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By B. Yu, N. Verbaan, A. Mezei

The recent 20 years witnessed a boom and bust in the nickel laterite industry. Most notoriously is the story of the first three Western Australian nickel laterite projects which all suffered major ramp-up issues. Many hard lessons were learned by the industry and it has been widely reported that the major contributing factors included insufficient testing as well as a limited understanding of the materials handling characteristics at the front-end stage of the flowsheet. This paper compares the current "race to production" in the REE industry to the laterite industry 20 years ago and addresses the fundamental question: ‘Have mining and exploration companies with rare earth projects learned from past lessons and are they doing sufficient and appropriate testwork to prevent failure’? The authors will provide the perspective of a commercial metallurgical laboratory that has gone through the laterite cycle and is active in the present REE cycle.

Jan 1, 2014

By D. Brand

"The risk management objective of the AMIRA Code of Practice for Metal Accounting has seldom been systematically investigated in the literature up to the authors’ knowledge. Risk is defined in the Australian Standard on Risk Management (AS/NZS 4360:2004), as “the chance of something happening that will have an impact on objectives”. The simplified economic analysis performed in this paper has lead to define “something happening” as measurement non-representativity and “impact on objectives” as NSR loss from the optimal NSR. This has pinpointed a missing link being the establishment of a relation between NSR in flotation plants and measurement representativity. The proposed framework, referred to as the total cost of representativity, answers the previously unanswered question of how much accuracy/reproducibility is fit for purpose in a given flotation plant. Authors readily acknowledge that it is way easier to assess the cost of accuracy/reproducibility than the cost of inaccuracy/irreproducibility. However, this exercise not only answers previously unanswered questions but also establishes an essential link with operational excellence. This paper exposes why such operational excellence could neither be attained nor proved without a state of the art metal accounting system. This should impact not only how metal accounting systems are audited/designed/refactored, but also how flotation plants are designed.IntroductionBecause representative metal accounting is a vital source of information for the financial accounts of a mining/metallurgical company, the need for a code on metal accounting was recognized in 2001 and a team was formed in 2003, under the sponsorship of several major mining houses, to produce such a code. Table 1 exposes the two main objectives of this AMIRA Code of Practice for Metal Accounting."

Jan 1, 2017

By H. A. Steane

"This presentation will cover some crushing and grinding considerations in plant design and operation. There is nothing basically new in the subject matter presented here; however, the viewpoint and interpretation may be novel and some of it controversial.The presentation is based on experience gained in the metallurgical design of plants for Placer Development Limited from 1960 to the present. The plants are listed on SLIDE No. 1.These plants have conventional crushing, followed by rod mill and ball mill grinding. I would like to think that autogenous grinding plants are the answer for eliminating secondary crushing plants and reducing the capital and operating costs; however, the autogenous plants seem to have some problems of their own and I have had no experience with them.Fineness of Grinding RequiredFirst let us consider the fineness of grinding required.The fineness of grind will affect the recovery obtained, and the relationship must be determined. If the grinding is too coarse, some of the valuable mineral, either free or locked in middling grains, will not be floated. However, as grinding is probably the greatest single operating cost, we do not want to grind any finer than is justified economically.Finer grinding should not be carried beyond the point where the net smelter return for the increment saved becomes less than the added operating cost. Even this fineness will be beyond the economic limit because of the additional capital cost for the equipment needed to achieve it. These factors will be discussed in more detail later.The Bond work index is the commonest method of expressing a measure of the effort that has to be expended in grinding. It is the kilowatt-hours required to reduce a ton of rock from an infinite size to 80% passing 100 microns. The formula allows a calculation to be made for other size ranges."

Jan 1, 1976

By Ish Grewal

"Batch centrifugal gravity concentrators, which produce very high ratios of concentration, have become common place for recovering free gold within milling circuits. Their effectiveness has proven to be especially useful in recovering finer gold particles. The knowledge related to testing, modeling and scale-up of these systems has been well established over the recent decade mostly due to the efforts of the late Dr. Andre Laplante.Gravity separation technologies such as jigs, spirals and shaking tables can provide the increased mass yields required for minerals that occur at higher concentrations than gold, however their effectiveness tends to diminish at finer particle sizes. The development of high mass yield centrifugal concentrators has provided the opportunity to be able to recover a wide range of minerals at finer particle size classes when compared to the more traditional gravity concentration devices. These concentrators also provide additional benefits such as smaller unit footprint and automated operation.This paper discusses the background, current practices and future applications for high mass yield centrifugal concentrators in base metals, sulfides and industrial minerals. Bench scale, pilot scale and plant practice examples are also presented.INTRODUCTIONGravity concentration, one of the oldest mineral beneficiation processes, has evolved over the decades and continues to play an important role in modern mineral processing operations. The development and growth of froth flotation in the early part of the twentieth century led to a decline in the importance of gravity concentration. However, gravity concentration continued to be used for ores that are difficult to beneficiate using froth flotation; such as tin, tungsten, niobium/tantalum, iron, industrial minerals and oxidized coal. In recent decades, many operations have begun to employ a combination of both gravity concentration and froth flotation Since flotation relies on surface chemistry and gravity concentration relies on specific gravity differences, putting these techniques in series provides today’s metallurgist with unprecedented opportunities to maximize grade and recovery of many of these minerals."

Jan 1, 2009

By B. M. Coombes

The McCracken and Stacey (1989) method of assessing geotechnical risk for largediameter raisebored shafts has been the basis for most Australian pre-construction raisebore investigations for the past 20 years. At the time of its publication, the McCracken and Stacey (M&S) Method did not include a database of raisebore diameter and rock mass conditions versus actual performance. It did, however, provide a chart that quantified geotechnical risk in terms of proposed shaft diameter and the raisebore rock quality index, QR. Two parameters, RQD/Jn and Jr/Ja were identified as being critical to raisebore stability, but the contribution of these to overall raisebore stability was not quantified. Peck and Lee (2008) published a database of raisebore performance from Australian case histories. Raisebore diameter and ground conditions, in terms of a Lower Bound QR value, were presented for 50 cases versus raisebore performance. This paper updates the database with further case histories and corrected SRF values. This paper further evaluates the reasons for the variable raisebore performance for similar RSR values. For all case histories, three parameters, RQD/Jn, Jr/Ja and Jw/SRF are investigated to assess their influence on raisebore performance.

May 1, 2011

By Sylvain Létourneau

Help organizations maximize the benefits of the data that they collect ? perform scientific research in: machine learning, data mining, statistics, artificial intelligence, soft computing, information retrieval, information systems, and natural language processing ? preferred application areas: Equipment Health Management, Bioinformatics, Health, Web Mining ? today?s talk limited to Equipment Health Management While the aircraft is still in the air, IDS: ? clusters relevant WRN, FLR, and snag (pilot) messages ? identifies probable causes based on TSM and provide links to corresponding TSM pages ? assesses MEL conditions (GO, NOGO, GOIF, ?) ? displays relevant maintenance history, suggests fixes based on similar cases ? Commercialization with MxI Technologies Ltd and Air Canada in 2000

May 1, 2008

By Chris Brown

"The Island Copper plant was designed and built by Fluor Utah Ltd, in conjunction with Utah design staff, Originally designed to treat 33,000 tons/day (t/d) of ore, the current average milling capability is 38,000 t/d (Nov'74). The first of six semi-autogenous grinding lines was brought on line in October 1971, startup of the remainder being governed by equipment delivery schedules.The summer of 1973 saw the start-up of an additional three ball mills, and attainment of the present production level. The current process flowsheet is shown in simplified form.CRUSHINGThe crushing circuit is relatively simple, comprising single stage crushing of the ore followed by screening to fine and coarse fractions.The crusher is a 54 x 74in. Allis Chalmers Superior Gyratory with a setting of 9-lOin., driven by a 500-hp motor. Trucks dump on three sides of a rectangular dump pocket. An 84in. x 20ft. link belt apron feeder draws crushed ore from a 250-ton surge bin below the crusher, discharging onto a 72in. wide inclined steel cord conveyor belt. A fixed splitter box at the conveyor discharge separates feed to two parallel Jeffreys 6 x 20ft. vibrating grizzlies for screening into +4in. and -4in. fractions. The fractions are collected on short reversible conveyors which feed the coarse and fine ore stacker conveyors. Trippers distribute ore to outside stockpiles adjacent to, and above, the concentrator grinding 'floor."

Jan 1, 1975

By É. Roberge, S. Makni, G. Gagnon, F. Lavoie, A. Faucher

"Feed particle size is an important variable for the primary grinding mill operation. Several commercial vision systems have proven to successfully measure online many types of ores and are used for automatic control. However, due to limitations associated with segmentation algorithms, these systems fail to provide good measurements when the feed is composed of a specific bimodal particle size distribution: very big rocks and a large amount of fine particles. This is typically the case for crushed iron ore. This paper presents a technique to overcome the limitations of existing vision systems by using 3D cameras and appropriate processing methods. It provides online particle size distribution indicators and bulk volume flow rate measurement. It is designed to be very cost-effective, robust, precise, easy to install and to maintain. The 3D system was validated in two iron ore processing plants and the results clearly show that it can be used to optimize primary grinding mill operation where 2D segmentation vision systems fail.INTRODUCTIONFragmentation measurement using digital image processing has successfully been applied in mining and mineral processing operations. Several maintenance and operating applications are already deployed in the industry: Measurement of rock fragmentation after blasting (Maerz, 1999; Palangio, 1999) (Pragyan, 2012) Truck inventory (Palangio, 2005) Monitoring of crusher mantle wear Automatic control of crushers and SAG mills (Bouajila, 2000) (Bartolacci, 2001)Commercial technologies like WipFrag (Maerz, 1999), VisioRock and others proved to be very efficient to precisely measure the particle size distribution of many types of materials. These products are mainly composed of a camera, a lighting system and an image processing system based on a segmentation algorithm. By controlling adequately the lighting conditions and with periodic maintenance on the segmentation algorithm calibration parameters, it is almost always possible to achieve reliable measurements.However, the segmentation algorithm is not adequate when the particle size distribution contains big rocks and a large amount of fine particles. In this case, the area containing the fine particles is accounted as a big rock while big rocks get segmented as multiple smaller sized particles, leading globally to a wrong measurement. This situation prevails for crushed iron ore and coke, among other materials. Figure 1 shows a picture of a material which is typically very difficult to process through segmentation techniques."

Jan 1, 2015

By Denis Labrie

Le minage en profondeur sous contrainte modérée à élevée présente de nombreux défis aux opérateurs et aux ingénieurs de mine notamment au niveau du contrôle de terrain et de l?environnement minier souterrain, pour assurer la sécurité des travailleurs sous terre et la continuité du cycle d?opération. Des conditions de contrainte élevée signifient une pression accrue au front de taille et sur les structures minières tels les piliers de mine et les fins de zone, un risque de rupture violente ou de coup de toit plus élevé, des zones de rupture plus grandes au pourtour des excavations, des charges accrues sur le support de terrain, etc. Le présent article fournit un aperçu du travail fait à l?intérieur du Programme de Contrôle de terrain de CANMET au cours des sept (7) dernières années, entre 1995 et 2001, pour comprendre et suivre l?évolution des niveaux de contrainte à l?intérieur des structures minières. Les propriétés déterminées en laboratoire sur des échantillons rocheux et les prévisions effectuées au moment de la conception sont comparées avec les observations effectuées en chantier à la paroi des excavations et à l?intérieur de la masse rocheuse. La plupart des cas discutés ici montrent une corrélation satisfaisante entre les observations effectuées en chantier d?une part, et les résultats d?essai obtenus en laboratoire et les calculs réalisés lors de la conception d?autre part. Ces observations peuvent donc être considérées comme des moyens relativement sûrs pour vérifier et suivre l?évolution des niveaux de contrainte présents à l?intérieur des structures minières.

May 1, 2002

By J. Chao, C. Tan, N. Stubina

"Since J978, Falconbridge Limited has operated two electric furnaces at its nickel-copper smelter in Sudbury. As part of its S02 Abatement Program, the smelter has undergone many changes over the last seven years.This paper describes the impact of these changes on the operation of the furnaces. Some of the topics to be covered include: the installation of sidewall copper coolers; current operating conditions; and furnace heat and mass balances. HistoricalFalconbridge began smelting ores in the Sudbury area in 1930. The original smelter consisted of a 1.3 m by 3 m blast furnace and two 4 m by 6 m converters. The blast furnace was supplied with untreated mine are and molten slag/matte was discharged into a round settler.In 1933 the smelter began treating flotation concentrates. The concentrates were mixed with fine magnetic ore and flue dust, then sintered on down-draught Dwight Lloyd machines. This provided an agglomerate suitable for furnace burden which was charged to the blast furnace while still hot.Between 1930 and 1954 nickel production was increased by lengthening the 3 m furnace to 4.6 m, then to 6 m, and later by constructing additional furnaces. By 1958, the plant consisted of one 7.5 m blast furnace, a settler, and three 4 m by 9 m converters."

Jan 1, 1994

By Marc C. Bétournay

Over the last four years, an international initiative, championed by Vehicle Projects LLC, the Fuelcell Propulsion Institute and Natural Resources Canada, has been active in carrying out research projects to prove out the concept of applying fuelcell technology to underground mining vehicles. These have been carried out by a consortium consisting of mining companies, equipment manufacturers, technology developers, national laboratories and consultants, with the participation of Canadian and U.S. mine regulatory agencies. This clean technology, which produces only water and electricity, would allow several advantages to be obtained, in the health area (by eliminating diesel emissions and reducing noise generation), in lowering production costs (such as reducing ventilation required) and lowering green house gas emissions. This article outlines the results obtained in several key areas, such as the operation of fuelcells in underground conditions, risk issues related to underground and surface operation of hydrogen vehicles and hydrogen production and delivery systems, and the design and mining performance of the world?s first hydrogen mining vehicle, a mine production locomotive. The work to date on the fuelcell loader, designing the power plant and power transmission systems, operational requirements, and operating cost reductions, is also presented. There is also an evaluation of the overall mining applications and advantages this technology can bring to underground mining, including the facilitation of automation and tele-remote operation.

May 1, 2003

By S. Hoskins, S. Chiovelli

"The annual budget for the repair and maintenance of equipment at Syncrude Canada Ltd. is in excess of $450 million. Of this amount, a significant portion can be attributed to the loss of material on various pieces of equipment throughout the operation. In order to effectively battle the different wear and corrosion mechanisms that lead to material loss, it is important to understand how materials behave in the environments in which they are used. Through the work carried out at Syncrude, and work conducted with various external collaborators, significant improvements in both equipment reliability and productivity have been achieved. This paper will review some recent field trials where materials research has demonstrated the potential for significant improvements in equipment run life and reduced maintenance costs. These field trials will demonstrate the need for understanding the interaction between various damage mechanisms and the materials used in different services. The paper will also discuss current areas of focus along with future directions for further work. IntroductionSyncrude Canada Ltd, located in northern Alberta, Canada, operates a mining, extraction, and upgrading facility that removes bitumen from oil sand to produce synthetic crude oil. Oil sand is mined from the orebody using conventional open pit mining techniques. Recently, the mining scheme has changed from a dragline/bucketwheel/conveyor system to a shovel/truck/crusher/hydrotransport operation as depicted in Figure 1. Since the start of production in 1978, the identification, development and application of wear protection has been an ongoing challenge due to the abrasive nature of the oil sands and the massive volumes of materials that are moved. The use of various materials and application processes along with component design modifications has resulted in significant improvements in both productivity and reliability (Adamic et al., 1995; Llewellyn, 1996, 1997; Anderson et al., 1998; Chiovelli et al., 1998).In an effort to continuously improve the operation, Syncrude has been quick to adopt new wear technologies. As seen in Figure 2, since the start of operation, a variety of materials have been used to increase wear performance and ultimately equipment reliability and availability. Although Figure 2 does not show a time axis, the bottom axis may also be used to represent a time progression for the predominate use of these materials at Syncrude. Tungsten carbide metal matrix composite (WC-MMC) overlays are currently the materials of choice for most of Syncrude’s critical production applications. Metal matrix composite overlay technology has potential for significant improvements and Syncrude is actively working with powder consumable manufacturers to advance this technology."

Jan 1, 2004

By M. Kane, B. Bissonnette, D. Hodouin

"A laboratory cell has been designed for a careful investigation of gold ore cyanidation using mathematical modelling of the process kinetics. The cell is a stirred vessel with continuous monitoring and control of pH, oxygen and free cyanide contents. Samples are automatically extracted for gold analysis. The instruments are connected to a microcomputer which records all the measured variables and calculates the reagent consumption (air or oxygen, cyanide, lime). For cyanide control a sample is automatically extracted and filtered and the solution analyzed, using a specific electrode, by a flow injection technique. The rate of gold dissolution is modelled using a kinetic model the parameters of which are calculated by a non linear least-squares technique. The parameters of an empirical model of reagent consumption are also estimated. The resulting model is used in a simulator for gold cyanidation plant design, tuning and control.INTRODUCTIONThe leaching of gold ores in a cyanide solution is the usual method for gold extraction from raw ores. This process requires long reaction times and leads to very significant consumption of cyanide. The optimization of the cyanidation plant operation is a very important aspect of gold ore processing for increasing gold recovery and decreasing operating costs. The key parameters to the improvement of gold extraction are the selection of an efficient solution chemistry, the design of the size and the arrangement of the equipment and the correct tuning of the operating variables. Automatic control strategies can then be applied to maintain industrial operations at their optimum setpoints.Two approaches can be used for optimizing design and control of cyanidation circuits, either empirical trials for improving process performances or mathematical modelling of the process kinetics for subsequent analysis, simulation and optimization. The advantages of the second approach, which is used in this study, is that it gives a systematic pattern to interpret data and reliable tools, in as much as the models are good, to improve operation performances. In order to determine the structure and the coefficients of cyanidation models, well controlled measurement and calibration procedures must be used. The purpose of the paper is to present an equipment and a test procedure for modelling the kinetics of gold ore cyanidation."

Jan 1, 1990

By D. Wolfe, R. Cleminson

"The Aurora North mine has been operating for more than ten years, and is the source of over half of Syncrude’s bitumen production. The hydrotransport systems at Aurora experience high rates of wear, and mission lengths on current slurry pumps are nominally 1,500-2,000 hours. Recent work has enabled a better understanding of the significant adverse effect of large particle impingement damage to impeller vane leading edges - which is the known life determining issue for Aurora hydrotransport pumps. A new pump design has been developed and installed at Aurora, incorporating significantly increased impeller diameter and pumping vane lengths. The new pumps are expected to triple Aurora’s previous mission length for hydrotransport pumps. Part II of this paper will share actual hydraulic and wear performance observed in the first several months of operation, and draw comparisons relative to what was expected for these pumps in design / development.INTRODUCTION Slurry Pumps are Critical Equipment at Syncrude Slurry pumps are a key component in Syncrude’s operations. In a typical Aurora application, each 5000 HP pump stage helps move over 8,000 dry tonnes per hour of oil sand, plus an equal volume of process water that has been added to create the slurry. The average impeller life in oil sand hydrotransport service at Aurora has been nominally 1,500 to 2,000 hours, or 12 to 16 million tonnes of oil sand pumped. Generally, the slurry pump application at Aurora has proven very difficult to improve due to the unique combination of high sand abrasivity, 125 mm (5”) large particle top size (lumps), and high flow rate relative to basic pump size; a factor that results in unduly high impeller vane leading edge speeds for the service conditions."

Jan 1, 2014

Block caving is an underground mining method for the profitable extraction of massive, low-grade orebodies. Lately, it has become the mining method of choice, for many mining companies, because of depleted high-grade orebodies, and declining metal market prices. Block cave mining, however, still faces several challenges. Lack of access to the cave remains a major issue in understanding the rockmass response to mining for method optimisation. Improving our understanding of the rockmass response to caving will lead to safer and more productive operations. Combining large datasets from multiple sources with virtual reality scientific visualisation (VRSV) is a viable alternative to understanding complex cave behaviour without access to the cave. This is achieved using immersive environments with the ability to view complex multi-dimensional data (beyond 3D) graphically. VRSV offers a unique platform where it becomes possible to immerse the multi-disciplinary experts, and/or management team, in a virtual mine environment for quick decision making and fast resolution to conflicting conclusions. The underground mining system is complex due to multiple interrelating factors such as geology, excavation geometries, stress and time. Block caving is even more complex than most underground mining methods due to the network of tunnels required, and the use of induced stress, among others. As a consequence of the complexity in the block caving environment, it is vital that the mining system is analysed holistically, as a system, rather than optimizing individual factors one at a time. This paper presents a customised software module developed for use in the Advanced Visualisation Interactive Environment (AVIE) at The University of New South Wales (UNSW), Australia, to enable VRSV investigation into block cave mining systems (BCMS). This approach has the potential to provide a better understanding of the effect of time in in rock engineering, which has proven to be an important factor in hard rock mines (Ma & Daemen, 2006; Malan et al., 1997; Suorineni, 2010) but never validated. This work back analyses the early undercutting phase of a case study block caving operation with the view to understanding time/sequence effects. There is evidence that heterogeneous rockmass time-dependent behaviour governs the seismic response of the rockmass following undercut developments.

Jan 1, 2015

Les Mines Inmet ? La Division Troilus exploite une mine d?or à ciel ouvert depuis 1996 et produit un concentré de cuivre. La Division Troilus est localisée à 175 KM au nord de la ville de Chibougamau? au 51 parallèle.

Feb 1, 2008

By Marc C. Bétournay

A mine production locomotive, the world?s first applied industrial fuelcell vehicle, has been designed and tested in the context of a number of proof-of-concept projects supported by the Fuelcell Propulsion Institute, an international consortium of stakeholders dedicated to facilitate the commercialization of fuelcell vehicles. The locomotive?s simple electric-powered motor and controller system was ideal to study a number of requirements related to fuelcell power application: hydrogen power plant operation, underground hydrogen use, risk and regulatory requirements, production performance versus the conventional battery-powered locomotive version under measured duty cycles and production requirements, power plant design improvements for other fuelcell vehicles, and cost-benefit aspects. This article will focus on the design and testing aspects of this project which has led to successful performance demonstrations of the vehicle under surface and underground conditions at two mines. It will also present information on the creation of a safe, reliable and efficient power plant which fulfilled its design objectives, including longer productivity time for a given vehicle fill-up.

May 1, 2003

By D. Bois, P. Keating, J. Lemieux, M. A. Vallée, M. Allard, R. S. Smith, L. Z. Cheng, M. Chouteau, D. K. Fountain

"As part of a larger research program, a number of MEGATEM airborne electromagnetic (EM) test flights were flown over the Gallen massive sulfide deposit in northwest Québec. A particularity of this test site is that a major part of the ore body was extracted before the MEGATEM survey. Therefore one of the purposes of this study was to verify the ability of the system to detect the remaining massive sulfides below the water in the open pit. The open pit is also surrounded by a metallic fence, and a power line is present in the vicinity. A large part of the case study involved accounting for the impact of infrastructure and acidic water on the survey, which will help in the interpretation of airborne EM responses in complex exploration situations.The Gallen deposit was also previously flown with the INPUT and GEOTEM airborne EM systems before the major exploitation period. A comparison between the results from the different survey results allows estimation of the physical properties of the Gallen deposit, which is a relatively poor conductor.A new method for removing the power line signal shows amplitudes with a smaller residual associated with the emanating fields, and more compact, cleaner responses associated with induced currents. This will make it easier to identify bedrock conductors close to power lines"

Jan 1, 2007

By J. O. Marsden

Over the past decade, the copper industry has been through an extended downturn followed by several years of sustained high copper price. A number of new technologies have been developed over the past 10 years aimed at reducing costs by decreasing energy, labor, and materials requirements, or by increasing metal recovery. The energy intensity of different copper extraction routes and different technologies varies considerably and this has a significant impact on the economics of extraction. Based on average ore grade materials, the total energy for the extraction of copper typically varies from about 24-26 MJ/lb (6.7-7.2 kWh/lb) for the mining, crushing, milling, flotation, smelting and refining route to about 14¬16 MJ/lb (3.9-4.5 kWh/lb) for the mining, crushing, heap leaching, solution extraction and electrowinning route. New technology developments are providing opportunities for significant reductions in energy consumption for copper extraction, representing energy savings up to 20-25% in some cases. In addition, in many cases, these new technologies have introduced environmental, safety and health benefits over the incumbent technology. Some of these technology developments have been more successful than others, and many hold great promise for application in the coming decade. This paper provides an overview of the technology developments that have occurred, and explores the underlying reasons behind successful implementation.

Jan 1, 2007

By Carl Bertrand, Patrice Nadeau, Claude Bazin

"Rio Tinto Fer et Titane processes the ore extracted from the Lac Tio orebody to concentrate the hemo-ilmenite (FeO.TiO2-Fe2O3) mineral that is subsequently smelted to produce pig iron and titanium oxide slag. The ore is crushed, heat treated (roasted) and concentrated using dry magnetic separators. This paper describes a model to predict the magnetic susceptibility of the roasted ore and its behaviour in the magnetic separation plant. The model uses a classification of the ore as a function of the size and magnetic susceptibility of the particles. A subsequent division into mineral species allows the simulation of the magnetic separation process. The model is used to assess various operating options when process disturbances occur.INTRODUCTIONOre processing operations consist of ore size reduction followed by the recovery of valuable species in a concentrate that is subsequently sold for its minerals or metal content. The concentration processes are based on the physical and/or chemical properties of the minerals contained in the ore. Flotation is typically used to recover minerals of base metals such as copper, zinc, lead or nickel. Iron ore and other dense minerals are typically concentrated by gravity separation processes. Magnetic separation uses the magnetic properties of the minerals to concentrate magnetite and other minerals, to clean coal concentrate and to recycle ferrosilicon for dense separation processes (Brophy, 1985).Magnetic separators can be divided into low and high intensity separators and high gradient magnetic separators (Gillet, 2008). Most of the low gradient magnetic separators are built as rotary drums that are operated in wet or dry conditions. Dry magnetic drum separators are used by Rio Tinto Fer et Titane in Sorel-Tracy, Canada to concentrate hemo-ilmenite from the ore extracted at the Lac Tio Lake mine near Havre St-Pierre, Canada. The analysis of production data suggests that process improvement could be achieved by identifying key variables for the control of the magnetic separation circuit and/or by modification to the circuit flowsheet. The use of a process model was considered to be an effective approach to conduct a preliminary analysis of the circuit with a view toward process optimization. However, the literature contains few detailed studies dealing with the modelling of magnetic separation processes."

Jan 1, 2011