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By Phil Molloy

"In March, 1968, Skega Ruh her Liners were used to reline the shell of an 8' x 12' Allis Chalmers ball mill.This mill is used to regrind the cyanided pulp from 58i -200 mesh to 92% -200 mesh prior to this pulp passing to the flotation circuit, at approximately 450 tons per day.Before the use of rubber liners, the regrind ball Mill shell had been lined with single wave ni-hard liner!'. These liners had an average life of five years. Ni-hard end liners were used both prior to and during the use of rubber liners, as the life of the ni-hard end liners was about seven years, and it was thus felt that little economic benefit would be realized by lining the ball mill ends with rubber.The rubber lining used has a thickness of 57.15 millimeters and the square shaped lifter bars which are spaced at 14~ inch centres, have a 4"" x 4"" cross-sectional dimension.With the use of ni-hard liners, the consumption of 1 1/4 forged steel balls averaged 1.062 pounds per ton, Using rubber liners the consumption of l~"" forged steel balls increased to 1.368 pounds per ton. Also the level of the ball load which previously had been kept at approximately 18 inches below the mill discharge, had to be increased to approximately 8 inches below the mill discharge in order to effect the same grind.The initial gri4ding performance of the newly relined mill was also poor, until the leading edge of the rubber lifter bars, which were square shaped in cross-section had been worn to a rounded profile. These lifter bars were replaced after 4 years and 3 months of operation.The advantages of rubber liners in our opinion is as follows:"

Jan 1, 1974

By George C. Coupland

"THE PRELIMINARY EVALUATION of the orebodies was computerized for tonnages and grades on a 20- by 20-ft grid. The evaluation was based on drill-core intersections over 40-ft vertical projections coinciding with the proposed bench intervals, taking the deviations of the drill holes into account. The computer print-outs gave an ore distribution and evaluation bench by bench and indicated the areas of varying mineralization. The two orebodies have a combined length of 2,200 ft. and a maximum width of 600 ft. They strike almost due north, dip about 85 degrees east and rake to the north. The computer print-outs were used to design an open pit with an over-all waste to ore ratio of 2.58:1. At the outset, the waste to ore ratio was 4:1. The pit is tear-drop shaped, with the narrow end to the south, and at the surface is 2,600 ft long by 1,800 ft wide. Ramps are 100 ft wide, with a 10% grade. The south ramp is left-handed, starts at the southeast and will continue to the bottom of the pit. A second ramp on the west and north walls runs from surface to join the south ramp at 7 bench. This ramp will handle the total pit production when part of the south ramp, from 4 bench to surface, is lost due to the underground operation. Over-all wall slopes are 53 degrees, and are laid out to avoid prominent protuberances which could relax and become unstable and potentially dangerous (Fig. 1) ."

Jan 1, 1974

By Dr. G. R. Hoey

"Abrasive wear and corrosive wear of carbon-steel grinding balls occurred simultaneously during the wet-grinding of hematite iron ore, and Ni-Cu sulphide ore, in laboratory ball mills. Two corrosion control methods, the use of corrosion inhibitors and pH control, were investigated and found to be effective means of reducing or preventing corrosive wear. Up to 50 % reduction of total ball wear resulted from the use of these methods.Corrosive wear is caused principally by the reaction of oxygen in air with the carbon-steel grinding balls, probably by the following reaction: 2Fe + O2 + 2H20 - 2Fe2 + 40H-.IntroductionA survey of corrosion problems in Canadian sulphide ore mines was completed and the findings were published in 197l(l). The corrosion survey was used to develop the present research program with the objective to find more economical and effective ways and means to reduce the corrosion that occurs in the mining and metallurgical industry. The purpose of this presentation is to review the projects being done by staff members of the Corrosion Section, Extraction Metallurgy Division, on corrosive wear and its control in wet-grind ball mills.Both abrasion and corrosion contribute to metal consumption during wet grinding of ores. The total wear of grinding media in this study is assumed to be equal to the sum of corrosive wear and abrasive wear. A great deal of research and development has been reported in the literature on ways to improve the abrasion resistance of grinding media but only a small number of studies has been reported on the corrosion resistance of conventional grinding media."

Jan 1, 1974

By H. J. Chalmers

"Since the advent of large volume flotation machines, Cominco Ltd. has actively studied possible application of such machines to their various milling operations. A number of installations have been made and more are on the drawing board. This paper gives a description of these units, information as to choice of equipment, and information as to operating experience. Mechanical and operating details of six installations are summarized. Three different types of machines are discussed.Pine PointThe original Pine Point zinc flotation circuit comprised conventional roughing with two stages of cleaning. Over the years with increase in feed tonnage there have developed two adverse conditions; namely, a reduction in zinc concentrate grade coupled with an increase in MgO in the concentrate. This resulted in higher freight payments along with more severe smelter penalties. An intensive test program, in 1971, showed that the concentrate grade could be raised by 1.5 units of zinc along with a reduction in MgO from 0.8% to 0.47.. Subsequently this was done by adding two additional stages of cleaning using 16 cells of Denver 200-V's. The project was completed in January 1973 at a cost of $510,000 to give an estimated annual savings of about $390,000.Selection of the Denver Model 200-V was based on minimum floor space requirement, availability, and favourable operational and maintenance experience with Denver 100’s. As it happens it was possible to ""shoe-horn"" the 16 cells into place with a minimum of plant alteration. Some problems have been encountered with a tendency to ""sand up"" at high pH, particularly at the corners. Otherwise operational service has been very good."

Jan 1, 1974

By Michael P. Amsden

"THE ECSTALL CONCENTRATOR is situated adjacent to Highway 101 and the Ontario Northland Railroad, 15 miles east of Timmins, Ontario. Ore is delivered to the concentrator by rail from the mine, which is 17 miles northwest of the plant. Power and fuel are obtained from the hydro and natural gas lines which pass close to the plant site. Water is obtained from the Frederickhouse River, 6 miles east of the concentrator. The main concentrator building is a large structure 500 by 640 feet by 90 feet high and contains facilities for fine crushing, crushed ore storage, grinding, flotation, tin recovery, concentrate handling and reagent handling. Located in the same building are the machine shop, warehouse, metallurgical laboratory, pilot plant, men's change room, sample preparation area and an assay laboratory. The general concentrator layout is shown in Figure 47. Originally designed to handle 9,000 tons per day, the concentrator now treats 10,000 tons per day. Two different ore types are processed by selective flotation in three individual circuits to recover copper, lead and zinc concentrates. In 1973, another circuit was added to recover pyrite and tin concentrates from the combined zinc tailings of the three main circuits."

Jan 1, 1974

By John R. Hawley

"This paper is intended as a review of the progress that has been made in the Province of Ontario in the field of acid drainage waste treatment technology.Three years ago, at the Third Annual Meeting of the Canadian Mineral Processors, we presented a paper entitled ""The Problem of Acid Mine Drainage in Ontario"". At that time I was working for the Ontario Water Resources Commission. The paper turned out to be the very beginning of the Commission's acid mine drainage control program. In the intervening three years, the Ontario Water Resources Commission has been amalgamated with other government groups and has evolved into the present Ontario Ministry of the Environment. Today the Ministry is involved in running one of the most advanced acid mine waste control programs in the world.As a part of its mining program, the Ontario Ministry of the Environment has published three major reports which deal directly and specifically with the industrial waste disposal problems that may arise at a mining operation. In order of publication, these reports are as follows:(1) ""The Problem of Acid Mine Drainage in the Province of Ontario"".This 338-page report covers all aspects of the problem of acid mine drainage and includes detailed sections on acid flow detection, acid flow chemistry and acid flow treatment.(2) ""The Use, Characteristics and Toxicity of Mine-Mill Reagents in the Province of Ontario"".This report, 244 pages in length, gives the chemistry and toxicity of nearly all of the chemicals that find common use in the Canadian mining industry. Most of the toxicity figures quoted are the result of a comprehensive bioassay program that was initiated by the Ministry."

Jan 1, 1974

By Gerald R. Larocque, Donald F. Grenville

"IN APRIL, 1965, the employee relations department (then called the personnel department) was established as a separate function within the company. Its aims and objectives were to hire an effective work force to operate the open-pit mine and the mill, which were at that time under development and construction. It was also directed to develop a sound policy for employee relations to assist the company in maintaining a stable and properly motivated work force, which included the establishment of satisfactory wage rates and fringe benefits, safety, fire protection and security. During the 8 years that the department has been in existence the scope of the company's operations has expanded to include a zinc plant and an underground mine. The work force has enlarged accordingly and now totals 1,680 employees working at the two sites, separated by 34 road miles. To cover the employee relations functions the department has a total of 29 members at the two sites. The department is organized under a superintendent, who has an employee relations supervisor, a safety director and a fire chief reporting directly to him. The employee relations supervisor, with 2 employment officers and 2 clerks, handles hiring, first-stage employee grievanoos, terminations, employee records, and the organization of company-sponsored functions and meetings. Safety, training and security are the responsibility of the safety director, who has 3 safety supervisors, 16 security men, 1 first-aid attendant and one hearing conservation technician to service the two sites. The fire chief operates as a one-man section responsible for plant-wide fire inspections and fireoriented training. Although"

Jan 1, 1974

By David G. Baskin

"THIS DEPARTMENT is unique in that it operates in the production stream and also provides an essential service. Its operating function consists of scheduling an ore train to haul 10,000 tons per day over 17.1 miles of track and switching all incoming and outgoing rail equipment on 2.2 miles of track at the minesite and 6.2 miles of track at the metallurgical site. The service it provides is traffic control of all incoming commodities and all outgoing concentrates, metals and acid by rail and truck, even extending to port and ship control for overseas shipments (Fig. 46). Although they cover many miles, the railroad and traffic department employees operate very efficiently, as indicated by the following organizational chart:Railroad and Traffic Superintendent ................ 1Railroad Supervisor .............................................. 1Assistant Railroad Supervisor ........................ 1Track Foreman ...................................................... 1Trainmen ............................................................... ... 4Switchmen ............................................................... 4Trackmen ................................................................ 10Traffic Supervisor ................................................ 1Clerk Steno ............................................................ 1Clerks ...................................................................... 3"

Jan 1, 1974

By A. J. Williams

"Whenever a decision is made to bring a mineral deposit into production, the Owner in actual fact has decided to convert substantial sums of capital into productive capacity with the intenti6n of making a profit from such conversion.Escalating costs of construction, frustrating and costly delays in comp1etion, the increasing tempo of technological change and the increasing size and complexity of mineral processing projects have convinced Owners that the best way of implementing their capital must be sought and utilized. This requirement has stimulated a search for ways and means of applying modern management techniques to the design and construction of mineral processing plants.This search by consulting firms has resulted in the evolution of the concept of project management and the development of planning and con trolling techniques with the result that Owners can seek and obtain better assurance that their project objectives will be fulfilled.This paper will attempt to outline how a mineral processing plant can be brought into production through the implementation of project management techniques.Definition And Objectives Of Project ManagementThe design and construction of mineral processing plants is subject to the restraints of three inter-related parameters -Quality, Cost and Time each of which influences and is influenced by the other two.Project management is a technique where the Owner delegates complete responsibility to a single organization for all phases of a project (design, procurement, construction and commissioning) for the above parameters but retains freedom for major decision making. Normally, the consultant under-takes full responsibility for all phases, but partial project management services can be provided when the Owner so desires.The objective of project management is first to devise and define and then to implement a program in which the relationship between the three parameters of Quality, Cost and Time is optimized, i.e., the desired functional and other requirements are attained (but not exceeded) at the lowest practicable overall cost in the shortest practicable time. The measure of success of a project lies in the degree to which this objective is achieved."

Jan 1, 1974

By I. E. Wahn, E. A. Boutin

"The Manibridge Mill is unique in its treatment of relatively high grade nickel-copper ore because in the mill design are included one 10' diam. x 10' Maxwell cell, and three 12' diam. x 12' tank cells. These large cells are used as rougher-scavenger cells. Three 8' diam. x 8' tank cells as well are used for cleaning and recleaning of the tank cell concentrate.Flexibility of flow is the main criterion in the tank cell circuit. Targets from these cells are a high grade nickel-copper product with a minimum of talcose gangue.The operation of the tank cells has been encouraging and they have performed well with both low and high grade heads, yielding a high grade concentrate product.Manibridge Tank CellsDescription:The tank cells at Manibridge consist of one 10' x 10' Maxwell cell, three 12' x 12' tank cells, and three 8' x 8' tank cells. The four large cells are currently being used as rougher scavenger cells. The three small cells are used as cleaner cells.Both sets of tank cells consist of Denver steel tank and Super Agitator Mechanisms with steel beam super-structures. The agitator mechanism has a totally enclosed ball bearing spindle housing with a cold rolled steel shaft, and a stanclard standpipe with adjustable collar.The air rings for the tanks were fabricated by Nelson Machinery. Both large and small cells have injection rings with equally spaced air holes in the bottom centre line of the ring.Air is supplied to the tank cells by a Dresser Clark low pressure air blower.The following is a table of pertinent data on the tank cells:"

Jan 1, 1974

By O'Halloran. Gerard F.

"ECSTALL MINING has installed in their plants the most modern equipment in the mining industry. At the minesite, digital blocked frequency controls are used to monitor all crushers, conveyors, ventilation equipment and pumps from underground. Distant pumping stations are monitored and controlled by radio. Modern friction skip and cage hoisting systems have been installed with static power supply designed for automatic operation. Rotary-type compressors of recent design are in service in place of the conventional reciprocating-type units. At the concentrator, the 800- and 1500-hp synchronous motors driving the grinding mills have static field excitation and pneumatic clutches, still meeting modern-day concepts, having been• installed in 1966. The maintenance work load has increased annually for the past eight years. The modern plant, with all the present-day sophistication, must have a welltrained and well-organized force of skilled workers, and a maintenance system which will supply realistic facts and guidelines. This presentation will review the relative location of plants, utilities, maintenance and services, plant maintenance control and mechanical control. It is the hope that enough information will be presented to weigh the size of the job and how the resources are utilized for controlled maintenance."

Jan 1, 1974

By L. D. Haig

"The Texada Mill is a unique iron operation producing High Grade sinter iron concentrate and a by-product copper, gold, silver concentrate. The plant is complex and extremely flexible to handle the many varieties of ore. Two iron concentrates are made and blended. A coarse iron concentrate from primary grinding and a fine concentrate after rougher flotation to remove all the sulphides.All the tailings from iron processing are collected, dewatered, reground and floated for additional copper recovery.The entire milling operation has been carried out in all sea water for seven years and mixtures of sea, fresh, and reclaimed water for ten years prior to that.A very stable float results from the use of sea water at the natural pH8. Reagent Consumption is lower and Metallic Corrosion of mill liners and grinding media is actually less than local fresh water or mixtures of fresh and sea water.Marine growth in pipe lines can be periodically removed by violently bubbling high pressure air up through the water filled mains.Location:Texada Mines is located on tide water on the west side of Texada Island 100 miles northwest of Vancouver, B. C.The Island is served by a 30 car ferry, tug and barge and a scheduled air service from Vancouver to a company maintained air strip near the mine.The climate is moderate with about 30 inches of rain during the winter and relatively dry summers."

Jan 1, 1974

By J. R. Maxwell

In 1970 expansion was completed increasing mill capacity from 2,000 to 3,000 T.P.D. Actual grinding capacity is 3,400 T,P,D. at a grind of 60% -200 mesh,The ore bodies are vein type, containing about 12% sulphides, with mill heads averaging 2.25% Cu, 0.015 oz.Au, and O.4O oz, Ag. per ton.Summary and Conclusions:During the period Jnnuar-1 1971 to December 1973 inclusive the use of large cells at Opeminka have shown that metallurgy is comparable to when using conventional cells, Operating and maintenance costs are lower, An on stream analyzer with reagents controlled by computer, are being assessed further.Opej1atljn Of Cells:!lo cell level adjustments are required when tonnage is adjusted 20 to 25%.Depending on mill heads and grade of concentrate reagents are adjusted to the first rougher for metallurgical control. Reagents to second rougher and scavengers are seldom adjusted as feed to this section has a maximum variation of about 0.2'~ Cu.Power – Maintenance and Space Requirement :Our total power consumption for 3,400 T.P,D. flotation circuit for operation and air supply is 280 H.P. Previous power drawn using conventional cells was 400 H.P. at 2,000 T.P.D.Total maintenance costs for flotation circuit has averaged $1,100.00 per year for the 3 years of operation, this cost should remain constant.Floor space required for cells and walkways is 2,000 sq.ft.

Jan 1, 1974

By C. E. St. Denis

"Training Program at Sherritt Gordon's Ruttar:. ConcentratorA formal training program for mill operators is being developed and employed at Sherritt Gordon's Ruttan Concentrator. The program was set up to fulfil the needs created by a shortage of skilled reliable labour, a 200% turnover of personnel within the first six months of operation and the rapid advances in mineral processing technology. All new employees are introduced into the Mill Department through an orientation program designed to familiarize them with the operation of the plant. All training and orientation of new employees is the responsibility of a. small training section consisting of two training foremen and one assistant. Using a combination of classroom and supervised on the job training, the training times have been cut by at least one half. High operating standards have been set and are maintained through the use of detailed manuals for each work area and competent instruction at all operating levels. The major portion of training costs arise from the salaries of the training staff but are negligible when compared to the improved recoveries, smaller turnover and less downtime. Government assistance is available to all industrial employers to offset the costs of training employees."

Jan 1, 1974

By R. D. Brown

"""A matter of serious concern to the mining industry in British Columbia""; this comment reflects the attitude of the Mining Association of British Columbia toward the proposed new B.C. Mineral Royalties Act. The proposed legislation, introduced by the provincial government in February and now being debated by the legislature, combines a basic 5% royalty on the selling price, less approved p1ocessing and transpo1•tation costs, of minerals produced in B.C. with an ""excess"" royalty of 50% of any price increases over a predetetmined base. Government estimates project annual revenues of $20 million from the new royalty structure. The accuracy of these figures has been contested by the mining industry. Based on current world prices for copper the industry estimates that the provincial revenues from this mineral alone may run as high as $140 million in 1974 and $150 million in 1975. The Mining Association has warned that the new royalties “threaten to become confiscatory""."

Jan 1, 1974

By G. M. Hughes

"400 cubic foot Agitair Flotation Cells are in use at Sherritt Gordon's Fox and Ruttan Mine Cu-Zn concentrators. The 4 impeller model No. 120, used at the Fox Mine Operation, appears to offer superior agitation and aeration qualities compared to the single impeller model 120A, in use at Ruttan. The advantages of the model 120 are most significant with ores of high specific gravity and coarse grind.IntroductionSherritt is using 400 cubic foot Agitair flotation machines at both the Fox and Ruttan Mine Concentrators.At the 3000 tpd, Cu-Zn Fox concentrator, 18 model 120 machines have been in operation since May, 1969.The 10000 tpd, Cu-Zn operation at Ruttan utilizes 49 model 120A machines. The plant started operation in May, 1973.The 4-impeller model 120 flotation cell has been marketed by Galigher since the early 1960's but the single impeller model 120A is relatively new.Model 120 Agitair -Cell DataThe Model 120 (Dwg. 1) has floor dimensions of 101 x 10' and a lip height of 2~ to 4 feet to provide up to 400 cubic feet of volume. This machine is shown with a froth crowder and stabilizer plates which are optional.Each motor drives two agitators. 20 HP is recommended by Galigher but 25 HP is more realistic with massive sulphides. The SG of ?ox ore is about 3. 6.The Model 120 can handle up to 600 cubic feet of air per cell at 2 psig which requires 5-6 HP at the blowers. Air volume to each impeller is controlled by a valve from a main header.During the first 3 years of operation at Fox there were few mechanical problems with the 120's."

Jan 1, 1974

By G. Merle, David L. McKay, Elmar Randveer

"THE ENGINEERING AND TECHNICAL SERVICES department is responsible for supplying the following services:1. Administration and co-ordination of the work required for capital projects.2. Engineering, design and drafting services for inplant changes or improvements as requested by the operating• and maintenance departments.3. Rock mechanics.4. Preparation of plans and layouts required for efficient extraction of the ore as mutually agreed with the mine operating departments.5. Mine planning and long-term schedules in co-operation with the mine operating departments.6. Grade control (long term and short term) and the preparation of ore and waste removal schedules to maintain a uniform grade of mill feed. This also includes the calculation of metal reserves and metal production forecasts.7. Surveying, underground and surface.8. Operations research at the mine site.9. Industrial engineering.10. Chemical analyses and assays.11. Instrumentation.12. Environmental control.A staff of approximately 35 supervisors, engineers and scientists, and 80 technicians, supply the foregoing services. Consulting engineering and drafting firms are used to supply specialized services and technical personnel in-house at Timmins to handle overloads on capital projects under the direction of Ecstall engineers.The operating and maintenance departments depend on the engineering department to supply engineering, design and drafting services for any new facilities or for any planned alteration to existing facilities. To do this efficiently requires a high level of communication and co-operation with these departments. This has been a major factor in developing the present organization of the department shown in Figure 63.The organization is predicated on a strong central technical and engineering resource from which personnel can be assigned responsibilities for different projects, and in different areas, as the work load demands. Job satisfaction is very high because of the variety and challenge in the tasks. Additionally, participation in projects with production and maintenance personnel broadens each technical employee's knowledge of operating and maintenance problems."

Jan 1, 1974

By G. M. Behrend

A group of mining men attending a recent workshop on "Analysis and Control in the Canadian Minerals Industry" issued, among others, the following statement: "Slurry flow measurement is considered to be one of the most inaccurate in the industry. A special program should be launched to encourage development." In response, this paper starts off the program with an investigation of the principles and the conventional practice of slurry flow measurement and identifies weaknesses which cause inaccuracies. Then it follows with descriptions of nonconventional systems in use at various locations and comments on their degree of success. The paper concludes that relatively simple methods, which it describes, can be applied to obtain an accurate slurry flow measurement.

Jan 1, 1973

By G. W. Poling

Sedimentation behaviour of siliceous mill tailings derived from a magnetite-chalcopyrite ore in fresh water, fresh water - sea water mixtures and full-salinity sea waters are compared. Results of batch settling tests are presented in the form of settling curves and solids flux curves. The addition of a few per cent of sea water markedly enhanced the zone sedimentation rate due to particle agglomeration caused by a reduction in zeta potential of the suspended solids. The presence of a small amount of residual, previously magnetized magnetite in the tailings also enhanced agglomeration and sedimentation. The significance of these results to submarine disposal of mill tailings is discussed.

Jan 1, 1973

By K. R. Coulter

"Good morning gentlemen. I am very pleased to have this opportunity to tell you a few of the things that happen within a completely unrelated activity, the electroplating industry, except that it does consume metals and has some slight similarity of problems so far as cyanide is concerned.First, just a few general terms about the industry. It is a relatively unsophisticated industry technically, and in many instances there are serious problems in obtaining staff that can operate the various systems that are currently available for destroying cyanide or precipitating metals.I would suggest to you that if you are investigating any system that you consider very seriously the personnel that are actually going to run it. The installation people; probably have some idea what it is all about but the operators must be chosen for their ability and not because they just happen to be available.We perhaps have another area in common. There is very little money for capital expenditures that produce no immediate return or even eventual return on the investment.The industry is largely made up of ""Jobbers"" who are strictly electroplating. There is another group in which the electroplating is captive as in large companions where it is a convenience operation. Also there are specialists, who do other things besides plating but it is a very major part of their operation. This applies to the automotive parts industry.Cyanide applications in the plating industry will be for copper, zinc, cadmium, silver, brass, and gold. Cyanide waste solutions come from those solutions adhering to the plated parts, and from the occasional discharge of the plating bath solutions. Also, in a related industry, the heat treating people with cyanide case hardening have some high concentrations of cyanide to dispose of. Concentrations of cyanide that we treat are 2500 parts per million or higher especially in wastes from heat treating. Solution volumes might be as low as 100 gallons per hour in a well run, carefully operated rinsing system. It may be as high as 3000 gallons per hour where dilution occurs."

Jan 1, 1973