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By K. Parameswaran, A. Veek, A. Fernandez, P. Safe

ASARCO LLC (Asarco) Hayden Copper smelter, in Hayden, Arizona, has operated continuously (except for minor labor and economic curtailments) since 1912. The current plant configuration comprises INCO flash smelting, Peirce Smith (P-S) converting and fire refining/anode casting. In order to comply with the U.S. Environmental Protection Agency (EPA) 1-hour National Ambient Air Quality Standards (NAAQS) for sulfur dioxide promulgated in June 2010, the Hayden smelter had to increase overall sulfur fixation from approximately 95 % to 99+ %, requiring a retrofit of the existing converter department and upgrade of associated emissions controls systems. The Converter Retrofit Project (CRP) involved replacing the five existing 13’ diameter Peirce-Smith converters (2 blowing, 2 hot standby) with three new 15’ diameter Peirce- Smith converters (1 blowing, 1 hot standby) to allow for more effective process gas capture using the existing acid plant contact section. Significant upgrades were made to the acid plant wet gas cleaning section and converter primary gas handling system to improve capture performance, reliability, and sludge handling. In addition, a new tertiary gas capture system was installed to further minimize fugitive emissions from the converter aisle. The existing furnace tapping ventilation ESP was replaced with a new baghouse to enable at least 50% SO2 removal using high-surface-area dry lime injection, which was also implemented on the existing converter secondary gas baghouse system. The first two converters and all gas handling system improvements were started up in April 2018, and the third converter was brought online in November 2018. This paper presents the regulatory context; genesis and rationale for CRP; detailed description of the project; challenges during commissioning; system improvements implemented, and design considerations made, and systems performance and process optimization achieved since startup.

Jan 1, 2019

By G. B. Langford

UOCK bursts are a phenomenon about which insufficient is known. This l.~ statement has a twofold meaning. In the first place, far too many people, both inside and outside of the mining industry, are woefully ignorant of the whole subject, and secondly, as those who are face to face with the problem in the mines realize, our knowledge of rock bursts is inadequate. The first group embraces the general public, who have never been enlightened on the subject, and a great many geologists and engineers who have never shown more than a curiosity about it. Such technical men do not realize what a vital problem it is to our mining industries. They are usually thankful that bursting ground is not their problem, and leave it to those unfortunate enough to run into it. From such men one often hears the pious opinion that if proper mining methods were used there would be no problem. It is hoped that this paper will give these people a different viewpoint. Those in the second group deserve much credit for what they have done and are doing. They are fighting a large and difficult problem. In the pages that follow, I have tried to give a bird's-eye view of that problem, and suggest new ways in which it may be attacked.

Jan 1, 1941

By J. A. Finch, J. Vergouw

"Flotation selectivity becomes progressively more difficult to achieve with decreasing particle size. One of the possible problems is agglomeration, i.e. particles clustering together. One mechanism derives from the surface charge all particles develop in water. Agglomeration driven by surface charge is known as coagulation. One form is coagulation between particles of two different minerals of opposite charge. Another is coagulation between particles of the same mineral when conditions are such that the charge approaches zero.The paper describes the method of measuring charge and a new automated settling technique for measuring agglomeration. The phenomena are illustrated with galena and pyrite. Methods of assessing the importance of agglomeration in the plant environment are still to be developed.IntroductionFine particles can agglomerate (i.e. adhere to each other) under certain conditions. This is counter-productive for any physical separation process, including flotation. One cause of agglomeration derives from the surface charge that all particles develop in water. Agglomeration due to surface charge effects is referred to as coagulation. There are two forms of coagulation. If the surface charge is brought to near zero then the force of repulsion is lost and particles coagulate. This usually applies to particles of one mineral type and the technical tenn is homocoagulation. On the other hand, if two particles have opposite charge there is an attractive force. Since the particles in this case are usually different minerals this is known as heterocoagulation.Both types of coagulation can cause minerals to be misplaced. In the case of heterocoagulation this is fairly obvious. One example that may be familiar is slime coating (fines of one mineral coating larger particles of another) But even homocoagulation can be a problem an agglomerate of the same mineral particles can entrap particles of another mineral."

Jan 1, 1997

By Michael G. Rulff, Tracy M. Holmes

"Vast amounts of time and money are spent fighting flow problems in plants that involve the handling or processing of industrial minerals. Because these types of projects tend to be capitalintensive, the right decisions, made at the design stage, can have a substantial positive effect on the economics of the project.Some of the problems related to solids flow in mineral processing plants include:•,Flow stoppages•,Uncontrolled flow•,Segregation of blended materials•,Build-up and dead material resulting in loss of live capacityUnfortunately few Universities in North America provide courses in the design or selection of bulk solids handling equipment, let alone the theory of bulk solids flow, with the result that engineers do not fully appreciate the effects of bulk solids handling on their process. The usual method of selecting “standard” equipment, all too often, leaves plant operators hammering on hoppers to promote flow, a technique that is not only usually ineffective but also unsafe and often causes damage to equipment. In short, too little consideration is given, at the design stage of projects, to the particular material and operating environment involved and how these will affect handling between process steps.This paper seeks to give a general understanding of bulk solids flow theory including flow patterns and flow property tests, and presents functional design guidelines to ensure reliable flow. As well, a case history will be presented. Our message is clear: To ensure uniform, reliable flow, a plant design must take into account the specific flow characteristics of the bulk solid to be handled or processed."

Jan 1, 2008

By M. K. Mishra, U. M. R. Karanam

Relative to slender pillars, larger size pillars exhibit improved strata control. Fly ash, though traditionally treated as a waste product, is emerging as an alternate engineering material. This paper deals with the development of a strong fly ash composite material with additives. The geotechnical properties of this fly ash composite were determined and used to trap model core pillars, which resemble squat pillars. The trapped samples were tested under uni-axial loading in the laboratory and the results showed higher load-bearing capacity of the model core pillars. The reinforced fly ash composites provide lateral confinement and exhibit improved post- failure behaviour of the model cores.

Jan 1, 2008

"This paper reviews the chemistry involved in the recovery of gold from cyanide solution with anion-exchange resins, and also discusses the most critical aspects of the engineering of an effective resin-in-pulp (RIP) process. As far as the chemistry is concerned, the conclusions reached by a great many researchers, as well as the performance of the only operating RIP plant in the Western World, at the Golden Jubilee Mine in South Africa, support the view that the process is technically viable and, in many cases, could prove to be more attractive economically than alternative processes such as zinc cementation and carbon-in-pulp (CIP). On the engineering side, there is still a need for further development before larger scale ( > 50,000 tpm) RIP plants can be designed, built and operated with confidence. However, the experiences gained during nearly 3 years of operation of the Golden Jublee RIP plant indicate that the process can be engineered with confidence for smaller operations ( < 50,000 tpm), and this will probably be the scope of application of the first-generation RIP plants. INTRODUCTIONThe use of anion-exchange resins in gold processing has, for a number of years, been proposed as an alternative to more conventional processes such as zinc cementation and carbon adsorption, and detailed research programs that have been carried out at a number of laboratories have demonstrated the technical viability of the process. (Burstall et al, 1953, Davison et al., 1960, Tataru, 1973, Laskorin et al. 1978, Hosking, 1984, Riveros and Cooper, 1987 and Palmer et al., 1988)The main incentive for this work was the fact that resins have several characteristics that are quite different from carbon, which make them potentially more attractive substrates for the recovery of gold. The following are examples: -"

Jan 1, 1991

By P. C. Holloway, A. Tshilombo, T. Xue, M. J. Collins, R. Lopetinsky, I. Mihaylov, I. M. Masters

The Voisey’s Bay deposit contains a trace amount of cadmium, which reports to solution during pressure leaching of the nickel concentrate at Vale’s Long Harbour Hydrometallurgy Plant, and must be removed to produce high quality nickel cathode. In 2006, Vale approached Sherritt Technologies to collaborate on the development of a process for removing cadmium to low levels (<1 mg/L) in the nickel raffinate. Following successful bench scale and pilot plant testing at Sherritt’s laboratories, the cadmium removal process was then moved through engineering and construction, culminating in the successful commissioning and startup of a cadmium removal circuit at the Long Harbour Hydrometallurgy Plant in 2017. This paper presents the results of this collaboration and the challenges that were encountered through each stage of development, as well as current results from operation of the commercial cadmium removal circuit. INTRODUCTION Vale’s Long Harbour Processing Plant, with a nameplate capacity of 50,000 t/y nickel, began operation in 2014. In addition to electrolytic nickel rounds, the plant also produces electrolytic cobalt rounds and copper cathode. The Long Harbour Processing Plant uses a unique hydrometallurgical process developed by Vale Base Metals Technology Centre, as shown in Figure 1, to treat a nickel sulphide concentrate produced at the Voisey’s Bay mine and mill located in northern Labrador (VBN concentrate) (Stevens et al., 2009).

Jan 1, 2019

By Zorigtkhuu Davaanyam, Bern Klein, Stefan Nadolski, Amit Kumar

"The High Pressure Grinding Rolls (HPGR) is a relatively new comminution technology that has been shown to be more energy efficient compared to semi-autogeneous (SAG) mills. Full and fair consideration cannot be given to HPGR-based comminution circuits in early stage projects, because presently pilot scale testing is required for assessing and sizing; pilot scale testing requires bulk samples weighing more than one tonne. A CAMIRO research program was conducted at the University of British Columbia to develop bench scale tests that would reduce the quantity of sample required to assess HPGR.Three test procedures were developed.1. The Direct Calibration Methodology calibrates piston press test results to pilot scale test results such that piston press tests can then be used to determine the energy–size reduction relationship for a range of ore types.2. The Database Calibrated Methodology, which is similar to the Direct Calibration Methodology except that it calibrates piston press tests against a database of pilot scale and piston press tests.3. The Semi-Mechanistic Methodology was developed to use piston press test results as an input for an HPGR based energy-size reduction performance model.Through utilization of these methodologies, the energy–size reduction performance of an HPGR can be predicted with minimal sample requirement. In addition, piston press testing is far more cost effective, faster, and accessible than pilot-scale HPGR testing.IntroductionOne could argue that in the future, decisions regarding selection of comminution circuits will be made primarily on the basis of energy consumption. The following facts and predictions support the argument:"

Jan 1, 2015

By Zhen Lei

In Alberta, Canada, heavy industrial projects are constructed using a prefabrication approach: spools and pipes are produced in the factory, and are assembled into modules that are transported to the industrial plants for installation by mobile cranes. Planning the onsite mobile crane operations is critical to the project budget and schedule. However, due to the large magnitude of industrial projects, manual heavy lift planning is tedious, and the results are not particularly responsive to site changes. This paper introduces an integrated mobile crane management system developed by PCL Industrial Management Inc., in collaboration with the University of Alberta, which investigates crane location selection and path checking for field module assembly. The project information is stored in a database, and the proposed system retrieves data, performs the calculations, and records the results back to the database; the calculations involve automatically selecting locations for the mobile crane, considering the crane capacity, lifting range and utilization. Lift paths for modules are checked for feasibility based on selected locations, satisfying the site and crane configuration constraints, and crane walking paths are planned if needed. The designed system is tested in an industrial project to validate the effectiveness of the system.

Aug 1, 2013

By F. Malek

At Creighton Mine, magnitude events are a regular occurrence due to depth and major seismically-active structures. Over the last ten years, major advances have been made in research and development to develop strategies for the management of these major events. Today, the number of rockbursts has been drastically reduced at the mine and damage due to seismic events, when they occur, is often minimal. This paper describes the evolution and implementation of appropriate geomechanics strategies, designs, and practical ground control measures undertaken for the management of seismicity at Vale Inco?s Creighton Mine. A description of the research and development approach, implementation, and ground control strategy is provided for placement of enhanced support systems to manage the consequences of magnitude events at Creighton

May 1, 2009

By Y. Sasseville

"Niobec has been using vibrating screens and screw classifiers as a double stage classification in its grinding circuit since the very beginning of its operation in St-Honoré. Most of the other mineral processing plants around the world uses cyclones as the classification device in their grinding circuit. The difference between these two methods are well known in terms of capital cost and grinding efficiency but the differences in terms of the impact on the downstream processing stages are a lot harder to predict and are case specific. In the interest of lowering the capital cost of a future expansion project, Niobec decided to test the cyclones in its actual grinding circuit and evaluate their impact on the recovery of the downstream processing stages as well as the operating cost of the mill. We switched between cyclones and screens for 8 month in 2013 and early 2014 and we are now operating only with cyclones since march 2014.INTRODUCTIONThe Niobec mine and concentrator were built in the mid 70’s and at that time, the mill was processing 1 500 tons per day. Over the years, many expansion projects have brought the plant to 7 000 tons per day. Throughout the initial concentrator design and commissioning, screens have been chosen over cyclones because of their higher classification efficiency which is known to reduce variability and limit the fine generation especially due to a high undersize classification efficiency. Just like many other plants, fine particle generation is a major problem at Niobec because of its negative effect on downstream processing stages. In the interest of lowering the capital cost of a future expansion project, Niobec’s engineering team decided, 35 years later, to test the cyclones in its actual grinding circuit and evaluate their actual impact on the final recovery and the operating cost of the mill.The grinding circuit is separated in two lines which will be called Circuit #1 and Circuit #2 along this paper. Circuit #1 is, as you can see in Figure 1, composed of a rod mill and two parallel ball mills in closed circuit with screens and screw classifiers. The screens oversize are sent to the screw classifiers while the undersize are sent to the next processing stage. The screw classifiers overflow are both sent back to the pump box while their oversize streams return in their corresponding ball mills for further grinding. Circuit #2 is, as you can see in Figure 1, quite the same as Circuit #1 except it has only one set of screw classifier and ball mill. Figure 1 also shows the modification in arrangement each circuits went through to integrate the new cyclones. One of the ball mills in Circuit #1 now appears dotted because it can still be used but is not now"

Jan 1, 2015

By D. E. M. Plaumann, B. S. Fee, R. D. Hansen, R. R. Klimpel

"The steps from experimental curiosity through to commercial product can be slow and tortuous in spite of the quality of the technological advances offered by the new development. Data generation and interpretation need to be done in lab tests as well as full-scale evaluations and, in each, the advantages of the new reagent must be clearly identifiable and measurable.The Dow Chemical Company has patented a novel new collector for the flotation of zinc. Fl (2-hexylthioethylamine hydrochloride) has several unique structural features that suggest atypical mechanisms for zinc collection. Laboratory data have demonstrated significant flexibility with respect to grade and recovery balance at dosages lower than those typically used for xanthates.In mill trials, the same phenomanon is evident - the choice between high grade and high recovery allows one to select the desired quality of zinc concentrate. One trial in particular was run over a three month timeframe and Fl gave improvements in recovery of 2.5% and a reduction in lead levels with less than 0.5% loss in grade. The dosages of other reagents in the flotation circuit were also reduced.Data demonstrating improved recovery and grade in lab trials will be discussed. Extensive data from the mill trial will illustrate how Fl works in both rougher and cleaner circuits."

Jan 1, 1990

By H. Warren Newcomen

The southwest wall of the Lornex Pit at the Highland Valley Copper mine has been experiencing slope displacements since 1978. Measures to manage the displacements on previous pushbacks have included stepping out, scheduling pushbacks to unload the crest of unstable areas, slope dewatering and mining with intensive slope monitoring. The final pushback on this wall is currently being mined and substantial modifications to the slope geometry could prove to be uneconomic. As a result, a campaign of surface water collection and diversion, horizontal drainhole drilling and deep well drilling is currently underway to maintain an acceptable degree of stability to the end of mine life. The various factors contributing to instability, including engineering geologic controls, rock mass strength, and surface and groundwater hydrology are presented. Movement trends, displacement magnitudes and stability analyses results are also discussed.

May 1, 2002

By C. R. Edwards

"Equity Silver Mines Limited, Canada&apos;s largest silver mine, has designed, built and operated a leach plant to reduce the levels of antimony and arsenic in its silver-gold-copper flotation concentrate. The orebody contained deleterious antimony and arsenic minerals in such proportions that the economic long-term sales contracts necessary to obtain project financing could not be procured. Construction of the leach plant therefore allowed development of the mine to proceed. Although the plant took some time to reach design throughput and product specifications, due to the complex and unique nature of the operation, these goals were successfully met and surpassed. This paper describes the physical plant and/or process technology modifications made to mold the main processes-concentrate leaching and filtering, autoclaving and filtration of by-products, and crystallization of salt cake-into an effective, economic operation.IntroductionEquity Silver Mines Limited, a member of the Placer Development Group, owns and operates an open-pit silver mine and related facilities located 37 kilometres southeast of Houston in north-central British Columbia. The mine occupies a 44 I-hectare (1089 acre) site at an elevation of 1300 metres (4265 feet) on the Nechako Plateau. Producing a copper concentrate containing high values of silver and gold, it is the largest silver mine in Canada and one of the largest in the western world. Equity stresses open communications, positive motivation, and production with safety, and achieved the best mine safety record in western Canada in 1984."

Jan 1, 1985

By C. Schuffeneger

"The design of SAG milling circuits for mining projects requires the incorporation of the energy consumption considerations and the evaluation between different flexibility-adding options to absorb the time-dependent variation in the ore lithology. In order to expand the focus of the engineering design, a higher level of deepness and quality in the baseline information must be achieved to elucidate all of the constraints on throughput, energy consumption and product quality generating a design optimization consistent with an integrated vision of the process. This paper presents a review of a collection of typical examples of the copper and gold mining project in the Chilean Andes, in which both process and energy efficiency criteria are considered when the focus is to deliver an integral solution that incorporate those areas in the design. The intensive use of energy in the SAG milling, the process continuity and the quality of the product are a function of the proper design and selection of grinding equipment and plant layout, aligned with the mining plan and associated with projected future expansions and production increases.INTRODUCTION Autogenous and Semiautogenous grinding technology, large diameter and short length mills, begins with the Handsel design. During the decade of 1930’s, Handsel-Hardinge studies led to cascade mill development. Nowadays, 80 years later, continuous improvements in design and technology have been conducted to a completely new generation of gearless SAG mills that have led to an increasing capacity at the concentrator plants. Considering the existing alternatives, SAG mills are the most implemented option for the grinding circuit today. This work presents a review of the SAG mill implementation parameters and circuit considerations and its correlations in the most recent projects in Chile with an ore treatment capacity above 50 ktpd since the decade of the 90’s up to now. From this period, the tendencies will be analyzed using project design data. Based on process design information, the recent SAG mill history in relevant projects related to the new generation of commercial SAG mills, technical associated considerations and performance will be discussed. Circuit selection based on energy utilization will be revised to bring up a more holistic perspective on the SAG mill circuit design concepts. As is now well known, the heart of every concentrator plant are the grinding mills. Higher demands on throughput, availability and power consumption optimizations require not only high performance electrical equipment but also a well selected grinding circuit. The energy efficiency issues associated to the circuits design will be reviewed."

Jan 1, 2012

By A. G. Spencer, A. D. Taylor

This paper discusses some of the advantages and problems associated with the selection of large unit equipment for a metallurgical plant. A given flowsheet and material balance for an iron ore concentrator is assumed. Then two plant designs are developed, one utilizing a number of smaller-size equipment units and one utilizing the largest available equipment units. The mechanical and electrical problems are discussed and a comparison of capital costs is made. Finally, brief consideration is given to a plant de-sign using units larger than those which are currently available.

Jan 1, 1968

By B Lumsden, B Lacouture

"Red Dog is one of the largest zinc mines in the world both in terms of reserves and annual production. In 2013, Red Dog produced 551,300 mt of contained zinc and 96,700 mt of contained lead. The mine, which is located in Northwest Alaska, is a partnership between Teck Alaska Incorporated, the operator of the mine and NANA Regional Corporation Inc, the local land owner. The Aqqaluk deposit, which is the current source of ore, has an average grade of 15.8% Zn, 4.1% Pb and 73 g/t Ag with the main minerals being sphalerite, galena, pyrite, barite and quartz. Surveys of the zinc flotation circuit at Red Dog identified that a substantial amount of fully liberated, sub 20 micron sphalerite particles were being lost to final tailings. As a means of improving fine sphalerite recovery, a four month plant trial of magnetic conditioning was conducted in the zinc retreat circuit. Magnetic conditioning technology has already been commissioned in several concentrators around the world to agglomerate fine paramagnetic minerals, increasing their probability of bubble collision and recovery in a flotation cell. The results of the four month plant trial at Red Dog showed that at a high level of confidence, a 1% increase in zinc recovery or zinc recovery and zinc concentrate grade combined was achieved with magnetic conditioning. The resulting economic benefit, which is also at a high level of confidence, is significant to Red Dog and therefore, magnetic conditioning has been permanently incorporated into the Red Dog zinc flotation circuit.IntroductionRed Dog is the largest zinc mine in North America and represents approximately 29% of North American zinc concentrate production. The mine is located in northwest Alaska, approximately 100 miles north of the Arctic Circle and 50 miles inland from the Chukchi Sea. The remote location makes the mine accessible only by air or seasonally by ocean-going barges. Red Dog is a partnership between NANA Regional Corporation Inc, the land owner and Teck Alaska Incorporated, the operator of the mine."

Jan 1, 2016

By V. Dinesen

"Grinding is simply the function of reducing particles in size or creating new surface areas. This may be accomplished by many means but we will only concern ourselves with the continuous grinding process as performed in a revolving drum or mill, containing a grinding media. Such a mill consists essentially of a feed head, a cylindrical shell section and a discharge head. To prevent internal wear of these parts it is customary to attach replaceable linings over the wear areas. The specification and design of these mill liners is more important than generally conceded. As they reduce the effective internal volume of the mill, they will consequently affect the whole mill ·design and operation.A number of mill designs of various sizes are available for combined crushing and grinding of materials within a wide size range. For simplif1cahon purposes we will refer 1n particular to conditions relating to standard mill shapes having a length which is greater than the diameter. Such mills usually rotate at speeds between 60% to 85% of the critical speed and may, depending on the grinding media used, be classified as rod mills, ball mills and pebble mills.LINER MATERIALSA great variety of materials have been and are being used for mill linings. These include wood, ceramics and cements, rubber and plastic compounds, rolled and forged steels, cast steels and cast irons, both plain, alloyed and specially treated.The choice of a liner material depends on many factors. In both dry and \\.:et grinding, it may be necessary to consider product purity, colour, chemical reaction etc. but for our purpose we \viii refer to wet grinding operations as generally used within the mining industry."

Jan 1, 1972

By S. Tuttle, R. Sisson

"Suncor Energy Inc. has proposed a 2.2 billion dollar expansion to the current oil sands operation, which will more than double the productive capability of the facility. As part of the application for this expansion, a comprehensive closure plan had to be developed and filed.Closure planning includes a systematic evaluation of the area to be developed, the development activities planned, the goals and objectives of the corporation in re-establishing landforms and ecosystems at the same time as running an effective operation. As early as is practical during the mine development, surface contouring is completed, soil is reconstructed, and vegetation, surface drainage and wetlands are re-established. Once active reclamation is complete and vegetation has been re-established, Suncor monitors maturation of landscapes and ecosystems to provide the submission basis for reclamation certification"

Jan 1, 1999

By A. H. Winckers

"The San Nicolás deposit is a complex fine grained polymetallic volcanogenic massive sulphide deposit located in central Mexico.Metallurgical testwork was carried out in 1999 and 2000 to develop a flowsheet. During the course of the metallurgical testwork it became evident that it would be impossible to develop an accurate head gradehecovery based model for the projection of metallurgy. It was suspected that variability in mineral texture was a predominate factor affecting metallurgy. For this reason it was decided to evaluate the applicability of QEM*SEM technology to this test program.This paper summarizes the metallurgical testwork and describes the evaluation and subsequent application of the QEM*SEM technology to characterize the mineral texture throughout the deposit. Finally it is shown how the QEM*SEM data are used in the mine block model to project the metallurgy.The QEM*SEM (Quantitative Evaluation of Minerals by Scanning Electron Microscopy) is an automated image analysis system developed by CSRO which provides quantitative numerical estimates of the compositional and textural properties of the mineral suite which govern the concentration process.INTRODUCTIONThe San Nicolás deposit, was discovered in 1997 through the application of geological and geophysical techniques. The property lies 60 km southeast of the city of Zacatecas on the central Mexican plateau as shown in Figure 1."

Jan 1, 2002