collector at the pH range of 3~11. The results showed that, the flotation rate of talc decrease with the increasing of flotation time, while that of chalcopyrite hardly affect by flotation time, besides, the flotation rate of chalcopyrite is much less than that of talc, so the laws of flotation rate of the two minerals are independent of pH value. The flotation test data of two minerals are simulated with first order and multi-rate flotation kinetic model respectively. The simulation results showed that flotation of talc only meet the first order kinetic model, while chalcopyrite’s meet the both. In addition, According to test results of talc and chalcopyrite by the particle size distribution, SEM photographs and the contact angle measurement, the reason why talc did not conform to the first order kinetic model is not because of particle size distribution, but of particle shape. That is to say, because of sheet structure of talc, the contact angle of layers and sections are 74°and 52°respectively. At the same time, the contact angle of layers and sections are different between the particles. So flotation rates between talc particles are difference.INTRODUCTIONPossessing superior self-induced, collector-induced and sulfur-induced floatability, chalcopyrite exhibits good floatability at a wide range of pH values and potentials. Serpentine are regarded as the most difficult selected type in various chalcopyrite ore, and the predominant reason is that it contains talc. Talc, as a nonpolar layered silicate mineral, is one kind of common associated mineral in sulfide ores (Lu, 2010). Concentrate quality and flotation process of chalcopyrite are influenced as a result from the presence of talc. It is because that talc has inherent floatability which makes it readily mixed with the floated mineral and talc is easy to slime causing the slime coating of the valuable mineral (Beattie et al., 2006). Thus in order to improve the flotation effect of chalcopyrite, methods can be introduced from two respects. One method is that fast-floating talc mineral is floated preferentially, and the other is that sulfide mineral is floated prior to talc by depressing the flotation of talc mineral (Beattie et al., 2006), nevertheless, no matter with which the flotation effect of fine-sized chalcopyrite is not positive. Therefore, in order to realize the flotation separation of talc and chalcopyrite, the difference between the inherent floatability of fine-sized chalcopyrite and talc is researched and analyzed in terms of flotation dynamics in the absence of collector and frother."

Jan 1, 2016

By G. W. Poling, J. R. Hoffert

"A common practice in preventing gravity-fed tailing pipeline from plugging due to sanding is to add lime at relatively high dosage rates. The lime affects the rheology of the slurry ""vehicle"" which transports the coarser particles in a heterogeneous flow-regime. This paper describes a study of the effect of lime on the critical deposition velocities and friction head losses of Highmont Mining Company's mill tailing. Testwork using an extrusion viscometer was related to the surface chemistry changes brought about by the high lime additions. Lime additions which typically increased the tailing pH from 8.4 to 11.5 reduced the critical deposition velocities from approximately 3.2 to 1.7 m/sec.IntroductionCommon practice, at least in base metal concentrators in British Columbia, is to use high lime additions in tailing slurries when the pipeline becomes partially plugged with sands. Some concentrators, such as the Highmont Mining Co. Ltd. plant, add lime on a continuous basis during low tonnage periods and during startup/shutdown transition s. Although such high lime additions often solve temporary plugging problems, the effect of lime on slurry rheology has not been well understood.Slurry pipelines are designed to transport solids in suspension with a minimum of wear and without particle deposition. These two objectives are in opposition because the velocities required to maintain solid suspension can sometimes cause high head losses in the pipeline, as well as wear problems. Thus, the optimum velocity for a long distance slurry pipeline is in the range that provides just enough turbulence to keep coarse particles in suspension."

Jan 1, 1985

By J. Q. Chen

The elastic-plastic behavior and the fracture mechanisms of two 2198 Al-Cu-Li thin sheets are investigated. The first material (2 mm thick) is in a recrystallized state after cold rolling. The second material (6 mm thick) is hot rolled and has a fibrous grain structure. The two materials are studied in both T351 and T851 conditions. Tensile tests are carried out along different sheet directions using flat and notched specimens. Fracture resistance was characterized using Kahn tear specimens and M(T) panels. Macroscopic fracture surface of smooth tensile specimens depends not only on testing material but also on the loading direction. For Kahn tear specimens, fracture is initiated in a small flat triangle whereas slant fracture is observed during crack propagation. Fracture mechanisms were investigated using scanning electron microscopy (SEM) and X-ray 3D tomography.

Jan 1, 2011

By Bryan Tisch

Goal of GMGE ??To advance mine reclamation through the beneficial use of organic residuals for the sustainable establishment of bioenergy crops and other productive land uses Objectives ??To advance the current ?standard? of mine reclamation by demonstrating that mining lands can safely become agriculturally ?productive? through the use of organic residuals. ??To generate and compile sound scientific data that can be utilized by stakeholders to better assess the environmental impacts of utilizing these materials. ??To complete a manual of best practices regarding the utilization of organic residuals on mine lands. *Considerable effort to be placed on operations/implementation side of utilizing residuals ?rather than just pure research

May 1, 2011

By A. Hekmat-Ardakan

Conventional hypereutectic Al-Si alloys such as A390 are used principally for the casting of components used in wear applications requiring abrasive resistance such as in engine or compressor blocks. A comprehensive study was undertaken to investigate the potential of improving the mechanical properties of these alloys by the addition of magnesium. A thorough thermodynamic study of the effect of the addition of Mg to the conventional A390 alloy showed that Mg2Si starts to form as a primary phase at 4.2% Mg as well as in the products of the binary and ternary eutectic reactions forming the matrix. Experiments were carried out in producing castings with different cooling and solidification rates of alloys with up to 10% Mg. Mg additions were found to increase the hardness over the as cast alloy due to solid solution strengthening. Also, T6 heat treatment greatly improved the tensile properties of these alloy compositions due to the strengthening effect of the theta-Al2Cu phase. The elongation of these alloys generally decreases marginally with Mg content. The most significant property improvement of the alloys with higher Mg content is the substantial increase in wear resistance. This is attributed to the dispersion of smaller particles of Mg2Si and their coherence with the matrix as compared to the large Si particles in the conventional alloy. A new rheoforming process for A390 is presented that improves the processing of the semi-solid slurry. Structure modification elements were also added to refine the primary and eutectic silicon greatly improving the processing of the semi-solid slurry.

Jan 1, 2011

By Y. W. Pan, Y. R. Liu

The disturbed natural rock mass tends to equilibrium state accompanying with non-equilibrium evolution process which has significant influence on the long-term stability of engineering structure. The deformation development in the non-equilibrium evolution is determined by two intrinsic processes, trend to equilibrium and damage development, which can be illustrated by evolution of excavated tunnel. Thus the creep and damage must be taken into account in study of non-equilibrium evolution process. Within Rice’s irreversible thermodynamics with internal state variable (ISV), the conjugate force function which equals to zero is a convex surface which divide the stress space into two parts, called equilibrium and nonequilibrium stress space respectively. The concept of effective stress of non-equilibrium has been proposed, in which the stress difference (d - d ) are the effective driving forces of non-equilibrium evolution process with hardening and damage effective. The formulations of inelastic strain rate and energy dissipation rate have been recast in the form of effective stresses. The inelastic complementary energy (ICE) is proposed to measure intensity of non-equilibrium evolution of material system. The specific equations of conjugated forces and kinetic equations of internal state variables are presented. The ICE and rate of energy dissipation are all calculated to be used to evaluate long-term stability of geo-engineering. The results show that rate of energy dissipation may be more convenience and flexible than ICE for internal state variable constitutive equation of rock mass.

Jan 1, 2015

By M. A. Halim, V. I. Lakshmanan, Z. Jankovic

An innovative mixed-chloride process for the separation of iron from lateritic ore is described. The separation of Fe(III) from leach liquor is an important process step for the recovery of nickel and cobalt. The patented process of Process Research ORTECH Inc. uses a lixiviant containing hydrochloric acid (HCl) and magnesium chloride (MgCl2) for the leaching of lateritic ores/concentrates followed by the selective solvent extraction step of Fe(III) over other value metals such as Ni and Co. The use of MgCl2 increases the activity of the hydrogen ion in the lixiviant, which reduces the consumption of HCl in the leaching stage and enhances the formation of HFeCl4-, thereby increasing the solvent extraction efficiency of Fe(III) with ketone. The process produces high purity iron oxide (Fe2O3) and regenerates HCl by the pyrohydrolysis of the FeCl3 rich pregnant strip solution. The developed process flowsheet is in closed loop, economically attractive and environmentally friendly.

Jan 1, 2015

By Chris Brothen

The introduction of new technology in mine operations has provided real opportunities for increased efficiencies and production gains which translate into enhanced profits. Computing and network technology usage has become integrated into surface mining operations and on average these investments in technology have proven beneficial for efficiency and productivity improvements. Embracing new technologies however, does not guarantee positive results. The expectations or improvements derived through the technology must be confirmed and clarified well before implementation. Tire Pressure and Temperature Monitoring Systems are an excellent example of an existing technology that can provide full time automated performance measurements of tires operating under harsh conditions and environments. Prompt warnings or alarms signaling when a tire has exceeded operating capacities will provide savings through lowered maintenance costs and increased productivity. To truly quantify the projected savings in tire life, fuel consumption, and increased levels of production, all costs associated with the technology, both direct and indirect must be considered. Apart from the initial cost of the system implementation, ongoing maintenance and support costs must be considered as well as the costs of system integration into existing mine operations

May 1, 2008

By M. Nzotta, L. Teng, S. Seetharaman, A. Chychko

The objective of the present work is to optimize the EAF practice towards Mo alloying with maximum retention of the alloying element in molten steel. During Mo additions, there were significant losses to the dust (ca 7 %) and to the slag phase (ca 2 %), which had serious economic and environmental impacts. The present work was aimed at designing a suitable Mo precursor, an alternative to ferromolybdenum, as the Mo source and a process sequence for optimal retention of Mo in the steel. The design of the Mo source should be in such a way that low cost raw materials such as MoO3 concentrate have to be used, stable during the addition so that the vapour phase losses as MoO3 are kept minimum and the dissolution of the precursor in molten steel is easy without loss to the slag phase. After thermodynamic considerations, three precursor materials were chosen, viz. CaMoO4, MgMoO4 and Fe2MoO4. Synthetic mixtures of the component oxides in each case as well as pure MoO3 were investigated by TGA and high temperature XRD in order to find out the temperature range in which the compounds were formed. Experiments were also conducted separately where the evolved gases were analyzed. All the three precursors were formed easily and the loss of MoO3 to the vapour phase was found to be extremely low. Addition of the oxide mixtures to steel melts were conducted in three different scales, viz. 16 g, 500 g and 3 tons (induction furnacle). Initial experiments showed that MgMoO4 was not suitable since the Mo yield in the steel melt was not very high. Fe2MoO4 was found to perform best, the Mo yield reaching 98 %. Further trials were conducted in the 65 ton Electric Arc Furnace (EAF) at Uddeholms AB in Hagfors. Mixtures of mill scale, MoO3 and carbon in suitable proportions were added in a pre-determined addition sequence. It was found that, in the actual practice, the Mo yield reached 99 %, equaling in performance the addition of ferromolybdenum. The process offers an effective use of cheaper raw materials and very high Mo yield avoiding a pre-treatment step like the production of ferromolybdenum. This is both cost effective and environmentally advantageous. The process has been patented and is being currently implemented at Uddeholms AB, Hagfors, Sweden.

Jan 1, 2011

By K. Scholey, S. Marcuson

As high grade nickel sulphide ores are being depleted and with the continuing challenges experienced in economically processing nickel laterite ores, it is important to investigate technologies that can extract nickel from low grade ultramafic ores which are present in large quantities worldwide. In the Thompson Nickel Belt, there are some hundred million tonnes of mineralization that are potentially amenable to surface mining. Since the original discovery of the Thompson orebody, recovery of nickel from these ultramafic deposits has been an elusive goal. Research and development projects as well as commercial processing have been attempted. In the 2000's as other resources became scarcer, a major drilling, mine evaluation and research project was initiated at Vale. In 2007, Vale Base Metals Technology Development invited Cytec and potential academic partners to participate in an industry-university research consortium with the goal of developing new technologies and methods of processing the ultramafic deposits. Three university professors, J. Finch of McGill, P. Somasundaran of Columbia and R. Pelton of McMaster accepted, each group attacking the problem with a different approach. This paper describes the management of the research consortium and the significance of the results from Vale's perspective. The next four papers in this session will summarize the project and results from the partners' point of view. Vale is pleased to share the experience of the collaborative research and development with the mining industry.

Jan 1, 2011

By V. Barranco, K. Yliniemi, A. Hubin, B. P. Wilson, D. Janas, M. Lundström, P. Hannula

Typical copper electrorefining electrolyte contains tens of grams of copper, some nickel and a wide variety of impurities. Some of these impurities comprise trace amounts of dissolved precious metals like Ag, Pd and Pt that currently are not fully exploited. This study presents an electrochemical method to recover precious metals via a combined electrodeposition-redox replacement (EDRR) process, where energy is used only to deposit copper during the ED-step, while the RR-step relies on the spontaneous replacement of copper by the precious metals (i.e. cementation). In order to conduct the recovery successfully, process parameters such as deposition potential (EDE), deposition time (tDE), redox replacement time (tRR) and the number of cycles (n) was adjusted. Investigations performed in synthetic electrolyte (40 g/L Cu, Ag = 10 ppm) proved the possibility to recover a high purity silver. Short deposition times (tDE) were found to result in small Cu particles that provided a suitably high surface area for silver cementation. In addition, experiments performed in real industrial electrolytes containing 44 g/L Cu and 54 ppb Ag (Boliden Harjavalta, Pori), demonstrated that EDRR could attain Ag recoveries of between 46–67% in an energy efficient, additive-free manner. INTRODUCTION The raw materials used in the state-of-art primary and secondary copper smelters contain mainly base metals, but also notable amounts of Ag, Pt and other precious metals. These valuable metals distribute mostly into the copper matte during the pyrometallurgical treatment (Tirronen et al., 2017) and end up into the cast anodes. During the electrorefining stage, metals more noble than copper such as gold and platinum, are not dissolved but enrich into the anode slimes. In contrast, silver may dissolve slightly and thus, minor chloride addition is used to retain silver in the slime as sparingly soluble AgCl. Moreover, other metals less noble than copper may also dissolve, such as nickel. Therefore the electrolytes used in electrorefining typically contain substantial amounts of copper, nickel and even arsenic as well as minor metals such as antimony and bismuth. In the Boliden electrorefinery these were reported to be in the magnitude of 51.2– 60.4 g/L of Cu, 10.9–15.8 g/L Ni, 7.2–15.9 As, 0.2–0.4 Sb and 0.1–0.4 Bi with an associated sulfuric acid concentration of 139–155 g/L (Lehtiniemi et al., 2018). Copper is the most noble of the dominating base metals in the electrolyte and is thus deposited on the cathode as 99.99% purity LME-A grade. Anode slimes are collected and subjected to precious metals treatment e.g. via pressure leaching—selenium recovery— Doré smelting—Ag refining—Au/Pt/Pd leaching and reduction process (Ludvigsson & Larsson, 2003). The Pori refinery, operating in Finland since 1941, not only produces 133 000 t Cu cathode and 2300 t nickel sulphate annually but also 66 t silver, 4.6 t gold and palladium and platinum (in year 2017).

Jan 1, 2019