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By Rodney Trevor Jones, Arthur Robert Barnes

Anglovaal Minerals acquired the Nkana slag dump from Zambia Consolidated Copper mines (ZCCM) in 1998 and embarked on an ambitious project to pioneer the recovery of cobalt from slag using DC smelting technology. Anglovaal Research Laboratories performed initial pioneering smelting tests in a 250 kW DC furnace over a 3-year period before engaging Mintek for three piloting campaigns at the 1.5 MW level. Mintek had previously developed a reductive smelting process, patented in 1995, using a DC arc furnace for the recovery of cobalt from slags. The results of the pilot-plant test campaigns were used as the basis for engineering the commercial 40 MW operation installed at Chambishi Metals plc in Zambia in 2001. This paper traces the development of understanding of the metallurgical fundamentals ultimately used to predict furnace performance, reviews some of the extreme technical challenges faced, how solutions were identified and highlights some of the critical issues identified during piloting and how these impacted both positively and negatively on the final commercial operation.

Jan 1, 2011

By G. Gauvin

Life span of aluminum smelting electrolysis cells can reach up to 3000 days. During this period, cathode blocks go under various physical and chemical changes that could result in an increase of electrical resistivity. The increase may be due to carbon migration from the cast iron to the steel bars, gap evolution between the cathode block and the cast iron, cathode cracking, etc. This paper focuses however only on the collector steel bar electrical resistivity evolution. To reveal the main phenomena responsible for the electrical resistivity increase, chemical analysis, metallographic and electrical resistivity tests were conducted on two steels bars picked from two Hall-Héroult cells after autopsies. Cathode voltage drop and temperature were measured using electrically insulated internal probes and thermocouples on 16 samples from each steel bar. Electrical resistivity can reach up to 1.21µO-m for a steel bar aged 2505 days compare to 0.142µO-m for steel AISI 1008 at room temperature.

Jan 1, 2011

By S. Torizuka, I. Mizushima. Kawasakitohri, A. Ohmori, K. Nagai

Strain (work)-hardening in tensile tests were examined for low carbon steels with various ferrite grain sizes ranged from 0.4µm to 16µm. The steels had microstructures composed of ferrite grains and dispersed cementite particles. They were fabricated through warm caliber rolling with an accumulative area reduction of 93%. Strain-hardening rate at a given strain increased with an increase in volume fraction of cementite particles. The balance of yield strength and uniform elongation for ultrafine-grained structures could be improved by the dispersion of cementite particles. Effects of the cementite dispersion and the ferrite grain size on the strain-hardening rate can be roughly explained by the work-hardening model with GN-dislocation density. Strain-hardening design using dispersed cementites was proved to be effective in controlling ductility of the ultrafine-grained steels.

Jan 1, 2004

By G. R. Guillet

Salt is restricted to five major beds in south western Ontario, totalling as much as 200 m in thickness. These beds are located at depths ranging from 270 m to 750 m below the surface, fringing Lake Huron and the Detroit River from Windsor to Kincardine, and extending inland as far as London. Manitoulin Island, the Bruce Peninsula and the north part of the Niagara Escarpment form the northeastern rim of the Michigan Basin, a major structural depression in which the salt was deposited 400 million years ago when much of North America was covered by the Silurian sea. Salt is mined underground at Windsor and Goderich; it is also brought to surface as brine through deep wells at Windsor, Samia and Goderich. Artificially- created caverns in salt beds are extensively used for storage of liquid hydrocarbons at Windsor and Samia.

Jan 1, 1984

By A. Singh

Deformation structures after tensile and compression tests on Mg926Zn64Y alloy extruded at 250°C and 400°C are studied, in as-extruded and heat treated conditions. The icosahedral phase particles stimulate recrystallization during extrusion, resulting in fine grain size. Tensile and compression tests at room temperature show comparable yield strength, with a yield asymmetry ratio up to 0.98. c-type dislocations are observed in the grains near the submicron size icosahedral phase particles. The source of these dislocations is believed to be dissociation of <c+a> type non-basal dislocations. No dislocation pile-ups on icosahedral phase particles are found. {10 1 2} type twinning occurs in compression.

Jan 1, 2006

By Sudarshan Martins

The measurement of acoustic signals produced by a tumbling mill has been previously used to determine the operating state of the mill and correlate the variations of the sound intensity with the operating conditions of the mill. Separately, the discrete element model (DEM), a software simulation of the mill, was developed to provide insight into the operation of the mill. Presently, there has not been much work reconciling the DEM simulation of the mill with the acoustic signal. Working from basic principles of linear, time-invariant systems, agreement between an acoustic DEM simulation and the measured signal is sought. First, the impulse response function of the mill is measured. The DEM provides the forces applied to the mill shell as a function of time. A convolution of these simulated shell forces and the transfer function gives the simulated acoustic signal. This signal is compared to the measured acoustic signal, both in the time domain and the frequency domain. Finally, a discussion of the results is given.

Jan 1, 2012

By Masatsugu Morimitsu

This paper introduces new technology of oxygen evolution anodes which can be applied to produce copper, zinc, cobalt, and other metals by electrowinning. The anode consists of nano iridium oxide particles dispersed in amorphous tantalum oxide matrix as a catalytic layer formed on a titanium substrate. The anode can reduce oxygen evolution potential by 0.25 to 0.55 V compared to commercially available lead alloy anodes and can suppress unwanted side reactions such as manganese oxyhydroxide, lead oxide, cobalt oxyhydroxide which occur during oxygen evolution in the electrowinning solutions. This technology is effective for environmentally friendly electrowinning processes with low energy consumption and less anodic deposition.

Jan 1, 2011

By Ron Bradburn, Derek Perkins

"The Brenda mine is located in south central British Columbia, 22 km north west of Peachland, in the heart of the Okanagan Valley. Situated at an elevation of 1500 metres, the mine area straddles the divide between the headwaters of Trepanier Creek and Peachland Creek. These flow into Okanagan Lake, the chief valley water resource located 1100 metres below. The creeks are of great significance to the water management of the area as they constitute the water supply for the Municipality of Peachland, a thriving retirement community with a population of 5000. A location map is shown in Figure 1.The history of the Brenda Mine operation has been well documented previously. After twenty years of operation, the open pit mine shut down in June 1990 due to the depletion of its ore reserves. During the course of its life, it produced 109 million tonnes of waste rock which is thought to contain approximately 0.10% copper as chalcopyrite and 0.015% molybdenum as molybdenite stored in four rock piles around the pit. Similarly, approximately 200 million tonnes of tailings were produced grading 0.015% copper and 0.005% molybdenum. During operation, tailings were hydrocycloned to produce a coarse sand for dam building with the fine slime stored behind the dam. It is estimated that 40% of the tailings were used for the dam construction. The layout of the mine site is shown in Figure 2.The mine was operated under a zero discharge permit. This was achieved by diverting practically all surface water flowing towards the mine area around the site. Water affected by mine operations, was discharged to the tailings impoundment, and recycled to the mill for reuse. The recycle rate was 90% and seepage from the tailings embankment and saddle dam was pumped back to the tailings pond. Because acid drainage was not a problem with the low grade Brenda rock, runoff from the rockpiles was initially released to the local environment. However, due to the alkaline nature of the waste rock, dissolution of low concentrations of molybdenum in the site runoff waters became evident by the late 1970's. The molybdenum content of Peachland Lake, the water reservoir for the municipality of Peachland, approached the Canadian Drinking Water Standard of 0.25 ppm. By 1979, a series of diversion and collection ditches was completed to direct all runoff water from the rockpiles to the tailings impoundment area. This had a significant detrimental effect on the site water balance causing it to go into a considerable surplus condition. During normal operation, this oversupply was contained by the rate of tailings dam building. An economic shutdown of the mine during 1984 forced a limited discharge from the site to protect the integrity of the tailings dam."

Jan 1, 1995

By L. Kilpinen, K. R. Kay, H. B. Fowler

"FOREWORDThe International Nickel Company of Canada has built four ore concentrating plants since 1950. The fifth and largest is now under construction. In each successive plant, the level and type of instrument control and sophistication of control techniques have increased as experience was gained. The type of control progress is illustrated in Fig. 1.At Frood-Stobie the high degree of instrumentation and the level of control were made possible by the constant evolution of techniques and improved instrument hardware technology. We have established in practice concepts that are sound, although many modifications to instrument sensor types and locations 1-rere often necessary. It is generally true that at other existing Inco mills, it is possible to run ""all manual"" for protracted lengths of time because of operator availability and dependence. The Frood-Stobie Mill is the exception, and it is the degree of reliability of the instrumentation hardware and level of maintenance that has made this possible."

Jan 1, 1971

By H. W. Little

INTRODUCTION MINERAL deposits of Salmo map-area (Figure 1) have aroused the interest of prospectors for more than a half-century. Properties within the map-area have produced lead, zinc, silver, tungsten, and gold. Sheep Creek mining camp ranks fifth in the Province in the total production of gold, but during recent years interest has been concentrated upon base metals, and meticulous prospecting and exploration have resulted in the discovery of many large zinc-lead orebodies. PREVIOUS WORK Geological investigations of the region were begun long ago, and it is interesting to trace the development of ideas with our increasing knowledge of the geology of this complex area. The first geological examination of the rocks of Salmo map-area was made in 1859-60 by H. Bauerman (1), who was employed as geologist accompanying the first international Boundary Survey. Bauerman examined the rocks exposed along Pend d&apos;Oreille river and published a section indicating that the sedimentary rocks are probably of Palaeozoic age, and are intruded by granite of unknown age. McConnell and Brock(2), in 1894 - 1900, carried out the reconnaissance mapping of the West Kootenay Sheet, on which they outlined the Mesozoic rocks of the Rossland Beaver Mountain volcanic groups that they believed rested unconformably upon the sedimentary rocks to the southeast, which they regarded as of Palaeozoic age.

Jan 1, 1951

By D. Nie, M. Ren, T. Mo

This paper studied the phenomenon of room temperature creep deformation at crack tip and its effect on fatigue crack growth rate of a X-70 pipeline steel using compact-tension (CT) specimen on a MTS 810 testing machine. Time-dependent deformation at the crack tip under constant load was observed in this steel at room temperature and the amount of deformation produced was seen to depend on loading rate and the magnitude of stress intensity factor. It is found that there exists a critical stress intensity factor below which the deformation decreases with time when the applied load remains constant. It is also found that the occurrence of room temperature creep obviously affects the subsequent fatigue crack growth rate. The observed behavior was explained based on dislocation theory.

Jan 1, 2005

By H. Perez, A. Lavoie, V. Prévost, P. Létourneau, P. Lind

The Home smelter is a custom copper smelter located in Rouyn-Noranda, Quebec. In 2005, the smelter produced 145,000 t of copper containing 807,000 oz of gold, 20,388,000 oz of silver in addition to 515,000 t of sulphuric acid. Recently, a flexible flow sheet has been developed incorporating the intermittent use of the Noranda Continuous Converter allowing for the increasing or decreasing of production based on market conditions, while attaining 90% or greater sulphur fixation regardless of operating mode. For 2006, the smelter is operating in full production mode and production is expected to be approximately 185,000 tm of copper. Mechanical modifications, process changes, metallurgical concepts, minor element treatments, and operational techniques that have allowed the smelter to develop this flexibility are presented. Current efforts to increase the productivity of the converter aisle and anode furnaces as well as improvements being made to address fugitive emissions are also discussed.

Jan 1, 2007

By S. Pinard, A. Desbiens, R. del Villar, D. Jakelski

"During the fall of 1993, a new Pill-based control strategy was installed in the B grinding circuit at the Kidd Creek Division of Falconbridge Ltd. The control strategy was first evaluated on a grinding circuit dynamic simulator (DYNAFRAG), which permitted the discrimination between more than a dozen possible control alternatives. Once the final choice was made the necessary instruments were purchased and installed. The control strategy was configured on the plant computer and is planned to be commissioned shortly.This paper summarizes the control strategy, the design procedure, the installation and the controller tuning. Some preliminary problems posed by the process prior to implementation are also presented.IntroductionIn 1990 the GRAIIM (french acronym for Research Group on Computer Applications to the Mineral Industry) of Laval University started a research project on Knowledge Based Automatic Control (KBAC). This project is sponsored by a consortium of eight mining companies under the umbrella ofMI1EC (Mining Technology Council of Canada), the Quebec Mining Association (AMQ), CANMET and the Centre de Recherches minerales (CRM). The project also benefits from important grants from the Ministere de l'Education Superieure et de la Science and the NSREC-CRD program.The main objective of this project is the screening of advanced (knowledge-based) methods for data processing (filtering, mass balancing, etc.) and automatic control (model-based control) for their use in the mineral processing operations. The project also aims at transferring these tools to the industrial partners through annual workshops for plant engineers, annual symposia, and through specific in-plant projects where the participation of plant engineers is strongly encouraged.The main objective of this project is the screening of advanced (knowledge-based) methods for data processing (filtering, mass balancing, etc.) and automatic control (model-based control) for their use in the mineral processing operations. The project also aims at transferring these tools to the industrial partners through annual workshops for plant engineers, annual symposia, and through specific in-plant projects where the participation of plant engineers is strongly encouraged."

Jan 1, 1994

By Siavash Zamiran, Abdolreza Osouli

"One of the most concerns of room and pillar mining system is subsidence of the ground surface due to coal mining particularly in room and pillar mines. Subsidence of ground surface is a result of floor, pillar, or roof failure of the mine. At the same, due to many difficulties associated with surface disposal facilities of coal refuse, some mining companies are trying to use underground space as a disposal storage place. In this study, stability and subsidence analyses of an underground coal mine located in the Illinois Basin are conducted. This room and pillar mine was abandoned and later on was used as a storage place to accommodate the coal fine refuse with slurry backfilling method. The geological stratigrophy and geomechanical properties of the mine floor and roof were collected. Floor and pillar stability analyses were conducted for areas with various extraction ratios. The stability of the mine was evaluated both prior and after slurry backfilling. The floor and pillar stability analyses results of the mine due to moisture exposure after slurry backfilling are discussed. The subsidence potential due to mine failure is also evaluated.INTRODUCTIONA typical lithology of coal seams in the Illinois Basin consists of weak underclay stratum. The immediate weak underclay causes frequent floor instability problems in Illinois underground coal mines. There are two different stages in assessing floor stability of the mines where slurry backfilling is planned. The first stage is during the mining operation when weak underclay layer squeezes under pillar stress and results in punching or bearing capacity failure. The second stage is after slurry backfilling. During this stage, the slurry material soaks non-durable floor layers and causes strength reduction in floor material. Pillar stability conditions should also be taken into account during both the operational period and after the slurry backfilling."

Jan 1, 2015

By G. Mihaylov

The basic principles of systems analysis are presented. A model has been designed to determine the location of the Main opening in the presence of three or more stock orebodies. The necessary condition is to find a location for the Collection point which is an essential element in opening up each orebody (stock). The model takes into account the total transportation costs from each orebody to the collection point. Three variants are considered provided that the orefield is divided into two levels at least: - a collection point is designed at every level; - a collection point is designed at the lowest level, i.e. where the so-called concentration level is formed; - the collection point is located at a point between the planes of the two levels; The effect of the depth of mining and mine output on determining the method of opening up the orefield has been analyzed by considering a vertical and/or an inclined shaft. A function has been constructed which allows for investigating in both a static and dynamic regime the capital costs for constructing the whole complex including the shaft. The character of the function does not allow finding the global limits. Therefore, it is of particular importance to specify the limiting conditions. In this case these are the flow capacity of development openings and the shaft. The basic groups of cost and natural indicators for assessing and selecting an optimal technological solution have been systematized. The combined analysis of the two approaches to finding the location of the Main opening and determining the mining method enables us to determine when an inclined shaft is best, and the depth at which opening by a vertical shaft has no alternative. Thus, a transition area is formed for which the selection of an optimal technological solution requires an analysis similar to that proposed in this paper. Conclusions are finally drawn which serve as a basis for determining the areas of application of each opening, including the use of a combined scheme of mine opening. The approach presented can be used in both investigating the possibilities for opening up new orefields and reconstructing existing ones in cases when the mining operations go deeper.

Aug 1, 2013

By N. Katsikaros, R. Agius, B. Adaszynski

"With stricter limits globally being imposed on cyanide discharge levels in plant tailings, having a reliable and well designed cyanide detoxification circuit is critical for any operation. The INCO SO2/Air method is most commonly used for cyanide detoxification where sulfur dioxide and oxygen combine to oxidize cyanide to the much less toxic cyanate. This paper discusses the steps involved with the development, from laboratory through to design, of a robust cyanide detoxification circuit. The goal is to produce a cyanide detox circuit that reliably meets discharge target with the lowest operating and capital cost.Design begins in the laboratory where continuous tests simulate full scale operation of a detoxification circuit. Detailed design relies on several design parameters, based on theory and experience, to ensure the reactor can satisfy requirements of the cyanide destruction reaction. Selection of the correct reagents and their supply to the reactor is important to an operable process with minimal operator workload. The operability of the system relies on correct process control strategies to maintain optimal reagent addition and chemical conditions in the reactor. These design factors are critical to providing a robust plant that will consistently meet cyanide discharge levels, ensuring uninterrupted production and plant profitability."

Jan 1, 2014

By J. Koponen, M. van de Vijfeijken, L. Bos

"The availability and reliability of large grinding mills and their Gearless Mill Drives (GMDs) are of paramount importance for the grinding process. Although GMDs have been in service for decades, and are known for their operational efficiency (reliability and robustness with reduced operating cost per ton), compared to conventional drives, in the last decade due to certain reasons some failures led to serious unscheduled shutdowns and significant insurance events.The majority of these notable ""insured"" failures have happened on GMDs installed on relatively large mills, as the financial impact of a failure is proportional to the through-put of the mill. Despite the occurrences of these events, as mining operations are driven by lower ore grades and the ability to continue reducing operating costs per ton, the trend for having larger mills is still very present and there is no reason why this trend should not continue.It is obvious that if not handled correctly, the possibility of large value GMD loss events, coupled with the continuing increase in mill size or required availability and reliability targets, could potentially lead to major conflicts as it becomes difficult for the insurance companies to judge the risk and hence may result in hesitation to insure these grinding circuits. This paper will not only describe the conflicting situation from both an insurer&apos;s perspective and from an equipment supplier&apos;s perspective, but also how these conflicting challenges can be successfully mastered. It has to be noted that not only the mining companies themselves, but also their insurance companies and the involved equipment suppliers have a common interest: to reach the highest availability and reliability in order to avoid or at least minimize unscheduled shut down times, and most importantly prevent unplanned events that result in extended production stoppages or reductions in through-put of GMD driven mills.From the very beginning onwards, the complete service concept together with emergency plans must be integrated on every level in the design of the grinding circuit. This approach must be implemented continuously and without compromises by all involved parties during all following stages, such as basic design, detail design, manufacturing, quality inspection and testing, packing, transportation, storage, installation, commissioning, operation and maintenance. The concept of formal risk analysis related to mill operations, maintenance and spare parts strategies must be an integral part of mining companies’ decisions related to the selection for installation and continued use of large mills powered by GMDs. The service concept in place for operating mills shall also have a clear focus on very early detection of any abnormalities, so that the risk can be mitigated and unscheduled shutdown times avoided. However, if a major failure occurs, then procedures and tools shall already be available in order to ensure that production impact is minimized."

Jan 1, 2012

In terms of throughput, product size and power draw, grindcurves provide a measure of the response of the mill performance to changes in mill operating parameters – usually mill filling. Since presenting the principle in 2006, grindcurves have been applied to a wide variety of AG and SAG mills. Mill response has been carefully measured for variations in: mill fillings from 15% to 40%; throughput by a factor of two; power by 50%; feed blends; liner profile; and mill speed from 65% to 80%. The outcomes of this extensive program of work are presented as the measured grindcurves. How they have enhanced our understanding of mill operation and how they may be applied to practical daily mill control is discussed. It is proposed that this technique provides a viable and valuable mill control tool that may find extensive application in the industry.

Jan 1, 2012

By James A. Deeks

"Motor failures and equipment bearing failures are responsible for reduced productivity.With the introduction of computers and data acquisition systems, users are now able to monitor, report and trend deteriorating conditions and take corrective action before a critical shutdown occurs.This paper discusses the monitoring and trend analysis of&apos; motors, and motor and equipment bearings. With today&apos;s digital electronics technology users are now able to monitor their equipment, detect deteriorating or abnormal conditions quickly, alarm the condition locally and or remotely, and decide if immediate corrective action is necessary or if it can be delayed until the end of a work Shift. All of this can be done long before any damage is done to the equipment.Monitoring Trend AnalysisIt is no longer necessary to compromise in selecting products, since state-of-the-art designs allow the adjustment in such small increments that the users are able to detect minute changes in a system&apos;s performance.Monitoring and trending of motors and equipment bearings is now available in economical packages which can be expanded as a system grows. Simply select the information you need, set the parameters, choose the scan time, and decide on the degree of reporting.Buffer storage of short-term monitoring of a number of analogue channels permit the user to view the recent history of motor data such as: motor average load, unbalance, motor current, ground fault, reserve thermal capacity, plus all of the settings of the protective device.A decision can be made to freeze the stored information after the motor stops or after the motor starts. Then the user is able to recall the conditions and diagnose the performance and the cause of the abnormal condition. Typical scan times range from ¼ second to 5 seconds ."

Jan 1, 1992

By Michael J. Lawrence

"The VALMIN Code was developed and formally adopted by The Australasian Institute of Mining and Metallurgy (AusIMM) in 1995 and a revision was issued in 1998. The VALMIN Code applies to all relevant reports under the Australian Corporations Law, including submissions to the Australian Stock Exchange (ASX) and the Australian Securities and Investments Commission (ASIC).The VALMIN Code and Guidelines sets standards for the preparation and commissioning of independent assessment and/or valuation reports on mineral and petroleum assets or mineral and petroleum securities.It is mandatory for AusllvI:M's members to follow this Code in these relevant circumstances and failure to do so will result in serious sanction of the member by the Ausllvllvfs Ethics Committee. Public support for the use of this Code has been given by regulators (ASX/ASIC) and market participants ( eg major accountancy firms). It is also endorsed as a guide to general best practice in project assessment and valuation.This paper will discuss how the VALMIN Code has worked in practice over the past few years. It will also examine areas where the Code could be improved and how it could form the basis of a new Canadian Code for mineral property valuation."

Jan 1, 2003