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By G. Minhas, M. Pule, Y. Laffitte, M. c. McGurn, T. Tzanetakis, Peacey. J., R. Susilo

Titanium (Ti) metal production from titanium tetrachloride (TiCl4) using magnesium (Mg) as a reducing agent is the well-known Kroll process. A chloride route is used to avoid oxidation of the titanium sponge. The sponge is consolidated into ingots and can then be made into powder by melting and atomizing or by hydriding/dehydriding. Attempts at direct powder production have met with difficulties, including low Ti yield and the formation of very fine particles (particles between 25-100 µm are desired). This paper discusses two methods to produce Ti powder in a molten salt medium using magnesium powder as a starting material instead of a pool of molten magnesium. The first method is a direct reduction of gaseous TiCl4 injected in the melt with the magnesium powder in suspension in the molten salt. The second method is a two stage TiCl4 reduction reaction where recycled Ti was used to form titanium dichloride (TiCl2) in the first stage followed by addition of magnesium powder into molten salt in the second stage. A correlation between Ti yield and processing variables such as TiCl4 to Mg ratio, Mg particle size, TiCl2 concentration in the melt, and reaction temperature was studied. The Ti powder formed was also analyzed for particle size distribution. Despite challenges and difficulties encountered, this paper shows some promising results which could provide guidance to others working on direct Ti powder production.

Jan 1, 2015

By Denni Nikols, Farrukh Z. Khan

"Highvale Mine, located at Wabamun, Alberta, produces thermal coal for TransAIta's Keephills and Sundance generating plants. Overburden stripping in the mine is conducted by draglines which normally operate on top of the overburden bench. In certain areas oj the mine, however, these overburden benches are susceptible to slope failure. In these areas, due to safety considerations, the draglines are utilized in the less productive chop-cutting mode, supplemented by mobile equipment where the bench height exceeds the dragline chop-cutting limit. This paper proposes maintaining the draglines in their normal digging mode through areas of unstable or jailed overburden, by utilizing a dragline carried toe buttress 10 ensure adequate bench stability. The data requirements and methods of slope analysis to design a toe buttress across an unstable highwall area are examined in rigorous detail. INTRODUCTIONLocationHighvale Mine is owned by TransAlta Utilities Corporation and operated under contract. It is Canada's largest coal mine with an annual coal production in excess of II million tonnes. The mine is located approximately 80 km west of Edmonton on the south shore of Wabamum Lake (Fig. I) and production is currently provided by three pits 02. 03 and 04 (Fig. 2). The entire coal production is consumed at the nearby Sundance and Keephills power generating plants.ScopeThe mining operation at Highvale Mine has had occasional slope stability failures of its high wall overburden bench. This paper examines one such failure which occurred in the summer of 1983 at Pit 03. In addition to an investigation of the failure, Terracon was asked to recommend mine operation procedures which would minimize the impact of these slide zones on dragline productivity. A method of removing the failed material by utilizing the dragline in its normal digging mode is designed. The method's advantages and disadvantages as well as the required support procedures are reviewed."

Jan 1, 1989

By Brian Hart, Stamen Dimov

"The Time of Flight Secondary Ion Mass Spectrometer (ToF-SIMS) is unique in that it measures the outermost atomic layers of any material. The technique is particularly suited for determining surface chemical composition of mineral particles. It is most commonly used as a diagnostic tool to measure mineral surface chemical variability in plant and bench top flotation separation processes. Recently, research towards understanding the full capability of the instrument has resulted in the development of new diagnostic applications related to various Au extraction technologies and the development of the ToF-SIMS as a predictive tool for assessing the chemical reactivity of the ore.In this paper we will present a brief review of the ToF-SIMS technique with recent advances in instrumentation and methodologies including:•,?recent developments and advances towards a semi-quantitative approach to the evaluation of mineral surface modifiers (ex. Cu),•,?flotation case studies investigating activator, depressant and collector loading variability within a flotation process,•,?the recently developed chemical reactivity test which we believe has the potential to predict the behaviour of minerals in a flotation test in response to chemical transfer during grinding,•,recent applications for determination of surface Au preg-robbed in carbonaceous materials.A portion of this material has been recently presented at the COM 2009 meeting and at SIMS XVII (see Dimov et al 2009 and Hart et al, 2009).INTRODUCTIONIn flotation seperation surface chemistry is the principal determinant for selective separation of the various mineral phases (Ralston, 1994, Smart et al, 2003). Determination of this hydrophobic/hydrophilic balance by particle therefore requires correct identification and selection of the particular mineral phase(s) followed by a statistical analysis of the surface chemical characteristics of the particles with an estimation of the spread of values (Smart et al, 2003)."

Jan 1, 2010

"Air Products approached LAC Minerals in 1987 to initiate trials with pure oxygen in the leach circuit at several LAC facilities in Canada. This paper gives an overview of oxygen use and covers specific operating data from the Doyon and Terrains Aurifères mills near Val D'Or in northwestern Quebec. LAC also uses oxygen at the Macassa mill in Kirkland Lake, Ontario.In addition to the LAC facilities, oxygen is currently in use for test purposes at the Holt McDermott mine in Kirkland Lake, Ontario and the Camflo mine near Val D'Or.There are two requirements for oxygen in the cyanide leach mill. Firstly, oxygen is required in the familiar gold dissolution reaction as follows:(1) 4 AU (s) + 8 NaCN (aq) + 02 (aq)+ 2H 20(aq) - 4NaAu(CN) 2(aq)+ 4Na OH(aq)Of the reagents on the left side of the equation, the availability of gold is fixed by the ore in question. Obviously, water is available in excess, 1eaving cyanide and oxygen as the limiting constituents in the process. Most mills operate with an excess of cyanide, which is fairly closely monitored. Dissolved oxygen levels, however, are not normally watched very closely and find their own level based on the temperature, the availability of compressed air and the ability of the ore to consume oxygen.Typical D.O. levels are in the 3-8 ppm range, however levels less than 1 ppm are not uncommon for refractory ores.With pure oxygen, dissolved oxygen levels as high as 30 ppm can be achieved. (Figure #1). This greatly accelerates the kinetics of the leach reaction and may also shift the reaction further towards completion thus increasing gold dissolution slightly."

Jan 1, 1990

By David F. Machuca-Mory

Modelling the geometry of a vein is a crucial step in resources estimation. The resulting models are used as mineralization domain boundaries and have a direct impact on the tonnage of estimated resources. Deterministic models are often built using time consuming wireframing techniques usually based on hand interpretation of the drillhole intercepts. Another approach consists in coding the drillhole samples by a function of their distance to the veins contacts. The coding is subsequently used for modelling the vein contacts away from drillholes. This is a more efficient approach and is able to provide a measure of tonnage uncertainty. The use of location-dependent variograms improves the modelling by incorporating local changes in the anisotropy of the vein structure. This combined approach results in more realistic vein models, particularly when the geometry of the vein has been are altered by folding, shearing and other structural processes. The approach is illustrated on a realistic case study.

Oct 1, 2009

By Y. N. Zhang

Friction Stir Welding (F SW) is a novel "green" manufacturing technique due to its energy efficiency and environmental friendliness. This solid-state joining process involves a rotating tool consisting of a shoulder and/or a probe. The shoulder applies a downward pressure to the work-piece surface, constrains the plasticized material around the probe, generates heat through the friction and causes plastic deformation in a relatively thin layer under the bottom surface of the shoulder. The rotating probe mainly drags along, plasticizes, and mixes the adjacent material in the stir zone, creating a joint without fusion. Friction Stir Processing (FSP), a variant of FSW, has been developed to manufacture composites, locally eliminate casting defects, refine microstructure and/or improve the associated mechanical and physical properties including strength, ductility, fatigue, creep, formability and corrosion resistance. However, major challenges such as tool design and wear currently limit the use of F SW/P for manufacturing applications, particularly for high melting temperature or high strength alloys. In this review, the FSW/P tools are briefly summarized in terms of the tool types, shapes, dimensions, materials and wear behaviors.

Jan 1, 2011

By M. Thérien, M. Rémillard

"Data from two industrial plants are treated by mass balance package BILMAT. The first application concerned a base metals/precious metals (PM) producer and the second, implementation of a hydrocyclone for the recovery of iron chips in the granite industry. Also LOTUS 123 software can easily be adapted for laboratory test mass balances using an IBM-PC computer. INTRODUCTIONThe present paper deals with two different BILMAT program applications. The first application concerns a copper-zinc-gol d-sil Yer producer based in North-western Quebec and the second, concerns the iriplementation of a hydrocyclone for the recovery of iron chips in Quebec granite company.Afterwards, we deal with some LOTUS 123 software applications for laboratory test mass balances using an IBM-PC.1. Base metal and P.M. producerNoranda Inc, Mattagami division, which operates mines in North Western Quebec, produces copper and zinc concentrates from a sulphide ore. Small amounts of gold (0,34 g/t) and silver (20 g/tl are present. At the time of the study, only 30% of the silver content was recovered in the copper concentrate. The main objective of this study is, to evaluate the metallurgical behaviour of silver in the flotation circuits, to increase its recovery in the copper concentrate and therefore to improve its final economic value. It is then worthwhile to identify the silver bearing minerals and to determine the critical flotation stages where they are lost. The methodology proposed is based on the coupling of a mineralogical study and a detailed mass balance ca1cu1ation in the flotation circuit performed using the BILMAT mass balance package (1, 2, 3).The results are discussed with respect to the distribution of silver in the circuit. The recoveries obtained at the various separation stages for the minerals present in the ore are also discussed."

Jan 1, 1987

By Jean Fortin

In order to remain competitive, the search for excellence has been and will remain the only viable option facing the Mount-Wright operations. Safety and environment, process and technology as well as cost performance have been the focus points on which the operations have concentrated their efforts in order to meet and exceed our company's "Vision 2000" plan. Some of our mine's accomplishments have been a new work organization, a world class maintenance and a new collective agreement. The concentrator, maintenance and production departments have evaluated their processes and implemented various improvements in areas such as power supply, dewatering, blasting, implementation of service centers for large and small vehicles, fleet standardization, crusher, mills and silos improvements... etc. Safety and work environment for personnel have been our driving force in order to achieve this plan.

May 1, 2003

By K. B. Chaudhuri, I. D. Webb, F. E. Rachor, F. A. Sauert

"A characteristic of all methods of copper concentrate smelting is that slags with a high copper content are produced at some phase of the operation. Recirculation to the smelting unit, electric furnace reduction or flotation are at present used on an industrial scale to recover the copper from these slags. This paper describes the application of the top-blowing technique, originally developed by KHD Humboldt- Wedag AG for refining of metallic copper, for the treatment of copper-containing slags. By this method, a mixture of a reducing gas and commercial oxygen is blown onto the melt at velocities which can be supersonic from the tip of a water cooled lance. The impingement of the reaction gas mixture on the surface of the slag forms a depression in the molten phase and a deflection of the jet which brings the slag into a rotating motion. This causes high rates of heat and mass transfer. Results of pilot-plant tests for batch and continuous treatment of slags are presented, and the potential applications of top blowing for industrial-scale operation are indicated. In combination with the cyclone as a smelting unit, this process appears to be economic for smelters of very low capacity."

Jan 1, 1980

By J. I. Mathis

"The failure that was utilized for developing this model was a double bench-scale failure, approximately 20 m in height, in the Misery pit at BHP Billiton’s EKATI mine site. The bench that failed was excavated in biotite schist. Due to previous problems with bench-scale toppling failures, this bench was excavated with a 70° inclined, 30 m deep preshear. Upon exposure, the wall was very clean with half-barrels commonly observed from the pre-shear operation.In August 2003, a bench failure of about 1000 t occurred in this pre-sheared biotite schist (Fig. 1). Upon examination it was noted that the foliation that paralleled and dipped at 70° into the face when excavated was approximately horizontal at the top of the failure (Fig. 2). While the failure mode itself appears complex, the failure was apparently driven by three factors:• a low-angle, low-frictional strength fault or discontinuity at the base of the failure area;• water either contributed meteorically from precipitation and/or from permafrost melt; and• foliation planes providing a viable toppling geometry once toe block motion began to occur.The above details are illustrated in Figure 3.After considerable thought and analysis, a model was postulated for the failure.It is thought that the entire failure had been triggered by displacement of a toe block (Fig. 4). This toe block is bounded on the back by foliation, the bottom by a low-angle, lowstrength fault, and the front by the bench face. Water pressures behind the bench face developed forces on the block as can be seen in Figure 5. These forces were sufficient to induce block motion. As can be seen in the relative shear strength diagram in Figure 6, only a small amount of water is necessary in the face to initiate block displacement. Note that in this figure, a simplistic piezometric pressure distribution was assumed."

Jan 1, 2004

Toronto 2013 Proceedings

May 1, 2013

By C. Díaz, M. Barati

Prof. Torstein Utigard's untimely death, in the spring of 2012, put an abrupt end to a meritorious career in the field of high temperature chemical process metallurgy. As an academic in the Department of Materials Science and Engineering of the University of Toronto, Torstein made solid contributions to the advancement of knowledge pertaining to production and refining of both nonferrous and light metals, and to the development of inquisitive and innovative young people in extractive metallurgy. In this profile, the authors highlight aspects of Torstein's rich personality and of his contributions to his field of expertise.

Jan 1, 2015

By W. Yang, R. Rajasingam, B. Tadesse, K. Mohanarangam

Copper electrowinning is a complex electrochemical process that involves the production of LME grade copper from copper rich electrolyte. The process involves the deposition of the copper ions onto the cathode from copper rich electrolyte with the production of oxygen bubbles at the anode. Acid mist is produced by these oxygen bubbles bursting at the electrolyte free surface. It is an undesired by-product of the Electrowinning process which unchecked could result in mist generation higher than the recommended time-weight-average exposure limit. Various approaches to alleviate the problem have been adopted by companies, all with varying degrees of success. All of these have been attempts to treat the symptom acid mist rather than the inherent problem, often proving expensive and, in some cases, ineffectual. In this paper, a new method was developed for acid mist quantification based on ‘total acid mist’ capture above the EW cell under well controlled conditions. With the use of sophisticated diagnostic analytical tools and measurement techniques it was possible to study all the operating variables including current density, flow rate, temperature, etc. independently and their effect on bubble size, bubble velocity, gas hold-up as well as acid mist generation and its droplet size. Results show that total acid mist capture increases with an increase in current density but remains more or less constant between 300–500 A m-2. Total acid mist also shows an increase with increasing electrolyte temperature. These findings are substantiated with the aid of bubble size and gas hold-up measurements with the transparent EW cell.

Jan 1, 2019

By G. Bourque

One of the design criteria for the Mount Wright facilities was to incorporate the latest proven automation techniques and devices for the new crushing, grinding and concentrating plant. The heart of the centralized control system is a Fox 1 process computer, located in the central control room in the administration building. The entire operation, i.e. crushing, conveying, storing, grinding and concentrating, is monitored and controlled, through the process computer , by one operator via a CRT console. In case of computer failure, the control is automatically, and without process interruption, transferred to manual back-up panels. One of the newest management tools, the process computer is programmed to collect and automatically print out shift. daily and monthly reports on tonnage, metallurgy and equipment operating time, for better planning of operations and preventative maintenance.

Jan 1, 1977

By Paul A. Glapa

Quality is much more than providing a product that functions properly. True quality is a way of thinking, a way of doing business, and, ultimately, a way of satisfying a customer?s long-term needs. A true commitment to quality requires a top-down management commitment, with a willingness to change what needs to be changed and to expand upon ?best practices? that are already done well. Is there a cost to creating and maintaining a quality program? Of course there is, but the cost of not having a focused program is much greater. We have come to regard quality as an investment that pays dividends to both the supplier and customer. The lack of quality costs everyone and the customer pays the ultimate penalty. With modern, highly engineered surface mining equipment the end user calculates cost in terms of lost production (revenue), not simply the cost of the part. Bucyrus International, Inc. is a company that has listened to its customers and has dedicated itself to implementing an advanced quality program. The ultimate goal being the creation of a high quality product with extended reliability for the customer. The result is reflected in Bucyrus? current product offerings and highlighted by the new 495HF electric rope shovels at Albian Sands mine.

May 1, 2003

By M. Morin

"This paper examines the design issues associated with the integration of mineral processing within underground mining using a total systems approach. It demonstrates conceptual integrated system design options appropriate to a range of geological scenarios. Particular reference is then given to a case study of stoping in narrow base metal veins.The performance of such integrated systems in terms of productivity, economical and environmental criteria is demonstrated by means of simulation. Particular attention is given to the potential benefits to mine waste management. Processing technologies appear to offer genuine potential benefits, while underground mining methods may need to evolve further to facilitate full integration. This paper is based on industry supported research aimed at developing selective and clean underground mining systems. IntroductionTotal systems thinking is simple in principle but complex to implement. The premise is that to achieve optimum effectiveness and efficiency from a system, the complete system must be considered. Using this approach will avoid the situation where the optimization of a localized component of any system results in a negative impact on the performance of the complete system. Take for example the parts manager who reduces inventory costs without consideration of the consequences to the plant. If the plant goes down and a part is unavailable, it would then cost significantly more than the cost of having it in inventory (Ackoff, 1994).A tool for applying total systems thinking toward understanding and analyzing different mineral extraction options is the structured analysis and design techniques (SADT). Originally developed by Ross (1977), SADT is a formal systems engineering methodology (FIPS PUB, 1993) for process and enterprise modelling (Marca and McGowan, 1993). Figure 1 presents a highlevel structured analysis of the traditional or conventional metal extraction process. There are three sequential processes with several arrows entering or exiting each process. In SADT, inputs always enter from the left-hand side and exit as outputs of the process on the right-hand side. Constraints affecting the transformation of inputs to outputs enter the process from the top while resources or mechanisms enabling the transformation enter from the bottom. SADT is a hierarchical decomposition technique and further analysis is undertaken by expanding downward into each process."

Jan 1, 2003

By Nancy E. Wilk

In 2015, more than 1.2 million deaths annually were estimated to be caused by occupational risks (WHO, 2018). In 2021, this estimate increased with the publishing of the World Health Organization (WHO) and the International Labour Office (ILO) Joint Estimates of the Work-related Burden of Disease and Injury based on data from 2000 to 2016 (WHO/ILO, 2021). These global estimates reported that each year 1.9 million people die from exposure to occupational risk factors, 81% of these fatalities resulting from non-communicable, occupational diseases. WHO/ILO notes that the health-related risk factors with the largest number of attributable deaths were exposures to long working hours followed by workplace exposures to particulate matter, gases, and fumes. The health outcome with the greatest work-related burden of deaths was chronic obstructive pulmonary disease, followed by stroke and ischaemic heart disease. In considering the 2021 data published by WHO/ILO, it is likely that the estimates are low and underestimate the true burden of occupational disease and injury. In support of that position, more recently the ILO estimated that “2.3 million women and men around the world succumb to work-related accidents or diseases every year; this corresponds to over 6000 deaths every single day” (ILO, 2022).

Jan 1, 2023

By J. Lee, K. B. Min, J. Rutqvist

Shear slip of fractures in fractured rock masses is a critical issue for many geological engineering applications, such as the design of underground nuclear waste repositories, enhanced geothermal systems (EGS), and geosequestration of CO2. This paper presents new development of the TOUGH-UDEC simulator for analysis of coupled thermal-hydraulic-mechanical (THM) processes in fractured porous media. As an alternative to developing a single coupled THM code in discontinuum, two existing wellestablished codes, namely TOUGH2 and UDEC, are coupled to cover coupled THM analysis of multiphase fluid flow, heat transfer, and deformation in fractured porous media. TOUGH2 is widely used for modeling heat transfer and multiphase, multicomponent fluid flow, and UDEC is a well-known discrete element code for rock mechanics, which have been verified and used by many groups all over the world. Although a sequential coupling of two codes is less efficient than having a single code in principal, a big advantage with coupling of TOUGH2 and UDEC is that both codes are well tested and widely applied in their respective fields. When linking two codes, the coupled equations cannot be solved simultaneously; they should be solved sequentially, with coupling parameters passed to each equation at specific intervals. After solving thermal-hydraulic equations through the TOUGH2 model, pressure (P) and temperature (T) information is delivered to UDEC model. Pressure information is directly stored at the center of each UDEC zone and domain, however, temperature information is interpolated from zone-centers to the corners nodes. After solving the mechanical equation through the UDEC model—considering new pressure and temperature—calculated fracture apertures are converted to equivalent permeability and porosity for TOUGH2 flow analysis. The solution was calculated by iteratively following an explicit sequence for numerical efficiency. Verification examples are presented to demonstrate the capabilities of the coupled TOUGH-UDEC simulator.

Jan 1, 2015

By W. R. Tyson

Pipelines for the transport of gas and oil are being designed to operate at increasing pressures in increasingly harsh environments. The steel used to construct these pipelines must have adequate toughness to tolerate weld imperfections (i.e. withstand bending strains) and to arrest running cracks (i.e. to prevent propagation of axial fractures). The problems posed in specifying suitable toughness parameters and the approaches currently being used to measure them are discussed.

Jan 1, 2005

By J. S. Redpath

There appears to a definite trend toward the hoisting of greater tonnages from greater depths. There is every indication that this trend will continue and we feel that improvements in the design, fabrication and installation of mine guides will be of significant importance in the future. The present state of the art in mine-shaft guide systems is reviewed and the parameters required for improvement are derived in this paper. Finally, a proposal is made for a new steel guide system which meets the parameters and is economical to fabricate and install.

Jan 1, 1977