Search Documents

By C. Landolt

Inco's Copper Cliff Smelter Complex produces some 11 5,000 tonnes per year of nickel and 120,000 tonnes per year of copper. The Smelter flowsheet has changed a number of times over the years. The most recent changes were effected in the mid-1980's in response to new realities in metal markets and heightened awareness about the workplace environment. By 1994, the flowsheet will undergo yet another metamorphosis as part of Inco's SO2 Abatement Program. The paper discusses the improvements implemented during the 1980's and projects the processing in the Smelter through 1994.

Jan 1, 1993

On the preceding pages, operations of the four major producers of nickel today have been described. There are, however, other operations in the world that, while not as large, are still of importance to the over-all picture of the industry. Among these are the Finnish producer, Outokumpu Oy, a state-controlled company that operates the Kotlahti mine 200 miles northeast of Helsinki. The ore from this operation, which began production in 1959, is pentlandite, chalcopyrite and pyrrhotite, occurring as disseminations in the host rock and in breccias. The flowsheet of the 1500-tpd mill at Kotlahti follows standard practices of crushing, grinding, and flotation to produce a pentlandite-pyrrhotite concentrate and a copper concentrate, both of which are shipped to the smelter at Harjavalta.

Jan 10, 1968

IN THE past, we have, perhaps, been somewhat careless in our furnace practice, in the use of high-grade material, lowering the production costs through demanding high-grade ores, increasing the size of units, and eliminating heat losses by collecting and returning unused heat to our furnaces. Further economies would seem to be possible through keeping out of the furnace those materials that appear to serve no useful purpose and carry with them heat that should be used in reduction operations. In the manufacture of pig iron, about three tons of inert nitrogen pass through the furnace for each ton of iron produced. This nitrogen serves no useful purpose in the chemical actions involved, but when discharged into the atmosphere it carries away a considerable quantity of heat. Can not this loss be eliminated, at least in part, through the use of more oxygen in the blast? Many metallurgical chemists, during the past 20 years, have stated that they thought it can and have urged that the plan be tried. Others have expressed doubt, not being able to visualize how more oxygen could be used in present practice; they have regarded it as impracticable, without trying to conceive of an entirely new practice based on a new reagent. That more experimental work has not been done is due to the fact that no cheap oxygen has been available, but the committee believes that there is strong reason to expect that, should a demand exist, 99 per cent. oxygen may be made at a cost not to exceed $3 per ton. The theoretical studies of the committee have indicated such marked economy by using oxygenated air in various operations that its members strongly recommend experimental work to verify the anticipated economies. The committee has developed plans for experimentally determining the effects of oxygen-enriched air on the operation of an iron, blast furnace. A furnace with a height of 30 ft. has been built and it is recommended that the plans be put in, effect as the first step in the research.

Jan 11, 1924

By Musa Karakus

Ceramic build-ups are synthetic mineral deposits formed in critical locations in or near the throats of inductor units in channel induction furnaces, the preferred melting and holding furnaces used in iron foundries. The build-ups are undesirable because they slow down melt circulation, increase power consumption and cost. and decrease the quality of the metal. This study involved the determination of the mineralogy of build-up samples and the quantitative measurement of phase abundance in those build-ups by cathodoluminescence microscopy. These undesirable deposits usually are hard and dense and contain variable amounts of entrained metallic iron. The non-metallic phases dominantly consist of oxides and silicates of several refractory elements, AI, Mg. Ca, Si, and Fe. Minor amounts of the sulfides of Ca. Mg, Fe and REE elements, especially Ce and La. and the oxides and silicates of Ce and La elements are locally present in the build-ups. The build-up samples were found to be ideally suited for study by cathodoluminescence, which has provided an easy means for rapid re-cognition of the phases present in the build-ups. The phase compositions were determined by electron microprobe analysis. The phases identified and their characteristic cathodoluminescence shown in the ceramic build-up samples were: spinel (bright green, blue-green, and red). forsterite (red and purple), periclase (dark reddish-brown, blue. and orange), corundum (red, blue, orange, and white), anorthite (yellow, yellow-green, blue, and blue-purple), hibonite or calcium hexaluminate (dark green), mullite (dull red-brown), gehlenite (deep blue), silica(dark brown, pink, purple, red. and blue), monticellite (light violet blue and light pale yellow-orange), silicon carbide (orange), oldhamite (bright yellow and orange). Ce-La silicate phases (purple), and glass (orange, dull red, and purple). Non-luminescent phases were: hercynite, Fe-oxides, Ce-La-oxides, Fe-sulfides, and metallic iron.

Jan 1, 1989

By Alan R. Buehler

The Bureau of Mines conducted a mineral investigation of the 10,500-hectare Cache Peak study area in 1992; the area had been proposed as wilderness. Bureau personnel examined and sampled prospect workings; 14 rock and 20 placer samples were taken during the investigation. The study area is centered about 40 km south-southeast of Burley. Idaho, in the Sawtooth National Forest. There were seven mining claims located inside the study area, and one additional historical mining claim location. Gold, silver, copper, lead, zinc: Possible resource, poor exposure precludes estimate. Marble: Several million tonnes may be suitable for a variety of uses; markets too distant to favor mining. Sand and Gravel: Several million m3, but markets and transportation costs do not favor mining. Quartzite: Several million tonnes may be suitable for metallurgical purposes; however, markets are too limited to mine. Slabs have been quarried at three localities adjacent to the study area, for decorative stone. Production: In 1979, two tonnes of ore were produced and a plan of operations was submitted calling for approximately 5 km of access road for the Last Chance mine. Decorative stone production was not recorded.

Jan 1, 1993

In 2011, the value of mineral production increased in the United States for the second consecutive year (Table 1). Production increased modestly for most mineral commodities mined in the United States, and price increases, especially for precious metals, resulted in increases in the value of production. Minerals remained fundamental to the U.S. economy, contributing to the real gross domestic product (GDP) at several levels, including mining, processing and manufacturing finished products. Minerals? contribution to the GDP increased for the second consecutive year. Trends in other sectors of the domestic economy were similar to those in mineral production and consumption rates. U.S. apparent mineral consumption (industrial) of 11 mineral commodities decreased substantially from 2005 to 2010 (aluminum, cadmium, cement, copper, iron, lead, salt, soda ash, steel, tin and zinc). Data for 2011 were not calculated, but the data show a sustained decrease (especially for the metals) preceding the recession through 2010, so consumption seems to be behaving differently than production and GDP. After continued decline following the 2008?2009 recession, the construction industry began to show signs of improvement during 2011, with increased production and consumption of cement, construction sand and gravel, and gypsum ? mineral commodities that are used almost exclusively in construction. Crushed stone production, however, continued to decline.

Jan 1, 2012

By R. Luchese de Moraes, J. A. Matthews, C. Feliciano Bruzual

The role of biomass char in blast furnaces has been re-examined by scientists worldwide, as a feasible option to reduce the carbon intensity of ironmaking. This contribution makes a technical and economic analysis of the ferro gusa industry in Brazil, with the last 172 charcoal-Blast Furnaces operating in the world. A key strategic question is presented: what is the current status and future prospects of biomass use in Blast Furnaces? Findings provide significant implications to metallurgists: while ferro gusa from charcoal is regarded as carbon neutral iron with low impurities, there are limiting factors that hinder the further proliferation of charcoal-BFs: biomass generation requires vast extensions of arable land and aggregates have low production capacity. Additionally, most of the charcoal is presently generated in beehive kilns with low yields. These elements combined make charcoal-hot metal expensive in price. With respect to the future prospects of biomass, the injection of small biochar particles through the PCI rigs in BFs (here coined Bio-PCI) and iron ore sintering may offer a practical alternative to significantly reduce the CO2 emissions in the ironmaking process.

Jan 1, 2015

By N Murthy

Alumina is a major impurity in Australian iron ores and as the higher grade ores become depleted there will be a stronger focus on treating lower grade haematite/goethite ores and developing suitable beneficiation techniques to reduce the alumina content. High alumina in iron ore is deleterious in that it can:• produce slags with lower desulfurising capacity,• reduce sinter/pellet strength and quality, and• produce higher slag volume and increase slag viscosity.Meeting iron ore quality specifications for alumina by blending ore from different sources will eventually be insufficient. Hence, innovative flow sheets based on new and commercially available technologies will be required. Their advantages and disadvantages, the testing methodologies and the challenges and diffi culties involved in reducing the alumina content of iron ores are presented and discussed.

Jul 11, 2011

By S Döpp

Commencing with early experiences in iron ore beneficiation made at Beeshoek Mine, the paper follows through the process of extensive mineralogical and metallurgical investigations carried out during feasibility study. The paper will discuss the design process and logic followed over the last years, the challenges and decisions the design team faced in order to draw the conclusions that ultimately resulted in today’s value add approach at Assmang’s Khumani Operations.As integral part of the benefi ciation concept, a focus is set on the jigs, explaining the plant concepts, planned expansions and their contribution to the overall value add approach at the mine.The case study is intended to describe the outcomes of the design versus the actual achieved and the further value add projects to be implemented. As for future prospect, the incorporation of Wet High Intensity Magnetic Separation (WHIMS) demonstrates Assmang Khumani’s pursuit to maximise productivity and overall recovery.DMS was evaluated as an alternative to jigging within a comparative test work study, but in conclusion the option had to be excluded due to its inability to achieve the high density cut point required to achieve the sales specifi cations. In contrast, the investigation on producing an additional middlings fraction on the lumpy ore jigs prove to be an adequate option for further improvements of overall mass yield. With further liberation, a saleable product will be achieved by secondary beneficiation on Fines Jigs and WHIMS.Concluding, jigs are considered the most viable and cost effective benefi ciation process for off-grade ore +0.8 - 32 mm at Beeshoek as well as at Khumani, while WHIMS is the process under consideration for super fines recovery.

Jul 11, 2011

By Paul Hatmaker

This paper covers briefly the particular field of dolomite and magnesium limestone; certain uses of high-calcium limestone are mentioned only to show more clearly the limita¬ tions of the magnesian rocks. Such a comparison is helpful because magnesium carbonate is essential for some uses; for others it is immaterial; and for many its presence in an appreciable amount is objectionable. Magnesium carbonate, occurring as a rock resembling limestone or dolomite, is described in United States Bureau of Mines Information Circular 6437, Magnesite. Other com¬ pounds of magnesium are described in United States Bureau of Mines Information Circular 6406, Magnesium Compounds (Other Than Magnesite). Limestone, geologically, is a rock composed essentially of calcium carbonate; commercially, however, the term may include dolomite and magnesium limestone.

Sep 1, 1931

By S. W. Marcuson

Smelting of nickel-copper sulfide ores at Vale Inco’s Sudbury operations commenced in 1888 and the first converting plant went into operation in 1892. As the demand for nickel grew, the smelting operations expanded and by the 1960’s the Copper Cliff Smelter featured the longest converter aisle in the world with space for nineteen Peirce-Smith converters. During this long period, different converting techniques and vessels were employed. The evolution of converting is reviewed with special emphasis on the modifications made to the Peirce-Smith vessel to accommodate the metallurgical and process needs of the changing times.

Jan 1, 2009

By E. C. Harder

BRITISH Guiana, Great Britain's only South American colony, may be reached by very comfortable steamers, both from North America and Europe. The trip from North American Atlantic ports requires about 12 to 14 days; that from Europe about 18 to 20 days. A number of steamship lines, including Canadian, American, and Dutch, have regular sailings between North America and British Guiana, with calls en route at various interesting ports in the West Indies and northern South America. Moreover, several lines, including British, German, and French, have steamships operating regularly between Europe and the West Indies. Indeed, so popular have the West Indian voyages become in recent years that, during the winter months, special cruises in considerable number are organized for many vessels that ply in the trans-Atlantic service in the summer. A trip to British Guiana, therefore, has become a delightful experience. After visits at the various attractive Leeward and Windward islands and Trinidad, the approach to the low, flat, British Guiana coast, with its muddy coastal waters extending for many miles offshore, is somewhat of a contrast. Arrival in Guiana waters is signalled by the appearance of the modern high-power Demerara Light, located "on a shoal about twelve miles from the mouth of Demerara river. From this point, if the tide is right, a pilot takes the steamer across the bar, eight to ten miles offshore, and into Georgetown harbour. At high tide, the water above the bar ranges from 15 to 18 feet in depth, depending on whether it is neap tide or spring tide; at low tide, the corresponding depths are 9 to 11 feet. As the bar is of soft mud, however, it is usually possible for vessels to pass over it with a draught of about two feet in excess of that indicated by the tide tables. Upon nearing the shore, one sees first the Georgetown wireless towers, then the light-house and the tall chimneys of sugar mills and of various factories in Georgetown, and finally the palms and other tropical trees and the houses of Georgetown itself along the sea shore and the east bank of Demerara river. Extensive wharves operated by various exporting and importing companies stretch along the river bank and activity prevails in Georgetown harbour. The principal exports are sugar, rice, gold, diamonds, bauxite, balata, lumber, fruit and other tropical products. The imports are food-stuffs, wearing apparel, and manufactured materials of many kinds.

Jan 1, 1936

By M. F. Goudge

Introduction It is only fitting on this occasion of the fiftieth anniversary of the incorporation of the Institute that we should indulge in a bit of retrospection and review the progress that has been made within this period in the various branches of the mining industry- progress that is so closely associated with the members of this Institute. Such a moment of retrospection will enable us better to appreciate the present status of the industry and to perceive more clearly the trends that should guide us in making sound plans for the future. The past half century has been a period of amazing industrial progress in Canada. In this period, the economy of our country has changed from one based chiefly on agriculture and the export of raw materials, to an economy based largely on a well integrated manufacturing industry. In all' o( these major developments, industrial minerals have played an important part and will play an increasingly, important part in the future. By ?industrial minerals? we mean the various non-metallic minerals (exclusive of fuels) as well as the rocks, sands, and clays used for industrial purposes. They are now used so widely and in such large quantities that modern industry could not function without them, and their continued availability at low cost is vital to the industrial future of Canada. The key position occupied by industrial minerals in modern Canadian industry was well illustrated two years ago when a strike occurred in the only Canadian plant producing soda-ash and calcium chloride at a time when those materials were already in short supply and unavailable from other sources. Within a short time of the shutdown of this plant, in which the two principal raw materials are limestone and salt, the great aluminium reduction plants on the Saguenay river were forced to curtail operations because of the lack of soda-ash, essential to the process of extracting aluminium from its ore. Automobile production, already harassed by a shortage of steel, was further hampered when glass for windshields and windows could not be supplied because the glass industry was slowed down almost to a standstill for want of soda-ash. Soap became almost unobtainable both to the housewife and to industrial users, because soda-ash is required in its manufacture. As a consequence of the soap shortage, the production o synthetic rubber at Sarnia was threatened because soap in large quantities is essential to the polymerization process. Motorists on gravelled highways all over Eastern Canada drove through clouds of dust because calcium chloride, used for dust laying, was not to be had. There were other cases of dislocation of industry related to the shutdown of this particular plant, but the above illustrates the wide ramifications of industrial minerals in modern industry. However, it is extremely doubtful if many Canadian citizens realized that these apparently unrelated happenings were connected in any way with limestone and salt.

Jan 1, 1948

By R. B. Ellestad

Introduction Lithium has been known since 1817, when it was discovered by the Swedish chemist, Arfvedson, while working in the laboratory of Berzelius on the chemical analysis of the mineral petalite, LiAl(Si205)2. Development of the chemistry of lithium proceeded slowly, following the early work of Davy, Gmelin, Bunsen, and Matthiessen. Approximately seventy years elapsed before lithium products assumed any commercial importance, and for a considerable period it was a' very minor industry. Their chief early use seems to have been in medicine, and in the production of lithiated water. Other more important uses were gradually discovered, and the industry has had a slow but steady growth. Chemistry Lithium is classified as an alkali metal, along with sodium, potassium, rubidium, and cæsium. Like these, it is a silvery-white metal, which can be cut with a knife; it is harder than sodium, but softer than lead" It is remarkable in having a density of only 0.53 gram per cubic centimeter, which makes it the lightest metal. On ignition in air, it burns intensely to form chiefly lithium monoxide, Li2O. Like the other alkali metals, lithium reacts vigorously with water to form hydrogen and lithium hydroxide. The later is a strong base, and reacts with acids to form salts. The salts of lithium are in general analogous to those of the -other alkalies, but many of them have unique properties. For example, lithium chloride and bromide are extremely hygroscopic, and have a very high water solubility. Lithium fluoride, phosphate, and carbonate, on the other hand, are all relatively insoluble, unlike the corresponding sodium and potassium compounds. In this instance, lithium exhibits its frequent tendency to resemble the alkaline-earth group of elements (calcium, strontium, and barium). Many of the special and valuable properties of lithium are related to the extremely small size of the lithium ion.

Jan 1, 1948

By M. Palfreyman

"Most of the minerals employed in Canadian refractory production are imported; in fact, most of the refractories consumed in Canada are imported. Whereas this situation is partly due to a definite shortage of suitable raw materials, e.g., fire clays, it is possible that the potential of certain mineral deposits which could be usefully exploited has not been recognized. There are exceptions, notably magnesite and dolomite, from which refractories are produced in Canada.In many cases, known mineral deposits are located either in inaccessible areas or in areas where transportation would be a major economic factor. This paper lists some minerals and their respective known deposits which could be employed in the production of refractories, irrespective of economics."

Jan 1, 1973

By H. C. L. Reemeyer

"The mining industry faces increasing economic, environmental and social challenges, as easier deposits deplete and ores become more difficult to mine and process; head grades decline; projects migrate to increasingly remote and difficult geographies; and the industry faces more stringent environmental and social standards. While these factors increase costs and risks, they also present opportunities for a more integrated approach to mining, processing, materials handling and waste management. Two key areas of risk are in tailings and water management. As mining and processing tonnage rates continue to increase, the disturbance footprints, water and energy consumption and scale of tailings storage facilities also rise. These factors can be mitigated by more selective mining, ore sorting and pre-concentration, and more intensive tailings dewatering. Such alternatives must be considered in conjunction with the selection of mining method, metallurgical flowsheets, major equipment selection, and key process design criteria. For example, increasing the grind size of a concentrator reduces energy consumption and eases tailings dewatering, but may cause challenges with metal recovery. Emerging technologies will be reviewed, and economic and environmental trade-offs for eco-efficient alternatives will be presented for metal sulfide mines.INTRODUCTION The metals mining industry faces significant challenges that can affect its financial viability and social license to operate. There has been a consistent decline in ore grades and a relentless push towards larger operations to capture perceived economies of scale. With these larger operations, the environmental footprint of mines has increased. Water and energy consumption, and resulting GHG emissions have also risen. In recent years, two issues have raised special concerns for stakeholders and companies: • Water scarcity, particularly in drier regions of the world such as Northern Chile, SW USA, Southern Africa and Australia • Tailings risks, following the high-profile failures of the Fundao tailings dam in Minas Gerais, Brazil in 2015 and the Mount Polley tailings dam in BC, Canada in 2014"

Jan 1, 2017

By Kefton H. Teague

This paper deals with the practical application of the Dutch State Mines cyclone separator for fine-coal cleaning. The more important operating variables are discussed, and results of a number of continuous-scale tests on various fine coals with a 6-in. cyclone separator are given. Descriptions of the Cyanamid Pilot Plant and the 50 tph Cyclone Separator Plant at the Emma Washery in Holland are included.

Jan 1, 1950

By Henry D. Hibbard

I. INTRODUCTION. THESE impurities are perhaps the most important things in steel-especially steel made by the oxidation processes-the effect of which has not been at least approximately determined. By oxidation processes I mean the Bessemer and Siemens-Martin, during which the metalloids in the charge are removed by oxidation. It has been truly said that it is a clear advantage to have a new name for a new thing. To secure this and to economize space, let us adopt the name sonim (plural sonims) to designate the solid non-metallic impurities existing in steel or other metal. I would define a sonim as a solid non-metallic portion of matter existing as an impurity in metal. A piece of sand, brick, clay, or such material, imbedded in metal, would be considered as a foreign body, not as an impurity, and therefore not a sonim. The studies of sonims of which the results have been published hitherto, have been made chiefly or wholly on finished or at least on cold steel, without much, if any, regard to the specific methods by which the steel was made. While many of the results so obtained are valuable, they give little help in determining the cause, effect, or cure of the disease. It is not enough, in such a study, to know merely the commercial name of the process; for within the field of each process lies a great number of possible variations, each of which will yield a result differing in some respect from all others; and the control of sonims is particularly dependent. on the metallurgical treatment of the metal, because of the inability of analytical chemistry to throw much light on their presence, condition, and effect, as they usually occur in commercial steels. The microscope aids more, perhaps, than chemistry in their study.

Apr 1, 1911

By H. El-Faramawy, A. Ahmed, M. Eissa, M. El-Fawakhry, T. Mattar, S. N. Ghali, E. M. Kotb

As a result of the depletion of high-grade manganese reserves, it has become necessary to consider the exploitation of low-grade manganese ores. The main problem of low-grade manganese ore is the low Mn/Fe ratio, which makes it unfit for the production of manganese ferroalloys. In this work, a selective reduction technique was used for smelting low-manganese ore in the presence of coke and fluxing material in an electric submerged arc furnace to obtain a rich manganese slag and low-manganese pig iron. The product slag was blended with medium-manganese ore and smelted in an electric submerged arc furnace, in the presence of coke and the fluxing agent, to produce silicomanganese alloy. The influence of reducing agent ratio, charge basicity, and charge Mn/Si ratio on the smelting process was investigated. The optimum conditions were found to be a coke ratio of, 1.35, Mn/Si ratio of 2.0, and charge basicity of 2.5. The silicomanganese alloy produced under these conditions satisfies the specifications for Si16Mn63 and Si17Mn65. The experimental results were applied on a pilot scale, producing a silicomanganese alloy with a chemical composition close to that of the standard specifications.

Jan 2, 2022

By J. R. Donald, K. Scholey

"Nickel has been mined and processed from the Sudbury basin for over 100 years. During this period, the process has evolved into what is one of the largest and most complex mining and metallurgical facilities in the world. This paper will describe the geology and mining of the Sudbury basin as well as the Copper Cliff metallurgical flowsheet circa 2005, including:•,Clarabelle Mill,•,The flash smelting furnaces,•,The bulk converters,•,Matte casting, separation, and processing•,The carbonyl refineries•,Carbonyl residue processing•,Copper processing•,Sulphur productsThe challenges of today and the opportunities for the future are discussed."

Jan 1, 2005