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"In mining operations, it is widely accepted that strategies to drive operational goals must revolve around improving plant availability, reliability and process efficiency. In this paper, an integrated solution framework for reducing process variability, increasing process efficiencies and maximizing plant availability and reliability is discussed within the context of a typical milling circuit. The framework exploits a real-time analysis “gap” evident in production operations that prevents timeous identification of equipment and process failures. This is achieved by leveraging predictive analytics for equipment health monitoring, control loop monitoring and advanced regulatory control solutions towards enhanced process performance, improved asset management and regulatory compliance. The framework provides for early and actionable warnings on equipment and process degradation using real-time operational data.INTRODUCTION The changing landscape of gold mining and processing presents many challenges that threaten sustainability of existing (marginal) operations as well as deter investment in new projects. As existing “shallow” ore resources become depleted, mining operations are increasingly treating low-grade ores with complex and randomly variable mineralogical characteristics. For example, in South Africa, historically one of the major gold producers, the average grade of ore treated has been decreasing from averages above 4.5 – 5 g/t to current grades averaging less than 3 g/t within a decade (Chamber of Mines, 2012). Moreover, lower tonnages are being treated as a result of the narrowing of the available resource base. Also, the regulatory framework has tightened over the years due to heightened concerns on the safety, health and environmental impacts of mining and related activities."

Jan 1, 2014

By George Hope, Brigitte Lacouture

"The Red Dog mine has increased mill throughput most years since start-up. Although flotation equipment has been added over the last 10 years, the Red Dog metallurgical performance has been restricted by a lack of adequate flotation capacity. Two reduced tonnage trials conducted in 1997 as well as numerous SAG relines have consistently indicated the potential to significantly increase both zinc concentrate recovery and grade with additional flotation capacity. Later in 1999, a new circuit was designed with increased flotation capacity while simplifying the current circuit, providing for three stages of dilution cleaning, and creating a retreat section. The purpose of the retreat section is to target the more complex particles and allow the chemical environment to be fine tuned for improved iron depression. In total, 21 Outokumpu OK50 (50 m3) mechanical flotation cells and four 3.66 mØ column cells were added to the current flotation circuit. The VIP (value improvement program) mill optimization project is also addressing thickening, water treatment, and power generation issues and has a total budget of US$105 M. Start-up of equipment was phased in to minimize the impact on current operations and the project was completed by the end of 2001. IntroductionRed Dog Operations started production in November 1989. The mine is located above the Arctic Circle in northwest Alaska. It is linked by an 80 km road to a port-site facility where the concentrate is stored. Concentrate is shipped to markets throughout the world during the one hundred days of open seas. As of January 2002, the Red Dog main pit had 38.4 Mt of reserves grading 19.2% Zn, 5.3% Pb, and 102 g/t Ag. Additional reserves and resources contribute an additional 72 Mt at 15.6% Zn, 4.2% Pb, and 78 g/t Ag. Red Dog is a Mississippian to Permian, black shale-hosted, zinc-lead-silver deposit located in the DeLong Mountains, western Brooks Range, Alaska. All the rocks associated with the mineralizing event are considered to be part of the exhalite rock package. Silicification was a dominant component of the mineralizing event and the host shale has been silicified and locally resembles a chert. The major sulphides in decreasing order of abundance are sphalerite, pyrite, marcasite and galena. Most of the deposit’s silver occurs within the crystal structure of the galena. The dominant ore mineral, sphalerite, is very fine grained to amorphous and is commonly intergrown with silica. Ore textures are massive, fragmental, chaotic, veined and rarely show classic sulphide sedimentary layering. The upper portion of the orebody has been physically and chemically weathered. Oxidation has altered the sulphides to sulphates. The zinc and iron sulphates are very soluble and are readily depleted from the weathered cap, while the lead sulphate is residual and is, therefore, enriched."

Jan 1, 2003

By V. N. Rampton, C. F. Gleeson

"Exploration results over three overburden drilling anomalies defined by the Ontario Geological Survey in 1981 in the Kirkland Lake area, Ontario are presented. The anomalies come from lowland areas where overburden is thickest. By mapping the bedrock and surficial geology, by prospecting, humus sampling and shallow till sampling over the surrounding upland surfaces, one can initially evaluate such overburden drill anomalies without costly reverse circulation drilling. The drilling should follow, if necessary, only after surficial base data has been obtained. Preliminary work on these three properties has defined the presence of at least two styles of gold mineralization. One occurs in silicified zones in intermediate volcanics closely associated with northwesterly trending faults and shear zones. The second occurs in quartz-carbonate alternation zones in volcanics intruded by quartz-feldspar porphyry dykes. IntroductionThe three examples presented in this paper present first-hand information on an approach to the follow up of several geochemical anomalies that were found by the Ontario Geological Survey when they carried out reverse circulation overburden drilling as part of the Kirkland Lake Initiative Program (KLIP) in 1980 (Routledge et al., 1981). The initial approach is relatively simple, systematic, and cost and technically effective. It readies the properties for further exploration, or conversely, it could downgrade the properties as viable gold targets."

Jan 1, 1987

By R. N. Murarka

"Hydrocyclone modelling and selection procedure is illustrated. Computerized procedure for hydrocyclone cut size determination for grinding and non-grinding applications is described.A standard procedure for evaluating operating hydrocyclones is described in detail. Many case studies are illustrated comparing actual plant performance with the computer simulation output in terms of overflow product size distributions.INTRODUCTION Cyclones are widely used for applications such as: close circuit grinding, backfill, tailings and dewatering. Normally, cyclones are used for very fine separations where screens are not suitable or too expensive. Figure 1 shows the separation size range of various classifying devices. Cyclones are popular because of their low capital and operating cost. Cyclone selection procedure for different applications depends on the amount of information available on the cyclone feed slurry characteristics. Closed circuit grinding applications will be discussed in detail in this paper. The Cut Size:The size of the material in the feed which reports 50% to each product stream (i.e. underflow and overflow), after correcting for the feed solids by-passing with the underflow liquid, is termed the cut size or ""d50c"". This is often used as the criterion and the basis for cyclone design.When the corrected recovery to underflow of each mesh size in the feed is plotted against the geometric mean size in microns on a log scale, the micron size corresponding to 50% recovery is the d50c size."

Jan 1, 1992

By Brad McBain

Agenda ? Accurassay Laboratories and Automation ? History and experience ? Features and benefits of automation in the lab ? Tata Steel Minerals Canada (TSMC) Iron Ore Laboratory ? State-of-the art systems and design ? The integration of fusion systems and XRF units ? Meeting deliverables: quality, reliability, safety

Aug 1, 2013

By M. Kalin

"Ecological Engineering, a biotechnological approach to the decommissioning of base metal mining wastes, is being tested on two pits (Gloryholes) in Newfoundland, Canada. Pit #2 has an average pH of 3.5 and flows into Pit #1 where, through additional ground water contribution, the pH is circumneutral, ranging between 5.5 to 7.The AMD in Pit #2 originates from underground workings and exposed massive sulphide on the pit walls. The overflow from Pit #1 averages about 10 L/s with less than 0.2 mg/L of Cu and 40 mg/L of Zn.Ecological Engineering utilizes organic substrate as a source of carbon and nutrients for microbial populations which can generate alkalinity and reduce metals. In 1989, limnocorrals (enclosures of 4 m diameter and approx 3 m depth) were placed in both pits to test the most suitable organic amendment (peat and sawdust). Microbial alkalinitygeneration was evident 95 days after placement of the amendment on July 4, 1989. The pH had increased after 120 days from 3.5 to 4.5 and by day 480 the pH was 7 in limnocorrals in Pit #2. Zinc concentrations in the limnocorrals in Pit #2, dropped from an average of 35 mg/L to about 2 mg/L or less, by day 480.A scaled-up experiment has been under way since August 25, 1990, where 390 m3 are treated in pit #2 and 750 m3 in Pit #1. One hundred eighty days after placement of the amendment, zinc was reduced in the acid Pit #2 from 40 mg/L to 15 mg/L. Research is underway to determine those factors which limit microbial activity."

Jan 1, 1992

By Adil Aledresse, Louis Mercier, Laxman Amaratunga

"The development of high capacity adsorbents with uniform porosity denoted, MP-HMS (Mercaptopropyl – Hexagonal Mesoporous Structure) using nanotechnology, and their ability to extract gold from solution, is presented. The preparation of highly effective heavy metal ion adsorbents by the incorporation of thiol moieties into the pore channels of mesoporous silica molecular sieves has been the subject of many nanotechnology research investigations. The unique feature of these nanoporous adsorbents is their ability to adsorb gold ions from ultra-low concentration solutions like mine effluent as well as from leached solutions in gold mills. The preliminary studies from laboratory simulated gold solutions show that the adsorption capacities of these materials are also among the highest reported. MP-HMS has shown the capability to adsorb 370 mg gold per one gram of the nanomaterials from Tetrachloroaurate solution (up to 37% of their weight). Experimental studies indicated that the maximum adsorption of gold (as high as 99.9% recovery). The current studies will be extended to investigate the interaction of ionic gold complexes with nanomaterials. Future development of this work may lead to either to replace the conventional CIP/CIL processes or use nanomaterials in tandem with the former, suggesting plausible use of mesoporous material in pulp, MIP or in leach, MIL, as a novel gold extraction process.INTRODUCTIONGold typically occurs at very low concentrations in ores less than 10 g/t or 0.001% (mass basis). At these concentrations the use of aqueous chemical (hydrometallurgical) extraction processes is the only economically viable method of extracting the gold from the ore. Typical hydrometallurgical gold recovery involves a leaching step followed by the separation of the gold bearing solution from the residues, or adsorption of the gold onto activated carbon adsorbent. After elution from the activated carbon the gold is further concentrated by precipitation or electrodeposition."

Jan 1, 2008

By Shichang Liu, Hongli Jia, Zhaolian Wang, Maotang Liu, Ltd. Shandong Huate Magnet Technology Co., Fengliang Liu

"Introduce and promote a latest technology and equipment for magnetite. It’s featured of purifying concentrate, lowering tailing grade, high concentrate recovery rate and stable operation. HUATE® New Style Elutriation Electromagnetic Separator is an equipment to obviously upgrade magnetite. The slurry is fed into separation area through feeder. Generated by excitation coil, the working magnetic field distributes specially in separation area. Under the combined effect of the background field, excitation and demagnetic field and gravity, the mineral particles float downwards in the form of magnetic chains, and interact with the rising water. The gangue, non-magnetic particles, lean intergrowth,etc will be discarded as tailing via overflow tank and pipe. While the magnetic will be discharged from concentrate pipe. Its grade is 2%-10% higher than that of traditional magnetic separation equipment. It adopts the technologies of transformer oil cooling, alternative and uniform pulsation magnetic field controlling the tailing grade, larger drum feed-in device, more uniform umbrella scattering discharge and stabler output current, and realizes lower coil temperature raise, stabler magnetic field, more uniform discharge, effective isolation of weak-magnetic area from non-magnetic area, more obvious upgradation and recovery rate and lowering tailing mFe%. It’s more suitable to purify and thicken the high grade and ultrafine iron powder. Compared with traditional elutriation equipment, it adopts new technologies in removing impurities, operation, large-scale, process simplification, water-saving, remote control, etc. It optimizes the comprehensive beneficiation index, expands its application scope, reduces resource wastes and increases economic benefits.INTRODUCTIONMagnetite accounts for a comparatively great proportion in various iron resources. As it’s a kind of strong magnetic mineral, we must adopt the weak magnetic separation equipment in magnetic separation process to realize removing Si and lowering impurities. While it cannot do very well to use the common weak magnetic separation equipment in the final cleaning to remove Si and lower impurities. At present, the plants, adopting single magnetic separation process to realize cleaning and removing Si and lowering impurities, are in the minority. Most magnetite plants adopt the flotation separation process to remove Si, lower impurities and purify the concentrate. Though with stable indexes and high Fe recovery rate, the flotation process is very complicated, high-cost and with lots of environmental pollution. If adopting the weak magnetic separation equipment can realize removing Si, lowering impurities and the final cleaning, the magnetic separation process should be the primary choice."

Jan 1, 2016

A key point in the manufacture of cemented backfill is the dewatering and settlement of the total tailings product. A new technology characterized by rapid non-mechanical settlement of total tailings has been developed based on a large number of laboratory and field tests, where dynamic settlement and continual slurry preparation of total tailings in a vertical sand silo are realized by the addition of an effective flocculating agent named NPA. It has been shown that the sedimentation velocity of the interface between total tailings and water after NPA was added is 10 to 20 times higher than that without any flocculating agent, that the mass fraction of sand slurry deposited at the bottom of the vertical sand silo reaches 70%, and that the solid particle content in effluent waste water meets national water quality standards. The simple devices used to add flocculants have little deleterious effects on the current preparation tank and have been tested in an industrial environment. The processing cost of total tailings by the new technology is only 10% to 20% of that required for mechanical settlement.

May 1, 2007

By G. Couture, J. -F. Dubé, F. Letarte-Lavoie

"The Xstrata Nickel Raglan concentrator, located in Quebec’s Nunavik region, has been in operation since 1997. Originally designed to process 800,000 tonnes per year of high-grade nickel ore, the plant’s current capacity is 1.3 million tonnes per year due to various optimization projects. In 2011 and 2012, the Metallurgical group, with assistance from BBA, updated and optimized the variables affecting SAG throughput in order to optimize process stability while maintaining maximum plant throughput. This project consisted of reviewing the control strategy and completely updating the pre-existing Fuzzy Logic controller. This paper describes the successful update of the controller including a complete revision of control rules, a new process control strategy and the integration of new process variables, most notably mill rotational speed. It will also show how this new approach has provided a simple and robust way of delivering both an increase in throughput while reducing process variability.INTRODUCTIONThe Xstrata Nickel Raglan Mine concentrator is located in Northern Quebec along the 62th parallel. It has been in operation since 1997 and was originally designed to treat 800,000 tonnes of ore annually. The Raglan Agreement held with the Makivik Corporation and the Inuit communities limits the annual tonnage of ore that can be processed at 1.32 million tonnes.The ore is processed in a 24 foot variable speed, semi-autogenous grinding mill (SAG). The conversion from Autogenous Grinding (AG) to SAG was completed in 2006. Before the ore is processed by the SAG, its size is analyzed by a Wipfrag camera that provides a granulometry estimate. A cone crusher reduces the SAG’s discharge screen’s oversize material. A 14 foot diameter ball mill ensures final grinding before the flotation stage.Many control strategies were used at the SAG over the past few years. Fuzzy Logic was first used in 2007 in order to control tonnage feed to the SAG. This first version only measured the value of the variables without taking into account their rate of change. Revisions were made over the course of the last few years to improve controller performance. Other variables were added such as slurry density and crusher Closed Side Setting (CSS). The previous revision of the Fuzzy Logic was done in 2009 with a review of the rules only."

Jan 1, 2013

By Pierre Pelletier, Julie Fournier, Gianni Bartolacci, Yves Breau, Dominique Girard, Ahmed Bouajila, Carl Duchesne

"The development of on-stream analyzers (OSA), such as those based on X-ray fluorescence (XRF), has been key to improve metallurgical performance of flotation processes. However, since these analyzers are shared between several streams, they typically provide grade measurements every about 10-15 minutes. In general, this frequency is too long compared to process dynamics and so, implementing an efficient feedback control strategy based on OSA can be difficult. In addition, due to the limited capacity of OSA systems, several important intermediate streams are not analysed, but could provide relevant information about the state of a flotation circuit.To overcome this problem, vision systems have been developed in the past to predict concentrate grade based on froth color – this could be very useful to control flotation performance between OSA measurements. However, applications reported in the literature typically use univariate summary statistics of the full red, blue, and green color distribution of froth images, while RGB images are truly multivariate. Although, in some cases, grade prediction was achieved with reasonable accuracy, one may, by using only summary statistics, miss important information about the state of the flotation process.This paper investigates the application of Multivariate Image Analysis (MIA) concepts to flotation froth images. These techniques are based on multivariate statistical methods such as PCA and PLS, which have the ability to analyze large databases (such as digital images) and summarize the relevant information content of the data into a small number of latent variables, capturing the most important features of the images for concentrate grade prediction. The potential of application of these methods in the mineral processing industry is illustrated using a few industrial case studies."

Jan 1, 2003

By C. F. Chung, F. P. Agterberg

"Prediction of a variable sulphur content in Cape Breton seams is important for planning the production of a highgrade metallurgical coal. Two extrapolation methods (Kriging and a version of Universal Kriging) to predict sulphur content in blocks of coal before mining are presented and applied to the New Lingan Mine reserves in the Harbour seam. The uncertainty of the predicted values is expressed by using standard deviations. Some statistical results for the Phalen seam, which occurs about 400 ft below the Harbour seam, are presented for comparison. The two mathematical models consist of two sets of equations which have been used in computer algorithms. Some limitations of the present approach and possibilities for further statistical work are indicated."

Jan 1, 1973

By Jon A. Carlson, W. Scott Williams

The EKATI"" Diamond Mine commenced operation in October 1998. It is operated by BHP Diamonds Inc., which is a part of the Non-Ferrous and Industrial Materials Division of BHP Minerals, a business unit of BHP Company Ltd. of Melbourne, Australia. The EKATI"" Diamond Mine is a joint venture of BHP Diamonds Inc. (51%), Dia Met Minerals Ltd. (29%), Charles E. Fipke (10%) and Dr. Stewart L. Blusson (10%). In December 1993, an office was opened in Yellowknife, Northwest Territories specifically for the then Northwest Territories Diamonds Project (EKATI"" Diamond Mine) development. EKATI"" Diamond Mine is located 300 kilometres northeast of Yellowknife and 200 kilometres south of the Arctic Circle in the Northwest Territories of Canada (Figure 1 ). The site is located in a remote tundra area of continuous permafrost, north of the tree line, which is part of the Canadian Shield. Wekweti (Snare Lake), a Dogrib community approximately 180 kilometres southwest of the project, is the closest neighbour. The mining area and facilities lie within the 10 960 hectares land leases held by the joint venture. The total claim block (core zone and buffer zone joint ventures) covers 344 000 hectares. To date, more than one hundred kimberlite pipes have been identified within the claims. Five of these provide the basis for the present mine plan. Total capital investment in the project is over C$700 million. At full production employment will be about 600, including employees and long-term contractors, with over 33% being Aboriginal from the Northwest Territories.

Jan 1, 2001

By Robert S. MacPhail, Chilombo Henry, Arnold Kabamba, David Mukelebai, Suresh Thirunagari, Bukali Victor, Yoram Kapai, Chomba Leonard, Kanna Amarasingham

"FLEX 31 is a chemically enhanced sodium isopropyl xanthate. Developed by Charles Tennant & Co (Canada) Ltd and has shown improved collection properties over SIPX for sulphide minerals flotation. Improvement of recoveries, grades, faster kinetics, lower dosages, high pyrite and pyrrhotite rejection capabilities have all been exhibited by FLEX 31. Recent plant trial carried out in the copper circuit at one of the largest copper mine in Zambia shown over US $ 2.00 Million annual improvement on the bottom line over SIPX at current copper prices. Data produced also showed superior grade and recoveries from rougher concentrates that previously had not been attainable with other reagents effectively. Flex 31 has also shown positive outcomes with zinc, Copper/Zinc, arsenopyrite and copper/molybdenum ores.IntroductionSodium Isopropyl Xanthate (SIPX) is one of the most popular flotation chemicals on the market today. Somewhat more specific than amyl xanthate, SIPX is used in a variety of ores like copper/zinc, lead/zinc, arsenopyrite/pyrite, and many others (Melis et al., 1991). An investigation carried out by the research division of Charles Tennant & Company (Canada) Limited has produced a chemically enhanced SIPX. This product has shown all the advantages of normal SIPX along with improved recoveries of copper and copper activated minerals. The product was named “FLEX 31”."

Jan 1, 2016

By Charles Camsell

At the Annual General Meeting of the Institute in 1924. I endeavoured to present the position held by the mineral industries in the commercial life of this country. The facts and figures were presented at that time in a detached way. Since then, however, I have made some attempt to analyze them in order to determine the causes for that position and to draw some conclusions as to the future of the mining industry. As everyone knows, our trade figures are very often used in political discussion, especially in discussion of tariff policy. It would be entirely out of order for me to say anything touching the tariff issue and I want to have it clearly understood that, in my opinion, the material I am about to present contains not a single statement or conclusion which anyone would be warranted in using as an argument for either a lower or a higher tariff or for tariff changes of any kind. As a starting point, let me re-state, very sketchily, Canada's general situation in external trade. In the last calendar year, 1924, we sold Canadian merchandise of all kinds to other countries to the value of $1,045,000,000 in round figures. Our purchases abroad reached about $893,000,000. Thus our sales exceeded our purchases by roughly $152,000,000. In other words, we had what is known as a 'favourable balance of trade' - one of the biggest favourable balances we have ever had in our history. The proceeds of our sales of Canadian products enabled us to meet the bills for all our purchases of foreign commodities and, in addition, placed a large surplus to our credit with which to offset our interest charges and other obligations abroad.

Jan 1, 1925

By V. Balakrishnan, A. Hewitson

"The Kudremukh Iron Ore Company Limited, a government of India enterprise, has constructed iron ore mining, crushing, handling and concentrator facilities at Kudremukh, in southwest India. Concentrate produced is pumped 65 km to dewatering, storage and ship-loading facilities which were built at the same time at the sea port of Mangalore.A computer-based distributed process control system was implemented for all operations at Kudremukh and to interface with and monitor the Mangalore plant.The control system is examined from various standpoints, beginning with a description of its architecture, method of process input/output connection, and major hardware items.Software considerations and process applications are then looked at, with a review of the integration of the computer vendor's system software with user-developed applications programming. A control example of crusher operations is provided.Following the descriptive segment is a discussion of the design considerations and decision factors involved in the implementation of such a system considering the type of process and the remote nature of the installation site. It ends with a review of actual operating experience and conclusions regarding both this system and future similar applications.ScopeThe following is a discussion of the computer-based process control system applied for the Kudremukh Iron are Company Limited's ore handling, concentrating and shipping facilities located in South India.A general description of the process and plant equipment will be followed by an examination of the control system from the points of view of hardware and signal flow, software requirements, design considerations, implementation logistics and operating experience. Conclusions will be drawn concerning this and future computer applications."

Jan 1, 1984

By Cameron J. Clayton

Cumberland Resources Ltd. is currently planning to develop the Meadowbank Gold Project located some 70 km north of Baker Lake, Nunavut in the eastern Canadian Arctic region. The Meadowbank Gold Project currently consists of up to 6 main gold bearing deposits within relatively close proximity to one another which are planned to be mined primarily as a truck-and-shovel open pit operation and using conventional gold milling and extraction. The mining plan indicates that approximately 20 million tonnes of ore will be mined over a mine life of 8 to 10 years. The operation will generate approximately 160 million tonnes of mine waste rock and about 20 million tonnes of tailings. The site is located in an area of continuous permafrost with mean annual average air temperature of -11 °C and average annual precipitation in the range of 100 to 200 mm. Lakes cover a large portion of the site, including some of the ore deposits. The location of the site, and the physical environment, pose challenges to development. This paper presents some of the designs considered to effectively manage and utilize the waste products of mining at the project.

May 1, 2004

By L. Garycki, P. Poks, R. Urbaniak, T. Gabka

In 2016 at Głogów Copper Smelter KGHM Polska Miedź S.A., after shutting down the shaft furnaces new FSF was launched. Currently, it is the only smelter with two direct to blister flash smelting furnaces in operation. The main difference between the vessels are the dimensions and production capacity. The new furnace design output is about 30% higher compared to the old flash smelting furnace working for 40 years. The paper presents a comparison of both FSFs operation, differences in technology and the way to optimize the process to maximize efficiency. INTRODUCTION KGHM Polska Miedź S.A. is the only company in Poland (eastern part of Europe) that extracts and processes copper ores. It is located in the south west of Poland and this region is called the "Copper Basin”. KGHM PM S.A. consists of three underground mines: Lubin, Polkowice-Sieroszowice, Rudna, concentrator plants, a tailings pond plant, three copper plants: Legnica, Głogów and Cedynia wire rod plant in Orsk. The publication relates to the operation of the furnaces in Głogów (the plant in Głogów consists of Głogów 1 and Głogów 2 which form integrated smelting and refining facilities). In 2016, after closure of the shaft furnaces technologies in the Głogów 1, a new FSF commenced operation. The simplified process flow sheets are given in Figure 1 and 2. Technological schemes are similar, but due to the differences in them, they will be discussed separately. Głogów 1 Enriched ores are discharged and directed to the feed preparation plant. Delivered concentrates are built up on the three bedding aisles in appropriate proportions. The concentrates are distributed in even layers in one of the three aisles. Aisle emptying is done with a blending machine which cuts across the concentrate layers and collects thus blended material, sending it via belt conveyors to a storage bin. From the cross- blending machine and conveyor assembly, the mixture of concentrates is directed to drying in the steam dryer. Part of the charge is directed to the FSF and part to the roaster for carbon elimination. Known in the world roasters are used to eliminate sulfur compounds or arsenic. In the case of KGHM deposits, the aim of the process is to reduce the energy value of the feed by eliminating carbon and converting sulfur from sulfide to sulfate. Changing the nature of exothermic to endothermic material is crucial in the case of furnace operation with design performance. Roaster is a separate furnace with an innovative character.

Jan 1, 2019

By G. J. Heferen, A. Pranowo, N. J. Aslin, P. O. Eriksson

Glencore Technology (GT) has over four decades experience supplying stainless steel cathode plates (“cathode plates”) to the electro-refining and electro-winning industry. Cathode plates are typically the single biggest capital investment in a refinery. Refineries may view cathode plates as fixed asset or consumables depending on their operational characteristics. This paper examines the issue of cathode plate life and the strategies and philosophies used by different plants in the management of their cathode plate asset. Some plants operate with their original plates after more than 20 years. Others accept high turnover and regular maintenance as normal operating practice. Reference data are provided on plate life for various operating plants including benchmark plants achieving best-practice plate life and operating cost. The role of the electrode handling equipment on cathode plate longevity is also examined, including latest developments in Cathode Stripping Machine, robotic copper stripping, and full-automation production cranes. The ability to identify and manage the population of plates in service is also critical for maximising plate life and minimising its overall operating cost. This paper discusses a novel and unique RFID system for tracking and managing cathode plate inventory. INTRODUCTION Permanent cathode plates The adoption of permanent stainless steel cathode electrodes in the electro-refining of copper was the most significant process development since the first commercial electro-refineries were built in the late 19th century. It provided significant improvement over the labour intensive and complicated starter sheet system. Copper grows over the permanent cathode blade for a number of days before being stripped, and the permanent cathode can be returned straight back to cells for the next cathode cycle. Glencore Technology (formerly Mount Isa Mines (MIM), then Xstrata Technology) has been manufacturing permanent stainless steel cathode plates from the late 1970s with the birth of ISA PROCESS™, and the Kidd process that came one decade later. Invented and commercialised by Mount Isa Mines, the ISA PROCESS™ was first implemented into Copper Refineries Limited (CRL), Townsville, in 1978. The KIDD PROCESS by Falconbridge evolved in the 1980s and was first implemented into the Kidd Creek Tankhouse, both operations converting from traditional copper starter sheets.

Jan 1, 2019

By Brad Wells, Wayne Bull, Wayne Dickinson

"Antiscalants were evaluated for control of calcium carbonate (CaCO3) in gold processing applications. Under severely supersaturated conditions, 100 percent inhibition was achieved with 30 ppm antiscalant. Laboratory and field testing established that an antiscalant could both inhibit scale buildup and remove an estimated 0.5 kg/m2 per annum of pre-existing scale. A program was developed to control CaCO3 at a gold mill experiencing severe scale buildup. Annual accumulation of as much as 3 cm of scale in process piping was reduced to unmeasureable levels when 10 ppm antiscalant was applied. No scale-related upsets in mill operation occurred during a five-month trial period.INTRODUCTION Inorganic mineral scale is a crystalline deposit that forms when dissolved mineral constituents exceed the solubility of the respective mineral phase. Formation of mineral scale adversely affects a wide range of industries and is of particular interest in mining and metals processing. Scale affects numerous stages of metal extraction processes. Restricted flow in piping, nozzles, valves, screens, pumps and other components used to transport mineral slurries, metal concentrates, and tailings as well as scale in millwater and thickener overflow circuits are primary concerns (Alfano & Boffardi, 1994). Heap leaching, comminuation, flotation, vat leaching, carbon adsorption, and heat exchangers as well as oxidation steps used in processing sulfidic ores are among key unit operations that may be adversely affected (Simmons & Gathje, 2003). Antiscalant chemicals are designed to prevent formation and growth of mineral scales such as CaCO3. These chemicals, which include two primary classes – phosphonates and anionic carboxylate polymers and copolymers - are added to the gold processing stream at low parts-per-million (ppm) concentrations to interfere with nucleation and growth of scale forming crystals and to disperse fine particulate material. Application points may be located throughout the gold extraction process. Evaluation of the performance of antiscalants plays a critical role in determining the best product for a specific application. Performance evaluations include laboratory testing, pilot scale studies, in-plant trials, and ongoing performance monitoring during mill operation."

Jan 1, 2014