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Study on Mineral Processing of Refractory Copper-Nickel Ore

Sep 13, 2010

By Leopoldo Mariscal

El presente trabajo describe los aspectos más importantes del proyecto de Fundición de Ilo como son: la tecnología, el desarrollo de la ingeniería y construcción, el impacto económico, social, tecnológico y ambiental de su ejecución y los planes de entrenamiento y comisionado de la nueva planta. Asimismo considera entre los equipos principales: un horno de fusión en baño ISASMELT asociado a un caldero de recuperación de calor y un precipitador electroestático, cuatro convertidores Peirce Smith, dos electroprecipitadores, dos plantas de ácido, dos plantas de oxigeno, dos plantas de efluentes, una planta de moldeo de ánodos, dos hornos de limpieza de escoria, y varias plantas auxiliares más.

Sep 12, 2005

By Donald F. Reed

Deposits of gray hematite occur in two districts in Talladega County, Ala., the Emauhee-Tallasechatch and Weewoka, both in the; vicinity of Wintorboro, 50 miles east of Birmingham. The deposits were investigated by the Bureau of Mines in 1945 and 1944. Approximately 15,000 feet of diamond drilling was done and 6,000 linear feet of trenches excavated and sampled.

Jan 1, 1949

By T. Ertekin, X. Dong

This paper identifies the need for the development of specialized inverse solution techniques for the analysis of pressure transient data for the characterization of the transport and sorption properties of coal seams. Central to the proposed inverse solution technique is a specially structured artificial neural network (ANN). The most important transport and sorption characteristics of coal seams are butt and face cleat permeabilities, macropore porosity, Langmuir volume constant, Langmuir pressure constant, and sorption time constant. Conventional methods, such as type curve matching techniques and laboratory-derived measurements are handicapped in terms of being representative over the entire domain of interest. In this paper, we utilize analytical forward solution techniques for various combinations of characteristics of coal seams to generate training and testing patterns. These training patterns are shown to an ANN structured to learn the ubiquitous non-linear relationships that exist between coal seam properties, input conditions and the pressure transients measured. The trained networks are then extensively tested to ensure that they have effectively learned the training patterns. In the final stage of the development, the networks are run in the prediction mode. The responses of the networks are found to be in agreement with the input data. The developed networks are able to generate results generally within 5% error margin for permeability and porosity and 20% error margin for the sorption characteristics of coal seams. A number of examples highlighting the capabilities and degree of effectiveness of the network in characterizing the coal seams areincluded. Keywords: artificial neural networks (ANNs); coal seam characteristics; pressure transient analysis

Jan 1, 2003

By William H. Hamilton

INTRODUCTION It was not very many years ago that tunneling machine manufacturers spent considerable time trying to convince contractors and mine operators of the advantages of mechanical tunnel boring over conventional drill and blast methods. Today there are few doubters left. There is universal agreement that, not only are tunneling machines here to stay, but the ratio of bored rock tunnels to blasted rock tunnels is increasing at an accelerated pace, and within the next twenty years I predict almost all tunnels will be bored by machine. I believe we are today at a very important mile-post in the development of tunnel boring systems. Felix Gaye stated in his recent article (1) "It is important to disseminate between the efficiency of cutting tools and the overall efficiency of the boring operation". Mechanized tunnel boring in the past placed almost total emphasis on the rock cutting and boring ability of the tunneling machine. With advancements in technology and better solutions to the problems of rock fracture, steering control, and structural design, the emphasis today can be placed on the total-system concept. Tunneling machine design, as one of the key elements in the overall system, presents many problems that are not totally solved today. These design problems are, in the most part, not related with rock fracture, but rather with criteria associated with the over-all operation.

Jan 1, 1997

By Jérôme Girard, Shiu Kam, Sue Longo

"Historically, tailings management in a northern climate has involved the deposition of tailings into the Tailings Management Area (TMA) as conventional slurry. This type of system is obviously viable but presents challenges that are difficult to manage as circumstances change over the life of mine. These issues can include:? Increases in mill throughput, and? Life of the TMA for the life of mine.This case study will present how thickened, high-density, non-segregating tailings are used as an alternative to conventional slurry disposal to achieve greater storage capacity and enhanced environmental performance for a gold tailings facility in a northern climate. This paper will focus on how this change in deposition strategy accommodated the increased throughput of the mill and the increased life of mine. Specifically, the paper will discuss the addition and integration of new processes to the exiting mill system to accommodate the tailings management issues. It will highlight the challenges from laboratory testing to pre-feasibility to the engineered design of the thickened tailings system implemented at Musselwhite Mine.BACKGROUNDGoldcorp Canada’s Musselwhite Mine, in Northwestern Ontario (120 km north of Pickle Lake), is an underground gold mining operation that began production in 1997. The current mill throughput is about 4000 tpd (1.4 Mtpa). Gold extraction is based on a CIP process with cyanide destruction.The existing tailings management area (TMA) is located about 2 km southwest of the mill complex. The TMA is contained by high ground to the north and to the west and flanged by a moraine ridge along the south side. A number of dams have been constructed along this ridge. The dams were first built in 1996 and subsequently raised in 2000 and again in 2005. Excess tailings pond water is discharged to a polishing pond then released to the environment via a wetland.The TMA was originally designed to contain 13.7 Mt of tailings under a ponded surface for closure. The water cover was to inhibit adverse long-term environmental effects because the tailings contain pyrrhotite and other sulphide-bearing minerals that are potentially acid generating. The design was modified during Stage 3 Construction in 2005 to expand the storage capacity to 17.3 Mt (Golder, 2005). As of end of 2009, over 16 Mt of tailings had been deposited in the TMA. The slurried tailings were historically deposited at 50% solids."

Jan 1, 2011

By D. Randolph Berry

The United States Bureau of Mines (USBM) awarded a contract to Foster-Miller, Inc. to develop guidelines for the storage and use of Self-Contained Self-Rescuers (SCSRs) in underground non-coal mines. An SCSR is a device capable of supplying, in an emergency, one hour of self-contained oxygen (no breathing of mine air). The information and recommendations in this report were developed primarily from three sources: discussions with mine representatives (including management, labor, and government), site visits in underground mines I and a detailed analysis of every reported non-coal accident which produced d hazardous atmosphere during the 5-year period 1976-1980 -plus ten other major incidents from prior years. Volume IV has three major sections: Recommendations and Discussion (Section 2), Analysis of Mine Accidents (Appendix A), and a Summary of Discussions with Mine Representatives (Appendix B).

Jan 1, 1983

The Taupo Volcanic Zone inNew Zealand and the Philippine Mobile Belt in the Philippines are characterized by active subduction, active volcanism and high seismicity. The main factors affecting characteristics of geothermal systems in both countries are: tectonic setting, source magmas, maturity of the systems, and depth to the degassing magma body. Within New Zealand, geothermal systems are grouped into arc- and rift-type. Fluids in arc-type systems contain high amounts of volatiles (<20%), with high CO2/Cl, CO2/He, and N2/Ar ratios. Mantle-type volatiles predominate in rift-type systems. Philippine geothermal systems are largely arc-type, the topography is rugged, leading to the separation of water and vapour upflows, as opposed to the overlap found in New Zealand. The relatively shallow depths of degassing magma bodies in the Philippines results in steeper geochemical gradients, leading to higher proportions of arc-type magmatic water (>40%) and higher Cl contents (3000 - 10 000 mg/kg), Maximum temperatures are also higher, reaching up to >400¦C. Arc-type alteration assemblages in New Zealand and the Philippines are similar. Because Philippine geothermal systems are less mature, have higher temperatures and steeper geochemical gradients than New Zealand ones, advanced argillization is more widespread occurring down to depths of 2000 m. Mineral phases are more varied due to the active input of magmatic waters and the formation of vapor conditions at depth, forming P04-, B-, Li-, Ce-, F-, and Cl-bearing minerals at high temperatures. In the Philippines, high temperature magmatic-hydrothermal to contact metamorphic assemblages containing biotite, amphiboles and pyroxenes are relatively common, but rare in New Zealand.

Jan 1, 1995

When the HSE Act was introduced in New Zealand in April 1993, one of the prime aims of the Government was to signal to the industry. The Government's recognition of the employer as the key person responsible for safety and health in the workplace and to actively encourage employers to self manage the health and safety function. Because of the significant change in the philosophy behind the new legislation, and because of the inherently conservative nature of the mining industry, it has taken some years for both the industry and the regulators to reach the stage of considering the framework in which a controlled degree of self management can proceed.   In this paper, some of the issues relating to the legitimacy of the process are considered, some of the questions raised in the minds of those charged with implementing the legislation are discussed, and the views of some eminent authors are examined.   The latter part of the paper focuses on a programme called the Reduced Site Surveillance Programme, which grew out of Goal 2 of the New Zealand Mining Inspection Group's 5-Year Strategic Plan. The programme is described in some detail, and the criteria applied at each stage of the programme is discussed. The paper concludes with the author's expectations of the longer term outcomes of the programme.

Jan 1, 1997

By Jose R. Hernandez-Aguilar

"Three models to predict the effect of bubble size (Db) on metallurgical response were tested in a pilot-scale flotation column at Teck Highland Valley Copper mine. The column was fed with slurry collected from the Cu/Mo separation circuit. The first model was the one developed by Gorain et al. (1997), which assumes that the collection zone rate constant (kc) is inversely proportional to Db. The second model was the one proposed by Hernandez-Aguilar et al. (2010), which considers kc as an inverse square function of Db. The third model was the one developed by Yoon and Luttrell (1989) which provides expressions to describe the efficiency of particle collection (E) based on first principles. The results showed a significant bias between experimental and predicted data using the model of Gorain et al. (1997), possibly reflecting the model’s inability to explain the impact of bubble size, bubble rise velocity and flow regime on E. The model of Hernandez-Aguilar et al. (2010) well described the experimental evidence. The model of Yoon and Luttrell gave accurate and unbiased predictions. However, Yoon and Luttrell’s approach calls for a criterion to determine whether the flow regime is potential or intermediate, a subject that requires more fundamental research.INTRODUCTIONParticle collection, i.e., bubble-particle collision followed by attachment, is the basis of flotation. In a quiescent environment (such as the one observed in a column, or away from the impeller in a mechanical cell), a collision event can take place as long as the “degree of turbulence” caused by the rising bubble does not prevent particle and bubble to flow in close proximity. Upon collision, the particle slides on the bubble surface for a period of time. If the particle is hydrophobic, attachment occurs when the “sliding time” is longer than the “induction time”, which is the time required to thin and rupture the intervening liquid (usually water) film forming a three-phase contact angle. While the induction time is largely influenced by the degree of hydrophobicity of the particle, the degree of turbulence is governed by the bubble size. Generally, direct control of bubble size is not exercised by most mineral processing practitioners, in spite of its obvious importance. Studies to model the effect of bubble size on particle collection using fundamental approaches have been conducted (e.g., Anfruns and Kitchener, 1977; Webber and Paddock, 1983; Yoon and Luttrell, 1989; Dai et al., 1999). However, these models have been validated under highly idealized laboratory conditions (micro-scale experiments using single minerals and uni-sized bubbles), far from resembling those existing in practical industrial applications. Fundamental studies to interpret the effect of bubble size on particle collection in industrial environments are largely absent in the literature. Partly because of this lack of practical knowledge, many mineral processing practitioners perceive laboratory “bubble size” studies to be valuable academic exercises, but not something that can be directly applied to daily production issues."

Jan 1, 2011

This study explores two evolving 3D surveying technologies, photogrammetry and laser scanning, and applies them to deformation monitoring of rock faces and mine highwalls. A quantitative analysis focused on 3D coordinate determination is performed. Furthermore, a qualitative assessment directed at the practicality and viability of each system operating near a rock face or in a mining operation is undertaken to reveal one systemÆs deficiencies over the other. Two photogrammetric and four laser scanning surveys aimed at optimising accuracy and precision within a short period of data acquisition are conducted on the rock face at Organ Pipes National Park, Keilor, Victoria. The accuracy and repeatability of each survey is determined using a combination of iWitness photogrammetric, and Cyclone laser scanning software. The 3D coordinates of targets placed on the rock face are determined by triangulation and resection principles within a bundle adjustment. The coordinates determined by each system are then compared in a 3D transformation. Controlled deformation conditions are established to determine the precision to which each system can detect movement in the rock face. An object of known dimensions is placed on the rock face to simulate deformation. The relative orientation of images taken for the pre- and post-deformation photogrammetric surveys provide an overall 3D point accuracy of 1.255 mm and 1.804 mm respectively. A 3D transformation shows discrepancies of less than ¦22 mm (RMS) between the geometry of the photogrammetric and laser scanning models. Both systems are able to detect the simulated deformation to a precision of 50 mm. This work also identifies how to obtain millimetre accuracy for 3D coordinate determination of rock faces, thereby providing a quality data set for surveyors, geotechnical engineers and mine geologists. Photogrammetry is shown to be a mobile, time and cost-effective technique that is more amenable to mining operations than terrestrial laser scanning. However, both systems demonstrate that they are capable of detecting movements that may lead to failures in the rock face, and possibly endangering human life. The implications are significant for surveyors, geotechnical engineers and mine geologists working in mining operations where enhanced safety conditions, increased productivity and lower operational costs are important considerations.

Jan 1, 2009

By C. O. Brawner, J. Kalejta II

The classical approach to control rock fall and ravel in open pit mining has been to use catch benches. The width and volume of benches is most dependent on the bench height, size of loading equipment, blast damage to the face and mining regulations. This was compatible with open pit slopes of less than about 45°. As our understanding of rock mechanics and blasting control has improved over recent years, much steeper rock slopes can be developed at many open pit mines. However, narrower benches result with less rock fall capacity. The transportation industry has been very successful in using catch fences to protect highways throughout North America and Europe for years. The authors recommend that cable and ring net fences have a potential major application in open pit mining to allow steeper rock slopes with significant economic benefit. This paper outlines the application, design and operation of catch fences in surface mining for specific conditions. Typical case examples are presented.

Jan 1, 2002

With the dawning of a new century came the beginning of a new era in the coal industry. Instead of the traditional practice of only buying and selling produced coal in the United States, a coal futures market was established. The New York Mercantile Exchange began trading coal futures in July 2001. But, even in this new era, many of the old is-sues that have beset the coal industry still remain, as was evident in2001. Coal production increased to are cord level during 2001, according to preliminary data from the US Energy Information Administration(EIA). Production in 2001 rose by4% to 1.01 Gt (1.12 billion st), compared with 2000 (Table 1). This barely surpassed the previous record level of 1 Gt (1.11 billion st)set in 1998. Coal consumption remained unchanged. The additional production was used to replenish the depleted stockpiles that had resulted after two years of declining coal production and increasing coal consumption.

Jan 1, 2002

By S. M. Rupprecht

Transportation accounts for some 26% of all mine accidents in South Africa. Although this figure may not be as prolific as fall of grounds accidents or accidents caused by seismic events, the enormity of transportation accidents demands attention, especially as many of these accidents are avoidable. This paper investigates vertical (i.e. shaft), horizontal (i.e. haulages), and in-stope transportation systems and their function as it applies to safety. Recent transportation accidents are discussed looking at current trends within the three transportation areas. In the shaft area, discussions will focus on handling of material cars, loading and off-loading of the workforce and management of shaft orepass systems. The horizontal component will focus on personnel transportation, safety around trains and hoppers, and handling of material in the cross-cut. The discussion on in-stope transportation will focus on the general congestion of the stope environment and how it affects the overall movement of personnel, material, and rock. Of concern are the large numbers of material handling and scraper winch accidents that occur and which will be discussed in some detail. The paper will conclude with a section on proposed guidelines within the three above-mentioned systems for mine engineers to consider in mine design and life of mine planning and scheduling. Keywords Underground logistics, safety in material handling.

Jan 1, 2011

By Alejandro Gutiérrez, David Ahues, Paola Merino, Felipe González

A Discrete Elements Method (DEM) study of load movement within a SAG mill 12,192 × 7620 (40′ × 25′) in normal operating conditions is performed. The purpose is to determine how the geometry of the lifters affects the kinetics of the load inside the mill. Specifically, the changes produced by the incorporation of inclined lifters and spiral or helicoidal pulp lifters to the kinetics are evaluated. Four study cases are identified: first, the base case corresponds to a conventional geometry; the second case corresponds to inclined lifters incorporation; third case corresponds to a mill with helicoidal discharge; and the fourth case corresponds to a mill with inclined lifters and helicoidal pulp lifters. To save computational resources, the water that enters the mill has been modeled by varying the coefficient of restitution. The results of a series of experiments are presented to determine how this coefficient varies when having impacts on surfaces with different liquid levels. A comparative analysis is made of the following variables: mean transport speed and material flow, for normal operating conditions. Taking as reference the mill with straight lifters and radial pulp lifters (case 1), the case with the inclined lifters and radial pulp lifters increases the material discharge flow less to 76 mm of size by 5.1%, and this value increases even more when the helicoidal pulp lifters are incorporated reaching a 58.6%. The most significant change is seen in the flow through the grates and the pulp lifters discharge, which can increase substantially improving the operation.

By Brian T. Burch, Paul N. Worsey

When fired, submerged Linear Shaped Charges (LSCs) lose all effectiveness in the cutting of steel. Users in underwater applications have reported having to substantially increase the charge size to the point where brute explosive force shears rather than cuts the target.

Jan 1, 2015

By David Conover

The El Boleo Copper Project is currently in the final design stages for development of a 3-MM-tonne/yr underground copper mine located in Baja California, Mexico. The nearly horizontal mineralized zones are amenable to exploitation by conventional mechanized coal mining technology using continuous miners, shuttle cars, and belt haulage. The mine design resembles a typical full-extraction coal mining operation utilizing a sequence of mains, sub-mains and production panels. Due to numerous faults, mining will be conducted as several small adjacent mines accessed through adits from large arroyos cutting through the mine area. Up to four seams may be mined in some areas with a maximum overburden depth of about 250 m. The ore zone is relatively weak and plastic, subject to extensive creep over time. The mine workings will pass through areas of historical shortwall mining panels where the ground has flowed into old entries and gob areas, and then reconsolidated. A small test mine was developed to evaluate mechanical cutting performance, roof-bolt anchorage capacities, roof and pillar stability and caving behavior. In-mine measurements were combined with two- and three-dimensional FLAC models to evaluate alternative development and production pillar designs. The paper will discuss the various factors influencing ground stability at the El Boleo project and the strategies employed in developing a suitable ground control design.

Jan 1, 2009

Silver is one of the three major metals produced from the Broken Hill mines. The accurate determination of the silver in these ores, therefore, is of economic importance.With due appreciation of the divergence of opinion of many who are interested in the subject of the determination of silver, the writer has been prompted to present the results of some recent experiments on silver losses during cupellation and conclusions from these experiments in the present paper. The losses of silver in the fire assay for this metal are due to silver retained in the slag during the fusion or scorification of the ore, and to silver volatilized from, and absorbed by the cupel during the process of cupellation.The literature describing the results of experimental work on silver losses due to the above causes is extensive, and the general conclusion of these experiments is that the silver lost in the slag is small, but that lost by cupellation is larger and more variable.The term cupellation loss in this paper refers to the total cupellation loss, no distinction being made between the absorption and volatilization losses.Volatilization loss is shown by King to be 0.5% of the total cupellation loss and, as it is generally accepted among assayers as being only a small fraction of the cupellation loss (3) (5), it will not receive further consideration in this paper.The factors causing the loss of silver by cupellation and the precautions to be obs~rved to reduce the loss in this operation are described in (1), (2), (3), (4) and (5). The...

Jan 1, 1940

By J. Wagner, P. Eger

Although lifetime estimates for sulfate reduction based on total substrate carbon typically range from 20 to 30 years, field and laboratory experiments showed that rates of sulfate reduction decreased over time as readily available organic material was consumed. When the rate of acid input exceeded the rate of sulfate reduction, alkalinity was removed from the substrate, pH decreased and metals increased. Output pH increased from 4 to over 6 after the system was shut down for several weeks and the rate of acid input was reduced. Successful long term treatment requires a design based on the input pH and the long-term organic decomposition rate.

Jan 1, 2001

Exploration work at the southern flank of the Mt. Coffin diapir has encountered three different types of copper ores: copper carbonate, largely malachite; secondary sulphides, mainly chalcocite replacing pyrite; and a primary arsenopyrite-tennantite-tetrahedrite-chalcopyrite association. The secondary copper ore is occasionally stratiform but mainly erratic at the contact between tillites and siltstones of the Tapley Hill formation.There have been two stages of primary mineralization.1. Arsenopyrite, tennantite, and tetrahedrite occur in siderite veins.2. Revival of the diapirism has caused fracturing and local brecciation of the rimrock and subsequently ascending solutions precipitated chalcopyrite. The chalcopyrite also partly replaced arsenopyrite, tennantite, and tetrahedrite.

Jan 1, 1972