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By T. Cutard, E. Cailleux, F. Nazaret, G. Bernhart

This paper deals with the study of the mechanical behavior in the 20°C-900°C temperature range of refractory concretes reinforced with metallic fibers. Fibers are introduced to improve the damage resistance and to minimize the quasi-brittle behavior of refractory concretes. In some cases, a plastic or ductile like behavior can be obtained. Two approaches are considered in these studies. The first one is based on the micromechanical scale. Main objectives are to understand, quantify and predict the thermomechanical behavior of monofiber microcomposites. Such considerations are helpful to optimize the composite formulation for a better behavior. The second one is based on the macromechanical scale. Main objectives are to characterize and to model the macroscopic thermomechanical behavior of randomly reinforced refractory concretes. A particular attention is firstly paid to the relationships between the microstructural changes and the mechanical properties and secondly to the structural size effects.

Jan 1, 2004

By Silvio E. Kruger

Real time measurement of wear and corrosion provides crucial information needed to determine an optimal schedule for corrective maintenance and is a powerful tool to maximise equipment availability and reliability. It also leads to savings from optimized spare parts handling and helps to avoid costs of accidents and their negative impact on safety and the environment. This paper presents the technology of ?painted-on? ultrasonic transducers that can be integrated to structures and accurately measure the remaining thickness and therefore determine wear or corrosion losses. These transducers have a small footprint, a performance comparable to other commercially available ultrasonic transducers and can sustain temperatures as high as 400ºC. The application of this technology to mining equipments and its potential benefits are discussed.

Aug 1, 2013

By Michel Aubertin

Mining activities can produce large volumes of waste rock, which are typically deposited in piles on the soil surface, above the water table. Such piles can cover areas of several tens of hectares and can reach over a hundred meters in height. For hard rock mines, the waste rock grain size can vary from silty particles to metre-scale blocks. The internal structure of a pile constructed on a relatively flat surface typically includes two main zones. The first zone corresponds to the heart of the pile, and is formed by several sub-horizontal stratifications (with dense and loose layers) due to the heavy mine equipment traffic which induces local compaction and degradation of the waste rock. The second zone corresponds to regions where waste rocks are deposited by push-dumping or end-dumping close to the external flank of the pile, inducing grain size segregation along the slope. Depending on the deposition sequence, grain size distribution and bench height, a gradation may then be observed, with coarser particles (with cobbles and blocks) near the base and finer particles near the crest, together with inclined stratifications due to the advance of the deposition face. These internal features affect the distribution and flow of water (and air) in the pile. To assess the internal distribution of material properties within the pile, a combination of several tools is usually required which can provide information on the hydrogeological and geochemical characteristics of the waste rock. In this regard, geophysical tools are very interesting because they can lead to a threedimensional mapping of property variations. The information gathered from a combination of appropriately selected techniques can be used to construct numerical models to further study unsaturated water flow and reactive transport. Such simulations help better understand the pile response in its actual and future states, which in turn provides input to adjust the deposition sequence, to plan for closure, and to select an in situ groundwater monitoring strategy. The presentation will give an overview of techniques that have been developed to characterise material properties in the laboratory and in the field, and to obtain a general picture of a pile?s internal structure. Additional results on unsaturated reactive transport modelling will also be shown to illustrate how the internal pile structure may influence its hydro-geochemical and environmental response.

Nov 1, 2008

By Dina Aloi

The need to be seen as responsible neighbours and good corporate citizens is a critical success criteria for mining companies. To be seen as responsible requires both achieving responsible performance, and making that good performance visible to the community, legislators, investors, and other stakeholders. This has broadened the skills required for the successful operation of a mining company to include social sciences, public affairs, communications, and environmental sciences. Mining companies still look to technical specialists to achieve the core of that good performance - broadly characterized as a sustainable operation. However, the degree of understanding that those specialists have of the requirements for sustainability and overall Corporate Social Responsibility has a tremendous impact on the overall performance of the project and company. In her keynote address to the Sustainability for Profit session, Dina will outline some of the key areas in which technical employees and consultants can contribute to achieving successful sustainable mining operations.

Jan 1, 2010

By M. Doucet

The introduction of high-nickel anodes to CCR in 2006 resulted in an increase of nickel in anodic slimes. Removal of the nickel in these slimes to below 3.0% is necessary in order to prevent slag viscosity problems in the subsequent pyrometallurgical step. A lower specification of 0.5% was chosen in order to minimize Ni losses to the slag and to recover this nickel as NiSO4. A 2-stage autoclave process, which was patented by CCR in 1992, was chosen to treat the high nickel slimes. Laboratory and plant?scale tests were performed in 2004 in order to validate the results of this process with the present slimes. These results along with corrosion tests were used to design two brick-lined autoclaves. These autoclaves were installed in October 2006 and successfully commissioned within 8 weeks. A "Design of Experiment" test program was performed in 2006 on an alternative autoclave process that reversed the cycles in the patented process. The effects of temperature and acid content were modeled using the results. The alternative process will be validated with the new autoclaves.

Jan 1, 2007

By K. D. Peaslee, J. M. Soto, IéDé Smith, A. D. Saikia

Spinel-forming refractories reduce penetration of metal and slags through a tightening of the lining resulting from the volume expansion associated with spinel formation. Sintered spinel is often added to reduce the overall volume increase that results. Tests were carried out to evaluate the difference between performance in spinel¬forming and spinel-containing refractory mixes. Eight refractory linings, one (1) pure magnesia, three (3) magnesia-base spinel-forming and four (4) alumina-base spinel- containing dry vibratable mixes, were tested for four hours in contact with a low-carbon, low-manganese steel in a coreless induction furnace at temperatures in excess of 1600°C. Afterwards, sample were cut, and wear and penetration were measured. For magnesia-based mixes wear was minimized using 20-30wt. spinel formation although further experiments are required to determine the optimal value. For alumina-based mixes, there seemed to be an optimal ratio of spinel added to spinel formed that minimized penetration and wear at the slag line. Sidewall accretion occurred and the accretion was the highest for the mix with the ratio of spinel formed to spinel added near the optimum value. Therefore to design an optimum refractory mix the benefits of higher ratios of spinel added to reduce penetration and wear at the slag line will need to be balanced with the tendency to form accretions on the sidewalls of the furnace.

Jan 1, 2004

By Percy Coulter

"GeneralThe Malartic Gold Fields mill is presently treating ore from four different companies. The ore is delivered by truck, by the shipper, and dumped into the Malartic Gold Fields ore bin. This ore varies in size from 'Run of mine' to minus 8 11, All ore is crushed to pass a 3/ 8 11 x 4 11 cross slotted screen.Weighing and SamplingAfter crushing the ore passes over an adequate-weigher (250 T .P.H. capacity) on its way to the fine ore bins. This weigher has a remote counter at the sampling point.A 36” Vezin sampler cuts 15% from the ore stream as it enters the mill bins. This portion is elevated, by means of a short belt conveyor, to feed the No. 2 Vezin sampler. (This elevation is necessary to give headroom for the following machines). The ore on the conveyor is levelled to give a uniform stream to the second sample cutter. The second, third and fourth cutters are 2411 •The No. 2 Vezin sampler cuts 19% from its feed and this portion falls directly into a 1611 x 1011 Denver rolls crusher. This crusher reduces the ore to -1/ 8 11 , approximately. The discharge from the rolls crusher falls on a revolving circular plate with scraper, which gives a uniform stream to the No. 3 Vezin sampler.The No. 3 Vezin cuts 10% from its feed. This portion falls on another revolving plate to give a uniform stream to feed No. 4 Vezin."

Jan 1, 1966

By E. P. Cadwell

"Throughout the years Cyanamid has been a supplier of cyanide and a supplier of information to the mining industry. In general, the knowledge of mineralogy is greatly overlooked. Mineral deposits in the Western hemisphere have been exceedingly rich in the past but now they are becoming poorer. In other words, we will have to use our talents to the utmost to extract the precious metals and base metals from these ores. Modifications of some of the mineralogical equipment displayed here belong in the mill.Cyanidation of copper has been one of the main projects in our labs in recent years. De-rimming or de-filming of copper in order to upgrade copper concentrate was the main aspect investigated. A study was made as to how wide spread was the filming of secondary copper on pyrite, and to what extent it affected the copper industry. It was very wide.Often there is no conception as to what the minerals are. One open pit copper producer with a chalcopyrite ore was producing a copper concentrate with a 5% copper value whereas chalcopyrite contains 35% copper. They used primary and secondary grinding and a regrinding section. The ore contained about 8 parts chalcopyrite to one part of other copper minerals. In tests, a 3 1/ 2% copper rougher concentrate, cleaned without regrinding but conditioned with cyanide for a low contact time of 30 seconds produced a 30% copper concentrate with 90% recovery by removal of the film. It was of utmost importance that some quantitative mineralogical analysis be made before flow sheet changes were made. Every man should be trained to do his own microscopic examination in order to get quick answers. The fundamental thing in all mineral dressing is to first of all know the minerals and the mineral associations."

Jan 1, 1964

By M. Specht, D. Pörzgen, W. Lorenz, A. /. Buhr, R. P. Racher

The introduction of the near net-shape casting process at CORUS Staal IJmuiden in January 2000 required changes of secondary metallurgy processes including a development towards more aggressive slag compositions in the steel ladle. Therefore the steel ladle lining has been changed from fired andalusite bricks to magnesia-carbon bricks and, most recently, to fired spinel bricks to withstand the severe slag conditions. In comparison to the andalusite bricks the new steel ladle linings have a higher thermal conductivity. This requires the capability to keep the lining warm by ladle preheaters to sustain the overall thermal stability of the steel ladle in case of interruptions during hot cycling of the ladles.

Jan 1, 2004

By Tracy-Lynn Humby

A recent report commissioned by the South African Chamber of Mines, Mining Vision 2030, identifies the South African mining industry?s negative legacy, its exploitation of people and the environment, as the single biggest hurdle to maximizing the industry?s impact on national development. Industry leaders have identified the need to put the past ?to rest?. With reference to three recent cases involving members of the South African mining industry, this paper points to the continuities between the past and present. It argues that the metaphor of ?multiple crossings? is more generative than the notion of putting the past ?to rest? for purposes of engaging with mining?s negative legacy.

Aug 1, 2013

By Christopher W. N. Anderson

Induced hyperaccumulation of gold by plants was first reported in 1998 by researchers from Massey University in New Zealand who proposed the idea of mining gold using plants (phytomining). Since that time research has been conducted to understand the conditions under which plants can be made to take up economic amounts of the metal. One key focus has been on the geochemistry of gold-rich soils, leading to a diagnostic test that can predict how suitable a particular soil might be to gold phytomining. Field trials have been conducted at several locations around the world in collaboration with industry partners. A Decision Support System has been developed to assist in the design and management of phytomining operations, and economic modeling has been carried out to set targets levels for phytomining technology. Novel studies are now examining the form of gold in plants. Research suggests that plants may store gold as discrete metallic nanoparticles in leaf and stem tissues, an observation that may lead to new ways to recover the metal from harvested biomass.

Oct 1, 2003

By George Hope, Dave Green, Jacques McMullen

The Est Malartic mill has been treating massive sulphide, copper/gold ore from the Bousquet 2 mine since 1989. The need to minimize copper content in flotation tails which are leached for gold recovery and to produce a saleable copper concentrate led to the evaluation of Conventional, Column and HG flotation methods. The HG method was preferred and two full-scale cells were installed and operated over a two-year span. In 1992, it was decided to expand the mill capacity from 1500 tpd to 2500 tpd. A total of nine additional HG Tank Cells were installed to provide additional roughing and cleaning capacity. The expanded plant has been operating since June 1993.

Jan 1, 1994

By Y. Vermeulen, J. Simoes, P. Guillo, A. Di Donate

New design techniques have been developed to optimize continuous casting (CC) refractory components. The overall objective is to increase CC productivity as well as steel quality by using optimized refractory from tundish-to-mold. These techniques allow the prediction of steel and refractory chemical interactions and, thus, steel chemistry evolution as well as build up and corrosion occurrence. Specific fluido-dynamic models (CFD) have also been developed to better take into account the physical parameters at the steel/refractory interface and to optimize steel flow control. The CFD model can be coupled with refractory chemical interactions to simulate steel chemical evolution. These two different approaches result in shape and material modifications. They are completed by dedicated thermal stress analysis in order to improve thermal shock resistance. The mechanical FEA evaluations take into account specific mechanical behavior of refractory components as well as high temperature evolution of their properties.

Jan 1, 2004

By F. Romero

In the last four years, Compañia Minera Doña Ines de Collahuasi has been working in the application of advanced multivariate statistical techniques for the improvement of the metallurgical processes. In this paper the main conclusions for the application of multivariable analysis to the EW process are presented; including the identification of (target) process patterns according to throughput and quality criteria. Based on the process patterns, process variables hierarchies were identified by selecting the most influential ones, as well as to identify and isolate the root causes of pattern deviations and sub-standard operating conditions, cause-effect relationships were established, leading to the definition of process policies and controls to give early corrections to potential failures. The analysis was focused on cathode quality, specifically in its sulfur content, using an empirical model based on those variables that from a phenomenological and statistical stand point appeared to be the most influencing ones.

Jan 1, 2007

By Forrest A. Kerr

The subject of the Coast Range batholith and its eastern contact zone needs no introduction to British Columbia mining men. Because of its reputed potentialities, this zone has aroused much interest. Because it has touched the pockets of the people by actually producing dividend-paying mines, it has been able, more particularly in certain isolated sections, to retain and accentuate that interest. However, the Stikine River section of the zone has never had the good fortune to have a mine developed, which, through profits or lack of profits, could create such interest. The Cassiar district, beyond the Stikine River area, has been a lure to the prospector for over half a century and was still strong enough in the last few years to attract close to a million dollars in capital and labour. All of this has passed through the Stikine river area, has looked at it, and ignored it. Sufficient interest has never been aroused in the area to bring forth an effort to see what is there, in spite of the fact that it belongs to the same zone in which some of our richest mining camps are located. Because the contact zone of the Coast Range batholith has long been recognized as an ore producer of considerable potentiality, the Geological Survey some years ago formulated a plan to map as much of this area as possible in order to assist in promoting its development. This plan has been furthered during the last fifteen years whenever opportunity presented itself, until today a fairly large part of the area has been covered. The work which has been done on the Stikine during the last two years is the beginning on what is the largest remaining gap in the general plan.

Jan 1, 1928

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 Jennifer Pakula

Productivity improvements in underground mining are becoming harder to find. Most mines quickly identify deficiencies in their processes and then struggle to make productivity gains beyond that plateau. One way to increase productivity in this situation is to modify existing methods of operation. Vale?s Stobie Mine has been in operation since the late 1800?s employing a variety of mining methods. Many mining advances have been incorporated over time. With the advent of mechanized rubber tired equipment, sublevel cave mining was introduced to allow economic extraction of a large low grade area. Additional productivity gains were seen in the sublevel cave area with the introduction of preloading production drill holes. In preloading, the holes are loaded with bulk emulsion ahead of the production cycle and then primed for blasting as needed. The introduction of preloading, although giving the Stobie sublevel cave process an overall productivity gain, saw an increase in oversize due to the collar priming technique employed. Handling oversize material prohibited the operators from handling additional units of optimally sized material. Prepriming, adding detonators at the toe and midcolumn of the production holes during the preloading process, was identified as a change that could reduce the formation of oversize. This paper describes the introduction of prepriming to the sublevel cave mining method and focuses on the process Stobie employees followed to ensure a safe transition to this productivity improvement.

Nov 1, 2011

By R. Abel

During the last eight years, the Ventanas electrolytic refinery has been improving its results by applying a series of new operational practices, such as the reduction of electrode spacing from 115 mm to 105 mm., raising the current density to 305 A/m2, modification in the operators shifts to about 70% of the workers, reducing the pulling cycles by two hours, and the erection of a new anode preparation machine. These improvements allowed an increase in the refinery capacity from 323,000 to 382,000 metric tons of electrolytic copper per year. In the same period it has obtained certification under the ISO 9001:2000 and ISO 14001:2004 standards. All of these developments have been achieved using conventional technology with copper starting sheets. The continuous improvement that is covered in this paper has allowed Ventanas to optimize its production, costs, and operational results. For the next years, it is planned to follow the same tendency, bringing the productivity of the plant to higher levels.

Jan 1, 2007

By M. Kalin

Tailings deposits are frequently the source of ground water contamination due to the transport of contaminated tailings pore-water. If amendments to tailings covers could be made to facilitate a precipitation reaction and halt or reduce the generation of acid in pyritic tailings, the quality of pore-water quality would be improved which would in turn reduce the production of contaminants. The effects of phosphate wastes, added to base-metal mine tailings in Newfoundland, Canada, were tested. Laboratory and field experiments determined the effects of different mixing ratios of phosphate wastes to tailings volume (1:4, 1:8, 1:12 and 1:20, dry weight) for a total period of 3.2 years. The addition of phosphate at ratios of 1:4 to 1:12 substantially increased the pore water pH, and reduced both acidity and Zn concentrations. These results suggest that addition of phosphate wastes to tailings covers can reduce acidity generation and improve tailings pore-water quality.

Jan 1, 2004

By S. -H. Sohn, M. -K. Cho, G. -G. Hong

In order to evaluate the properties of coating materials for BOF, the effects of dolomites (dolomite and light burned dolomite) addition on durability of coating materials were investigated. In all coating materials, matrix was dicalcium ferrite(C2F) and both free MgO and dicalcium silicate(C2S) were precipitated. Fe203 content must be controlled to improve the adhesion and durability of coating materials for BOF during oxygen blowing process. The amount of dolomites added to BOF slag must be controlled in optimum condition with high refractoriness of C2S to improve the adhesion of coating materials for BOF. The weight ratio of converter slag to dolomite must be below 8 to improve the adhesion and durability of coating materials simultaneously.

Jan 1, 2004