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By S. McPherson, M. Chalkley, R. Ellenwood, W. Nicot

"The Moa JV was formed in December 1994 as a 50/50 joint venture between Sherritt Inc. and General Nickel Company S.A. of Cuba. The joint venture consists of the mine and Pedro Sotto Alba processing plant in Moa, Cuba and the Corefco refinery in Fort Saskatchewan, Alberta, Canada. Throughout its now nearly 23-year history, the Moa Joint Venture has faced a number of global, operational and process challenges. Global challenges have included high input costs such as for fuel oil and sulphur, as well as low nickel prices. Operational and process challenges have included increasing ore haulage distances, decreasing ore Ni + Co grades, and increasing ore impurity contents. For example, increases in impurities such as Mg and SiO2 in the ore result in increasing acid demand in leaching and decreasing solids content of preheated leach feed slurry, respectively. In spite of these challenges, the mixed sulphide production capacity from the Moa Joint Venture has increased from 12,500 to 37,000 t/y Ni + Co since 1994 by judiciously targeting expansion projects and by continuously performing process and operational improvements.INTRODUCTION The Pedro Sotto Alba high pressure acid leach (HPAL) plant at Moa Bay, Cuba has a long history (Maslenitzkiy, 1969; Chalkley, 1996; Carlson, 1960; Roy, 1961; Carlson 1961). The plant was constructed by Moa Bay Mining Company and started up in late 1959 after several years of process development by Freeport Nickel Company, including operation of a 10 t/d plant in Hoskins Mound, Texas and a 50 t/d plant in Port Nickel, Louisiana (Southwick, 2004), as well as development work by Chemical Construction Company (Chemico) to precipitate metal sulphides (Roy, 1955a; Roy, 1955b). The Moa plant had an original reserve of 50,000,000 t of ore, graded at 1.35 wt% Ni, 0.146 wt% Co, 3.70 wt% Si, 1.00 wt% Mg and 4.5 wt% Al. At original design rates of 2,000 kt/y of ore, the design capacity of the plant was around 25,000 t/y Ni + Co as a mixed sulphide product, which would be shipped to the Port Nickel Refinery in Louisiana for processing. In 1960, the plant changed ownership and was restarted in 1961 under Cuban management. Between 1961 and 1989, the plant was also supported by involvement from the former USSR, supplying spare parts and consumables. In 1994, Sherritt Inc. partnered with the General Nickel Co. S.A. of Cuba and formed the Moa Joint Venture. This joint venture includes the mine and Pedro Sotto Alba HPAL processing plant in Cuba and the Corefco refinery in Fort Saskatchewan, Alberta, Canada. Under this partnership, ore is processed in Cuba to produce a nominally 55 wt% Ni and 5 wt% Co mixed sulphide product that is shipped to Canada and processed by Corefco to produce class 1 nickel, high grade cobalt and byproduct ammonium sulphate fertilizer."

Jan 1, 2017

By W. S. Hargratt

THE present era of exploitation of the Little Long Lac and Sturgeon River areas commenced in 1925, when Beardmore Gold Mines started development of what is now the property of Northern Empire Mines. A shaft was sunk in 1927-28 and a very limited amount of underground work was carried out, following which the property was shut down. It remained idle until 1932, when Empire Star Mines, a Delaware Company, optioned the property. This Company formed the Northern Empire Mines Company, Limited, to operate the mine, and immediately instigated an aggressive programme of surface and underground development. By the summer of 1933, sufficient ore was indicated to justify the installation of a small mill. The decision was also reached to bring in electric power. A power-line was built from Hydro, the Ontario Power Commission's development on the Nipigon river, to the mine, a distance of approximately 50 miles. This work was entirely financed by Northern Empire Mines. Mill construction was commenced in October, 1933, and completed by March, 1934, thus making this mine the first producer in this district.

Jan 1, 1940

By Clifford R. Stanley

"Abstract - Reproducible analyses of representative samples for elements affected by the ‘nugget effect’ is vital in mineral exploration and reserve estimation. Unfortunately, a priori knowledge of what size of sample is representative from a mineral deposit or its dispersion train is commonly unavailable. Use of the simple ‘equant grain model’ and the NUGGET computer program facilitates determination of the sampling parameters that will produce appropriate samples for chemical analysis. Based on Poisson statistics, NUGGET can be used to determine: (1) the ‘effective grain size’ of nuggets in a suite of samples, (2) the level of representativity (precision) that samples with specific nugget grain sizes will exhibit, and (3) the sample size required to obtain a specific level of sample representativity. The program determines these sampling parameters for any element in any mineral, including solid solution minerals (e.g., Au, electrum, Pt-Fe alloy, diamond), and allows assumption of a variety of grain shapes (e.g., ellipsoids, cylinders, parallelepipeds, etc.). Furthermore, it outputs the effective number of nuggets expected in a sample of given size and the percentile confidence bounds on any element concentration affected by the nugget effect.Results from the software allow determination of effective sampling and analysis strategies that minimize the nugget effect in geochemical analysis/assaying used in mineral exploration and reserve estimation. This will not only improve confidence in the resulting exploration results or reserve estimate, but will facilitate estimation of the error associated with any subsequent interpretation or reserve figure."

Jan 1, 1998

By Ben C. McLellan, Philip J. Bangerter, Andrew Murphy, Glen D. Corder, Damien Giurco

Sustainability now forms a critical part of metallurgical plant design. In addition to compliance with requirements and corporate principles, design engineers must also consider how community and societal responses to the metallurgical industry affect the way they design and build plants. Three broad areas to consider are: the design engineer’s contribution to sustainability through the design process and the relationship to the social license to operate (SLO)—the unwritten license communities give companies to safely and responsibly operate the plant and equitably share benefits; the realization of sustainability goals through methodologies emerging in the design activities; and the integration of design frameworks into a contemporary project design context and its investment objectives. This chapter explores sustainability in metallurgical plant design in the context of SLO, design tools and frameworks, and community and societal influences.

Jan 1, 2015

By A. Khan, C. Ciriello

The purpose of this paper is to demonstrate the value of constraint modelling in optimization of mineral processing systems. This will be achieved by first understanding the overall concept of variation and constraints present in any system. Next, the value of using a Constraint Model in optimization is demonstrated through comparison of business cases. The benefit of understanding the severity of constraints and movement of the bottleneck within a mineral processing system will be understood through the use of a case study. Paper will conclude with a summary of all optimization benefits that utilization of a constraint model can bring.

Jan 1, 2015

By P. A. Distin, Jr. da Silva

The history of commercial processes for zirconium/hafnium production and separation is reviewed. A new technology is then proposed as a potential alternative for zirconium/ hafnium separation in a simpler, cleaner way than achieved with current processes. Primary sources of zirconium always contain small amounts of hafnium that must be removed during production of zirconium metal for nuclear applications. This separation is usually carried out by a solvent extraction process, developed in the 1950s, that selectively extracts hafnium, as a thiocyanate complex, using methyl isobutyl ketone (MIBK). Environmental problems inherent to this process are the high aqueous solubility and low flash point of MIBK, and possible gaseous contaminants formation generated by the decomposition of the thiocyanic complexes in hydrochloric acid medium (H2S, HCN, mercaptan’s formation). The present work shows how these problems could be avoided by using organophosphorous extractants that were unavailable when the MIBK process was developed.

Jan 1, 1998

By Colin P. Skidmore

Long touted as Australia?s fourth uranium mine the sediment-hosted Honeymoon Uranium Project is close to commercial production using insitu-leach mining methods. Uranium mineralisation occurs as pitchblende coatings on unconsolidated quartz sand and gravels within a stacked aquifer system in a buried palaeochannel located in the Curnamona Region of South Australia. A final NI43-101 Feasibility Study is close to completion which has included extensive delineation drilling using PFN technology to accurately measure uranium grade and distribution. This data integrated with a detailed 3D sedimentalogical model is being used to optimise wellfield and plant design.

May 1, 2006

By M. Bender, H. D. Goodfellow

"Belt conveyors, because of their low capital and operating costs and inherent flexibility in handling a wide variety of products, have numerous applications in the mining industry. With the increased emphasis on improving the workplace environment, dust emissions from belt conveyors at transfer and other points have become a significant problem for many applications.The paper reviews belt conveyor dust control technology and compares dust emissions from belt conveyor systems with other possible materials handling systems. Technical information on existing belt conveyor installations which have been designed to minimize or eliminate dust emissions is summarized. The important features of good design as well as the necessary input from operating and maintenance personnel are highlighted. The status of research and development work on dust control on belt conveyor systems on a world-wide basis is discussed. A proposed methodology for field measurements of emission factors from belt conveyor systems is presented. Data collected from such a test program can be used to establish a design basis for new dust-free belt conveyors.IntroductionBelt conveyors have proven themselves over the year s in the mining industry as a reliable and low-co st method of moving bulk material at high tonnage rates. Because of the above, as well as their inherent flexibility in handling a wide variety of products, belt conveyors are often called the ""workhorses"" of bulk material handling systems. For many processing plants, belt conveyors serve as the ""vital link"" in providing feed to the plant and the removal of the finished product. As would be expected, there has been considerable engineering effort in designing rugged and reliable belt conveyor systems.It is also well known that belt conveyor systems are a primary source of respirable dust emissions. The major sources are from the tail pulley where material is received and the head pulley where material is discharged, from the return idlers, due to the fine material attached to the return belt, and from the take-up pulley. It is usually considered that for dust particles less than 10 microns, these particles will remain airborne and thus can have a profound effect on the workplace environment."

Jan 1, 1982

By J. P. Morris, J. T. Novak, E. A. Sarver

"A variety of reagents are utilized in coal preparation, but aside from performing their desired function relatively little is known about the behavior of these reagents within the processing circuits. Where exactly do reagents go once dosed? In this paper, we present preliminary results of partitioning studies on frother (i.e., MIBC) and collector (i.e., diesel) chemicals commonly used in coal flotation, and examine implications for water management (e.g., in closed-loop systems). Additionally, we discuss the usefulness of such data in predicting environmental transport and fate of chemicals – which is currently a top priority for industry.INTRODUCTIONThe purpose of coal preparation is to upgrade mined coal into more valuable products. Since coal is primarily used as a fuel source for electricity generation, product specifications are typically contracted to minimize unwanted constituents that detract from the overall heat value (e.g., ash and moisture) or that add to environmental pollution or other problems like corrosion at a power plant (e.g., sulfur) (Pitt & Millward, 1979). Failure to meet specifications results in a financial penalty for the coal producer (Szwilski, 1986), and thus preparation processes have evolved to simultaneously optimize recovery of valuable “clean” coal with rejection of mineral matter and moisture. In addition to advancements in equipment and circuitry, development and application of various chemical reagents has dramatically improved the performance of coal preparation processes.Contemporary preparation plants typically include multiple circuits that can be categorized by the size of particles they process: coarse, intermediate, and fine/ultra-fine (Figure 1). Coarse and intermediate circuits generally rely on size classification and gravity separations (e.g., dense-media cyclones), and do not require significant chemical reagents. However, fine and ultra-fine circuits often use froth flotation to separate coal from impurities, which requires chemical additives (Table 1). The primary additives include collectors, which coat the surface of the coal particles to render them (more) hydrophobic and thus more likely to attach to air bubbles and float; and frothers, which aid in the formation and stability of the froth that will accumulate the floated coal particles. Modifiers are also commonly added to flotation circuits to regulate pH in instances where coal or impurity characteristics may change water chemistries (Laskowski, 2001). Following flotation, coagulants and flocculants are often utilized in solid-liquid separations (i.e., dewatering or clarification) for coal products, and for tailings slurries prior to their disposal in impoundments. Coagulants function via double-layer compression1 to bring colloidal particles together, while flocculants promote bridging between the grouped colloids – and the combined result is enhanced sedimentation (Wills, 2006). Defoaming or anti-foaming agents may also be required to avoid fouling of dewatering operations."

Jan 1, 2012

By Ryan W. Siggelkow

Mines today use various methods of mining to extract ore. Because of the dangerous nature of many of these processes, remotely controlled LHD machines are being used to extract the ore from the draw point. The remote control system, although being made safer all the time, has remained virtually unchanged for many years. The basic functionality is an operator switching the machine to remote control, getting out of the cab, walking up a stand, operating remotely, returning to the cab, switching to manual, driving manually, switching to remote, and switching to manual. It seems repetitive, and time consuming, does it not? Networking, convergence, video, voice, and data infrastructures, and other technologies are growing by leaps and bounds in virtually every industry and region, except for mining. From the comfort of the living room couch, a Canadian can play hockey online with full voice conversations over the Internet with someone in Russia in real time. Yet, a mine superintendent must jump through hoops to have a private conversation with the front line supervisor underground. "Is Joe around anywhere?" If Joe hears the message, he will respond. If not, who knows? Maybe he's hurt. Maybe he's not. Where is Joe? Nobody really knows, and that is scary. Today, surface knows that the workers disappeared into the cage at 7:00 a.m. They also know that the workers will probably and hopefully return at 3:00 p.m. Is there not a better way to handle this? With such a complex industry, it seems as if, for the most part, the introduction of new technology into mining has either been overlooked or has been met with some resistance. It is time to step back, look at the process, and see how it can be improved. Key areas of focus will be safety, productivity, dependability, and cost-effectiveness.

May 1, 2010

By M. Leahy

"Very little is known about the large scale fluid dynamics and associated distribution of copper in an operating electrowinning cell, yet they will have a major influence on mass transfer and plating quality. The CFD model in this work is used to simulate an entire EW cell with 60 cathodes and 61 anodes, or 121 anode–cathode pairs, elucidating for the first time the three-dimensional (3D) flow and copper distribution in an industrial cell. Two methods for the distribution of electrolyte are modelled:1. Downcomer method: electrolyte is fed by a downcomer at one end of the cell, overflowing at the opposite end.2. Manifold method: a horizontal manifold pipe runs the whole length of the cell and feeds electrolyte via small holes in the top of the manifold pipe.The recirculation that develops within each anode-cathode pair, driven by oxygen bubble generation on the anode, is similar to that seen previously in two-dimensional models of single anode–cathode gaps. However a more complex 3D flow recirculation is established, which involves flow of electrolyte down the side gaps (being a path of low resistance for return flow) as well as the usual return flow down the cathode side of each pair gap. The bubble-driven flow is not influenced by the mode of electrolyte distribution.The electrolyte flow due to the manifold and downcomer is somewhat secondary to the bubble driven flow. In the case of the downcomer distribution mode, the high injection velocity causes a very turbulent flow in the first 1–2 m down the cell from the downcomer, with several large vortices developing. This may lead to some sludge particles being entrained into the bulk of the cell.In the manifold pipe case, the jet from each hole is dissipated very quickly, within the first 10–20 cm. The jets are directed into the downward flowing zone of the bubble-driven recirculation, which leads to unstable and periodic behaviour on a large spatial scale.In both the manifold and downcomer cases, there is a marked two-zone vertical stratification in copper concentration."

Jan 1, 2016

By D. W. Li

Due to the ultrasonic testing and mechanical wind speed sensor have high requirement for the environmental of the coal mine, the charge induction wind speed detection method based on wavelet analysis is proposed. The same wavelet disturbance detection method is used at a fixed distance to obtain an induction signal to obtain a pass time, and then calculate the magnitude and speed of the wind. Simulation and verification experiments show that the method has application across a wide range of test speeds (up to 60 m/s). The metal probe causes little pipeline flow field interference. The method is particularly well-suited to dusty environment, and does not cause dust deposition through long-term operation. It can be widely used in coal mines for point wind speed continuous online testing.

Aug 1, 2013

By J. W. Hohn

The precipitation of Fe(III) to form ferrihydrite in the presence of arsenic is the United States EPA's Best Demonstrated Available Technology for treating arsenic-containing hydrometallurgical solutions and waste streams. This technology has been widely adopted throughout the world and developments have been well reviewed. The adsorption and long-term stability of ferrihydrite can be improved by co-precipitating Fe(III) and Al(III) together to form an aluminum-modified ferrihydrite. Arsenate adsorption into ferrihydrite and modified ferrihydrite as a function of pH, Fe/As or (Al+Fe)/As mole ratio, and the initial As(V) concentration is presented and compared. The results of long-term aging of both adsorbents at 70°C for over a year are also summarized.

Jan 1, 2006

By D. Berkley

Off-gas systems often become the limiting factor in production increase and environmental projects. Any upgrade or new off-gas project needs to address control instability issues, instabilities that can result in safety hazards, significant loss of system capacity and/or emissions to the environment [1]. In addition, the design engineer must optimize system configuration and equipment size for the new operating conditions, to have a technically feasible and economically viable project. Dynamic simulations can be used for addressing both the control stability and the design optimization issues. This paper illustrates how the dynamic simulation of transient processes and of their control system can be used in "real life" situations for these purposes, presenting the example of an electric furnace off-gas system design.

Jan 1, 2005

By I. Farr, M. R. Mock, J. C. Robison

"HPAL and POX autoclave vapor-space gasses are vented through an autoclave PCV (Pressure Control Valve). The downstream steam-born mist of liquid droplets and solid particles travels in excess of 1000 m/s with megawatts of kinetic power at temperatures up to 160 C. The characteristics of downstream states often result in problems with corrosion, erosion, noise and vibration. Comprehension of those and related characteristics aids in improved pressure control, overpressure control and autoclave level control. We introduce compressible multiphase flow concepts and constructs germane to such flow including choked flow, continuous phase change, shock waves and supersonic flow plumes. Flow modeling based on first principles quantitatively predicts such flows providing a tool for component sizing and a method to estimate effects of water injection on flow. Insight deduced from modeling aids in mitigation of afore mentioned problems of which we share some from-site examples.INTRODUCTION First principles related to fluid thermodynamics and compressible flow have been employed akin to their application in the rocket industry. We will present the results of the application of those principles conceptually and authentically without mathematical rigour while using language of the pertinent disciplines. The autoclave (AC) vapor space over the slurry of a POX (Pressure Oxidation) or HPAL (High-Pressure Acid Leach) system (depicted in Figure 1) is vented via a PCV (pressure control valve) followed by certain ducting, and perhaps a nozzle, before exiting at atmospheric (typically) pressure. As indicated by its name the PCV controls the AC pressure as the flow control component of a pressure control loop."

Jan 1, 2017

By C. Morlot, C. Auvray, E. Fourreau, J. Talandier

"During the excavation of underground galleries in a rock mass, reorganisation of the stress field around the site results in damage to the surrounding material. In the framework of research undertaken at the ANDRA underground laboratory in France, galleries have been excavated in a Callovo-Oxfordian argillite formation. The damage has manifest as a number of fracture systems in the adjacent rock. Observations have shown that fractures generated during excavation and storage exploitation are able to self-seal during re-saturation of the site in the post-closure stage. Although indirect evidence for argillite self-sealing has previously been reported, from experiments performed both in situ and on samples, no direct observations of self-sealing have yet been made.For the present study, we performed a range of self-sealing experiments using a newly-developed triaxial compression cell placed within a nano-CT scanner with a 10 µm resolution. The body of the compression cell is X-ray transparent, allowing sample healing to be monitored directly. The samples contained an artificial fracture that had been generated in the laboratory, into which a fluid was injected. The fractures were orientated either perpendicular or parallel to the plane of anisotropy of the material. Our initial results demonstrate that when fluid is injected perpendicular to the plane of anisotropy, the flow-rate has no apparent influence on the kinetics of fracture closure. Permeability varies significantly, from 2.10-14 to 2.10-18 m2 over 116 hours. Post-test observations of the fracture lips show swelling that appears to be orientated perpendicular to the fracture plane and therefore parallel to the plane of anisotropy. Initial results for an injection parallel to the plane of anisotropy suggest that, in this case, the rate of flow affects the kinetics of fracture closure. For a flow-rate of 0.25 ml/min, closure begins after around one minute. In contrast, for a rate of 0.05 ml/min, it is necessary to wait several minutes before partial sealing of the zone is observed. The reduction in permeability is again significant, from 2.10-15 to 4.10-18 m2 over 96 hours. After completion of the test, swelling was observed in elongated zones that lie parallel to the fracture plane and therefore to the plane of anisotropy."

Jan 1, 2015

By Yu Chen, Charlie C. Li

The application of rock bolts for the stabilisation of underground openings needs a good understanding of the response of the bolts during rock excavation. The pull-and-shear performance of two types of rock bolts—that is, the fully encapsulated rebar and the D-Bolt—has been studied both experimentally and numerically. The rock bolts were tested under a pull-and-shear load at five displacing angles (i.e., 0°, 20°, 40°, 60°, and 90°), and at the same time, the strains on the bolts were monitored during testing. The two types of rock bolts have similar loading capacities, while the loading angle has obvious influence on the deformation capacity of the D-Bolt. The ultimate total displacement of the D-Bolt decreases from 140 mm under pure pull loading to 70 mm under shearing. The displacement capacity of the rebar is not significantly influenced by the loading angle but remains at a quite low level from 29 to 53 mm. The D-Bolt yielded in a longer section the rebar bolt under pure shear. A trilinear material model was used to simulate the strain hardening behaviour of the bolt steels in the numerical code FLAC3D. The numerical results show that the axial load in the bolt decreases exponentially with the distance from the loading position for the rebar bolts, but it remains constant in the bolt sections between the anchor positions for the D-Bolts. When the bolt is subjected to a lateral load, shear stresses are created on the D-Bolt surface within a short distance from the loading position.

Jan 1, 2015

By Schrade F. Radtke

THE law of our present industrial society is the law of the jungle. By this I mean survival of the fittest. I do not refer to man or animal or the development of superior genetic strain. Rather do I refer to one's product, one's process, or one's material of construction. Each must perform in a superior manner or it is doomed to extinction; it must be steadily improved so that it can meet the competition of ether materials, of other equipment, or other processes. We have before us the classic examples of the horse and buggy vs the automo-bile, cf silk vs nylon, of the steam locomotive vs the diesel engine; in each case, a superior product has virtually wiped out its predecessor. Furthermore, a product, process, or piece of equipment is sold on its performance, together with engineering data which define its •characteristics and performance. For the most part, the present day sales-man must deal in terms of engineering performance of his product; he must know competitive materials -their strength and limitations as well N either old fashioned salesmanship, tradition, nor custom could have saved the horse and buggy from extinction; a superior product which has been steadily and con-sistently improved won out, 'and in turn, this change-over caused a dramatic• change in our whole way of life.

Jan 1, 1960

By K. El-Ouassiti, M. Zouadi, C. Bazin, D. Hodouin

Data reconciliation techniques are used to attenuate the effect of measurement errors and estimate unmeasured variables. This paper illustrates the application of data reconciliation to hydrometallurgy processes using measurements from leaching and solvent extraction obtained from laboratory experiments. The application of data reconciliation provides an efficient way to detect gross and systematic errors and produces reliable performance indices for process evaluation.

Jan 1, 2005

"5.1. IntroductionThe sample preparation requirements for bulk analyses of platinum-group elements (PGE) are different from the requirements for ore microscopy and in-situ analyses. It is necessary that the initial sample collection results in as representative a sample as possible for both types of analyses. Ingamells (1980) believes, however, that sampling is always imperfect and that there is no such thing as a truly representative sample. Once collected, the usual low content and irregularly dispersed nature of the PGE require that samples for bulk analyses be made as uniform as possible, whereas in samples for ore microscopy and in-situ analyses the PGE must be concentrated. Because of the generally high specific gravity of platinum-group minerals (PGM), certain precautions must be taken, such as mixing the sample material in the bags prior to opening.5.2. Preparation forBulk Analytical MethodsThe principal factors that determine the size of the sample required for a bulk analysis are grade, heterogeneity and grainsize. Initially, the grade and sample heterogeneity can only be estimated and a sampling methodology is developed with experience. It is essential at all times, however, that the assayers have information about the source of the sample and the purpose for the analysis. Information on the grain-size, which can only be obtained through mineralogical analysis, is also very important for PGE analyses, but, unfortunately, is often ignored.5.2.1. Samples fromUnconsolidated DepositsConcentrations of PGE may occur in eluvial deposits as well as in a large variety of alluvial deposits, including those of fluvial and glaciofluvial origin. These deposits are often difficult to map and sampling is further complicated by the wide range, from sand-size to boulders, of the non-POE-bearing constituents, and by the irregular distribution and shape of the ""pay streaks"". PGE concentrations in unconsolidated deposits are largely composed of resistant Pt-Fe and Os-Ir-Ru alloys (cf. Cabri and Harris, 1975 and Raicevic and Cabri, 1976), thus making comminution to the usual-150 to -200 mesh somewhat unreliable, due to the malleability of these alloys."

Jan 1, 1979