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By David Berberick

"Hecla Limited’s No. 4 Shaft at the Lucky Friday Mine is the largest capital expenditure in the corporation’s 128-year history and is considered the deepest shaft in the United States. This paper will discuss the project’s history and lessons learned from the initial conceptual design work in 2007 through project commissioning in 2017. Change management was key for the owner, contractors, and vendors in delivering the operational and organizational success on the project. The No. 4 Shaft has extended the life of the Lucky Friday Mine by 21 years to 2039. INTRODUCTION The Lucky Friday Mine of Hecla Mining Company (Figure 1) is the oldest active (77 years) and deepest mine in the Coeur d’Alene mining district, producing approximately 725 tonnes (800 tons) per day from narrow, vertical, silver, lead, and zinc veins. Primary access into the mine is via the Silver Shaft, a 5.5-m (18-ft) diameter, concrete lined shaft sunk to an original depth of 1,890-m (6,200-ft). Current production is from the Gold Hunter vein system, approximately 1,525-m (5,000-ft) northwest of the Silver Shaft.Cut and fill stoping is currently employed at depths to 2.3 km (7,500 ft) below ground surface, making it one of the deepest mines in the western hemisphere. No. 4 Shaft is a 5.5-metre (18-foot) diameter, concrete lined circular shaft, constructed as a 1.2 km (3,860 feet) deep winze in the Lucky Friday Mine. The 2.4 m (8 ft.) diameter, double drum, double clutch, Siemag hoist and associated headworks are situated at the 4760 level, top station at 4940 and shaft stations at 5900, 6500, 6580, 7500, 7580, 8300, 8380, 8500, and 8620. Shaft stations reference depth below Silver Shaft top station. The 4 Shaft was designed, constructed and commissioned over ten years, between 2007 and 2017. Basic design work was completed by Nordmin Engineering, followed by detailed design completed by Cementation Canada. Shaft construction was awarded to Cementation USA and lateral development was initiated in early 2008. Over the course of the next nine years, the project was suspended and restarted twice, dealt with the loss of a miner, added scope including shaft depth and mine infrastructure facilities, experienced squeezing ground that required liner replacement, changed excavation section, and dealt with a final alignment that was not within design requirement for verticality. Hecla and Cementation were successful in delivering a facility that provides fully functional access from collar at 4940 level to shaft bottom at the 8620 level. Two active mining levels below the collar, 5900 and 6500 are accessed. In addition, the shaft provides access to the future mining level at 7500, skip loading facility at 7580 level, station and loading pocket cutouts at 8300 and 8380 levels, spill pocket at 8500 level, and shaft bottom pumping facility at 8620 level (Figure 2)."

Jan 1, 2019

By Yuki Soma, Tsutomu Ogawa, Jae Hyung Hong, Toshihiro Nagato

The Saganoseki flash furnace was built in 1973. The steel frames of the flash furnace were designed to absorb the expansion of refractories and contain expansion-absorbing materials between their frames and the skin plate. Expansion and deformation resulted in the furnace settler because of the repeated increase and decrease in temperature from more than 30 maintenance shutdowns. Preliminary investigations were conducted to confirm the condition of the settler, and it was found that partial cracks accompanied the expansion in the lower layer of the refractories. As a result, the risk of molten-matte leakage increased. Based on the above investigation, it was decided that the entire settler should be replaced by introducing a spring-displacement structure that was capable of maintaining the furnace integrity over an extended period. The difficult redesign and rebuilding of the Saganoseki flash furnace was accomplished successfully and safely in 76 days from September to December 2017, as planned. Because of various redesigns, the furnace was changed to a flash-smelting furnace that can withstand higher thermal loads based on recent trends of copper concentrate with increased sulfur and reduced copper. The new furnace is operating smoothly at present. INTRODUCTION The flash-smelting furnace of Pan Pacific Copper Co., Ltd. Saganoseki Smelting & Refinary commenced operation in 1973, with an original designed feeding rate of 71 t/h. As a result of facility remodeling and operational improvements, shown in Figure 1, the feeding rate was increased to 215 t/h in recent years. After more than 40 years of operation, the original settler in the melt holding section of the flash furnace underwent significant expansion and deformation.

Jan 1, 2019

By G. N. A. Senhorinho, J. A. Scott, C. A. Laamanen

"Closed mine sites are widely regarded as a negative asset due to their legacy of environmental impacts. These sites are often characterized by waterbodies with elevated metal concentrations and low pH that are traditionally considered to have little or no value. These sites are potential sources of beneficial biocompounds produced by microalgae in response to environmental stresses. A bio¬prospecting program found that certain microalgae from waterbodies near historical mine sites exhibited higher antibacterial activity than any microalgae previously reported in the literature. There is potential for the mining industry to be involved in examining features such as tailings ponds at mine sites for high-value compounds, including ones that might help mitigate rapidly growing microbial resistance to current antibiotics. ¦ KEYWORDS Antibacterial, Closed mining sites, Metabolites, Microalgae, Stressed environments RÉSUMÉ Les sites miniers clôturés sont généralement considérés comme des actifs négatifs en raison de leurs répercussions sur l’environnement. On trouve souvent sur ces sites des étendues d’eau affichant de fortes concentrations en métaux et un pH faible, généralement considérées comme ayant peu, voire pas de valeur. Ces sites sont des sources potentielles de biocomposants bénéfiques produits par des microalgues en réponse aux perturbations environnementales. Un programme de bioprospection a permis de déterminer que certaines microalgues trouvées dans ces étendues d’eau à proximité de sites miniers historiques présentaient une activité antibactérienne supérieure à celle mentionnée dans toute la docu¬mentation existante. L’industrie minière pourrait bien participer à l’examen de particularités telles que la recherche de composants à haute valeur dans des bassins de décantation des résidus sur des sites miniers, notamment des composants qui pourraient aider à atténuer l’augmentation rapide de la résistance micro¬bienne aux antibiotiques actuels. ¦ MOTS CLÉS antibactérien, environnements perturbés, métabolites, microalgues, sites miniers clôturésINTRODUCTION The mining industry is one of the largest economic drivers in the world. Within Canada, for example, it contributed 2.8% (C$57.6 billion) of the 2016 gross domestic product (Marshall, 2016). Canada also has the highest non-ferrous exploration budget worldwide (Marshall, 2016); therefore, it is likely that mining operations, mine waste disposal, and the number of closed sites will continue to grow in Canada. The environmental impact of mining operations stems from the volume of tailings produced, which can be up to 97–99% of the total volume of ore processed at a mine (Adiansyah, Rosano, Vink, & Keir, 2015). In 2010, mining was the world’s largest industrial producer of waste at a total of 65 billion tonnes: 51 billion tonnes of waste rock (mine overburden) and 14 billion tonnes of tail¬ings (Jones & Boger, 2012)."

Jan 1, 2019

By B. Kruger

The Dundee Precious Metals Tsumeb Smelter has evolved over the last decade to meet the challenges and opportunities brought about by a changing copper concentrate market, technological advances, environmental legislation as well as social and political changes. The paper discusses some of the challenges, successes and lessons learnt through the expansion and modernization of its smelter complex. It considers the details and impact of the transition from slag granulation to that of slag slow cooling as well as the improvement program that was implemented to more than double the refractory campaign life of the Ausmelt furnace from around 6–9 months to 15–18 months. In addition, given the evolving world we live in, it considers the challenges that the smelter faces today, not the least of it being how to remain relevant in an age of digital and other 4th Industrial Revolution disruptions. INTRODUCTION Dundee Precious Metals Tsumeb (DPMT) Smelter is located just outside the town of Tsumeb, in the Oshikoto region of Namibia. It is the largest town in the region with a population of approximately 45,000. The smelter was built in the early 1960s to treat concentrate from the nearby Tsumeb copper mines. Construction of the site was completed in 1962 and the smelter was officially commissioned in 1963 by Tsumeb Corporation Limited (TCL). At the time the smelter consisted of a lead section (including a refinery), a copper section and plants that produced cadmium, sodium antimonite and arsenic trioxide. Production commenced in early 1964, with 3,500 tonnes of copper and 6,000 tonnes of lead being produced per month. TCL was acquired by Gold Fields South Africa in 1988, and a few years later the lead section was shut down due to reduced lead content of the mined ore. In mid-1996, all mining and smelting operations were halted due to labour strikes. Ongopolo Mining and Processing Limited (OMPL) re-opened the mines and the smelter in 2000, only operating the copper section of the smelter. At the end of 2008, all mining operations were halted by the new owner of OMPL, Weatherly Mining International, while the smelter continued to operate. The closure of the Weatherly owned mines in Namibia, the primary feed source to the Tsumeb Smelter, meant that the smelter had to transition its business model from operating as a ‘captive smelter’ to that of a ‘toll smelter’. Its Ausmelt Top Submerged Lance (TSL) smelting technology and various ancillary plants made it especially suitable for accepting and treating complex concentrates that were available on the global market.

Jan 1, 2019

By C. Pichler, S. Luidold, C. Wagner, C. Sagadin, D. Kreuzer

Engineers and scientists have been combating the attack upon refractory materials of molten metals/matte and slags for hundreds of years. The details in many cases are still questionable or at least debatable. The corrosion is a major concern for furnace operators as refractory wear or failures inevitably results in reduced production efficiency and furnace reliability. Also the cost to industry is considerable and only a thorough understanding of all the complexities of the process will help to minimize that cost. One of the critical questions to overcome is the correct selection of refractories for the individual process steps to provide long and predictable refractory life together with high furnace availability. To understand the nature of the reactions involved in refractory corrosion, it is crucial to determine the complex thermo- chemical equilibria of the reactions occurring between the refractory materials and the process phases. A simulation model coupled with commercial software like FactSageTM is demonstrated aiming to understand the corrosion mechanisms between refractories and the molten process phases and draw implications for improving the performance of refractories and refractory lifetime. INTRODUCTION The extraction or recycling of valuable materials, e.g. metals, can be done by two main routes, pyro- and/or hydrometallurgical processing, depending on the chemical behavior of the used ore, scrap or pre-treated concentrate. Sometimes it is also necessary to use both process routes for the extraction or the recycling of valuable materials. In the case of a pyrometallurgical treatment, the usage of refractory materials is inevitable. This is mainly caused by high temperatures, prevailing during processing. The interaction between refractory material and slag, metal or matte leads to different reactions and interactions. As a main result corrosion of the furnace lining (refractory material) takes place. Hence, recurring furnace shutdowns occur for renewing the refractories. This leads to reduced production efficiency. Such refractory lifetimes are between some hours and decades, depending on the processes.

Jan 1, 2019

By R. E. Ray

"As real estate for new development in urban settings becomes scarce, commercial high rises are being constructed above open passenger rail tracks and vehicular roadways. Rail and roadway overbuilds are treated as tunnels requiring emergency ventilation systems for train or automobile and truck fires. The value of floor space in residential and office towers poses challenges to engineers responsible for designing fan rooms and shafts for tunnel ventilation systems within the towers. This paper describes a case study of the unique incorporation of tunnel ventilation fan plants in the overbuild structure of a passenger railyard and an adjacent roadway.INTRODUCTIONTunnel ventilation systems are required for passenger rail and transit (subway) tunnels by the NFPA 130 Standard for Fixed Guideway Transit and Passenger Rail Systems, and the NFPA 502 Standard for Road Tunnels, Bridges, and Other Limited Access Highways requires tunnel ventilation systems for vehicular (road) tunnels. Passenger rail and transit (subway) tunnels are typically ventilated with a series of shafts placed longitudinally along the tunnels to provide piston relief for normal train operations and emergency ventilation of train fires utilizing reversible axial flow fans. The shafts are incorporated in dedicated ventilation buildings that house the tunnel ventilation fans and starters, switchgear to power the fans and other equipment and systems in the building, Programmable Logic Controllers (PLCs) to control fan operation with Supervisory Control and Data Acquisition (SCADA) software, and HVAC fans and ductwork to ventilate the spaces in the building. These ventilation buildings may also provide access to the tunnels below with ingress/egress stairs for use by first responders and firefighters entering the tunnels and train or transit system passengers exiting the tunnels in an emergency. A photograph of a passenger rail ventilation building that encompasses four tunnels is shown in Figure 1."

Jan 1, 2019

By K. M. Deen, E. Asselin

Hydrometallurgical processes, i.e., Cu extraction from a mineral concentrate and Zn electrowinning, are coupled in a battery-like system. A naturally-sourced CuFeS2 concentrate mixed with activated carbon is used as a positive slurry electrode separated by a membrane from the negative compartment. The Zn is deposited on the negative Al current collector from the circulating solution containing 100 g L–1 Zn2+ in 0.2 M H2SO4. In this battery-like system, both CuFeS2 oxidation and Zn deposition are possible during the charging cycle. The additional benefit of this setup is the energy storage if discharged by re-dissolving the Zn in the negative compartment. Cyclic charge/discharge testing revealed oxidation of the mineral concentrate supported by the Zn2+/Zn redox reaction. The coulombic and energy efficiencies increased monotonically to 95.6% and 43%, respectively, with approximately 7% Cu extraction during the first 10 charge/discharge cycles (completed in 2.4 hours). The discharge energy density also increased from 2.7 to 36.2 mWh L–1. In the following 90 cycles, the low energy (~14%) and coulombic (~33%) efficiencies that were obtained confirmed the progress of irreversible reactions e.g. Cu extraction from the mineral concentrate. Overall, approximately 16% Cu was extracted from the mineral concentrate over 100 charge/discharge cycles (or about 12.2 hours). INTRODUCTION Chalcopyrite (CuFeS2) is the main economic copper-bearing mineral, which is generally processed through pyro-metallurgical methods to produce Cu. However, environmental challenges with smelting, depletion of high-grade ores and a large number of impurities (some toxic) have resulted in continued research aimed at the development of hydrometallurgical technologies to process CuFeS2. There are a number of different proposed hydrometallurgical routes in the literature to treat CuFeS2 concentrates, but only a few have attained commercial acceptance (Dreisinger, 2006). Zn is another commercially important metal that is mainly produced via acid leaching of roasted sphalerite (ZnS). The pregnant leach solution is rigorously purified to remove all the soluble metal impurities, particularly those that are electrochemically more noble than Zn and present large kinetic activity towards H2 evolution (Hu & Piron, 1992; Mackinnon, Brannen, & Fenn, 1987; Mureşan, Maurin, Oniciu, & Gaga, 1996). Metal impurities such as Cu, Co, Ni, Cd, Pb, Sb, As, Ge and Fe etc., if they exist in the leach liquor beyond the tolerance limits, can decrease the current efficiency during electrowinning and deteriorate the deposit quality (Alfantazi & Dreisinger, 2001). A complete flow sheet, describing the process steps of Zn metal production from mine site to pure metal is presented elsewhere (Brown, Meisenhelder, & Yao, 1983).

Jan 1, 2019

By T. Lux, M. Hanel, Degel, A. Filzwieser, R., H. Joubert

It is the increasing demand for an economic and cost saving operation mode that requires effective cooling in order to achieve low refractory wear and good furnace lifetime, which is making cooling technology an important aspect of furnace operation. In addition, the requirements for safety are getting more and more into focus. However, the use of water—today’s standard cooling medium—has major drawbacks as it can cause problems both during furnace start up and operation, namely hydration problems, corrosion, and explosion. Not to forget the severe risks for the operators as well as economical damage in case of a malfunctioning water cooling system. With this new and patented cooling technology ILTEC and the ionic liquid IL-B2001 as the cooling medium, it is possible to realise a water-free cooling solution and therefore the door is wide open to rethink existing and conventional cooling solutions. Furthermore, there is also the chance to recover heat from the process in a more efficient way. However, since the technology is novel and unique there are a lot of concerns and doubts regarding safety for plant operators and employees. The paper is intended to cover both: highlighting the enormous potential of the technology but also to eliminate concerns mainly caused by rumour and unawareness. INTRODUCTION All of us are aware of the risks when water is used as a coolant and placed in the vicinity of the liquid metal phase. Unsuitable design solutions or wrong operation modes of the furnaces or failures of refractories can cause a direct contact of water with liquid metal. The consequences can lead to equipment failures, vessel destruction but even worse to injuries and even fatalities. Over the past decades, countless incidences were reported. Fatal accidents caused by water coming into contact with liquid metal happen every year (Oterdoom, 2014; Filzwieser, Konetschnik, Filzwieser, Wallnerm & Preiss, 2014). With the novel ionic liquid cooling technology virtually all negative effects of a water cooled system regarding safety are eliminated and even additional benefits can be provided (Voermann, Ham, Merry, Veenstra, & Hutchinson, 1999;Verscheure, Kyllo, Filzwieser, Blanpain & Wollants 2006; Wallner, Filzwieser & Kleicker 2006). The fact that no explosion occurs when IL-B2001 gets in contact with molten metal results in a revolutionary solution for the metallurgical industry in terms of safety—new safety standards can be achieved.

Jan 1, 2019

By S. Ross, M. Mayhew

"Kirkland Lake Gold introduced battery equipped vehicles (BEVs) at the Macassa Mine in 2011. The fleet of underground BEV haulage trucks and loaders has grown over the years to over 30 units, the world’s largest, currently handling approximately 80% of the daily production tonnage. The inflow and outflow of air occur through a limited number of relatively small openings, which limits the air volume delivered to the underground workings. In addition to improving air quality, the reduced heat load generated by the BEV (when compared to diesel equipment) had a significant positive impact in the workplace. The use of BEV for material handling has enabled increases in production that would not have been possible using diesel equipment.INTRODUCTIONMacassa mine was developed as a track-drift access mine, with the most recent shaft (#3) sunk in 1986. A new mining complex, the South Mine Complex (SMC) was discovered below the 5025 foot elevation south of traditional mining areas, and the majority of mining now occurs in the SMC. The discovery of that zone has led to an internal ramp which is used to access the SMC and haul ore to #3 shaft.The amount of airflow that can be moved through the mine is limited by the existing infrastructure to surface. This amount was recently increased to near its practical maximum from 118 CMS (250 kCFM) to 151 CMS (320 kCFM).Both diesel and electric equipment are used at Macassa. Tethered Load-Haul-Dump Machines (LHDs) have been replaced with Battery Electric LHDs, due to their increased mobility and depth of the mine. Battery trucks continue to replace locomotives to transport both ore and waste to the shaft, as mining has transitioned from tracked levels to trackless level and haulage has transitioned from horizontal levels to an inclined ramp.EQUIPMENT FLEET AT MACASSAMost of the primary material movers utilized at Macassa Mine are battery operated. As the mine goes deeper the battery technology will continue to be critical to the success of the operations. With over 300,000 hours of proven operation success, the battery technology and equipment will continue to be a major part of Macassa’s future."

Jan 1, 2019

By Laura Steeves, Inoka Eranda Perera, Jhon Silva, Arend Spaeth

"This paper reviews the main concepts ruling the design, implementation and performance of active explosion barrier systems for underground coal mines in the USA. The document examines the parameters needed for the design of this type of system, such as overpressure and flame speed, suppressant deployment speed and duration time of the active barrier. The document also discusses the available solutions for gassy mines and the concepts behind the selection of machined mounted and roadway active explosion barrier systems. The paper includes a review of active explosion barrier systems developed in the USA and South Africa. The paper provides an overview of the current status of this technology in the underground coal mining industry in the USA, and the possible implementation of such systems. The paper concludes with the identification of the future work needed for the successful implementation of the systems in several conditions to enhance the safety of underground coal mine operations and to provide more tools to the miners for their safety.INTRODUCTIONUnderground coal mine explosions can be addressed in two ways, through prevention or mitigation. The United States mining industry practices have emphasized the prevention of explosions in underground coal mines, with little being done to mitigate the explosion once it occurs. Despite successful practices for the prevention of underground coal mine explosions in the US, the threat of an explosion does still exist. Other mining countries around the world have developed and implemented mitigation systems such as active explosion barriers in their underground mines. In the 1970s, the United States Bureau of Mines (USBM) carried out extensive research on the use of active or triggered explosion barrier systems in the US; however, they are not currently used.Explosion barrier systems do not prevent explosions but mitigate the propagation of the shockwave and flame to other areas of the mine. The use of active explosion barrier systems enhance the safety of underground coal mines. Active or triggered explosion barriers will detect the arrival of the shockwave or flame front of the explosion and release inert material to suppress or extinguish the flame. The technology required for active barrier systems is readily available based on their presence in other mining countries and must be adapted for their use in US coal mines. The adaption must consider the coal dust and methane concentrations in US coal mines, the mine geometry, and the mining equipment used."

Jan 1, 2019

By I. Silin, M. Stapelmann, H. Wotruba, K. M. Hahn, C. Gerold, J. Katzmarzyk

New deposits are often characterized as low-grade and complex ore bodies. To date, processing of fine grained ore deposits implies complex processing routes with high energy consumption. For that reason, the investigation of dry grinding, e.g. with vertical roller mills (VRM), is an approach to save energy reserves. It is already proven that dry grinding can influence subsequent processing steps. In terms of flotation, the surface characteristics of the minerals are crucial for a successful flotation process, e.g. the sufficient adhesion of mineral particles and air bubbles. Wet grinding results in different surface properties of the product entering the conditioning stage than dry grinding, which has direct influences on the subsequent flotation process. To investigate the consequences for flotation, processing of a copper sulfide ore containing chalcopyrite and bornite was investigated, including grinding and rougher flotation. The effects of wet tumbling mill and dry VRM grinding on the degree of liberation of valuable minerals are characterized using mineral liberation analysis by scanning electron microscopy. The obtained flotation results, as well as the recorded flotation parameters such as dissolved oxygen, oxidation reduction potential and conductivity are presented and discussed. INTRODUCTION Copper production is mainly connected to porphyry copper deposits as main source for copper sulfides such as chalcopyrite and bornite. State-of-the-art processing of these deposits is already established worldwide for decades, combining crushing, fine grinding and subsequent flotation with rougher, cleaner and scavenger stages (del Villar, Desbiens, & Maldonado, Bouchard, 2010). While the demand for copper is increasing, copper grades of the deposits are decreasing and the remaining ore bodies have more complex mineralogy and finer particle size distribution. This implies processing routes with high water and – due to the liberation of fine grained valuable minerals – high energy consumption by fine grinding. One of the main energy consumers in processing plants is the grinding section, which accounts for more than 50% of the energy consumption in processing plants and even 4% of the worldwide energy consumption (Jeswiet, & Szekeres, 2016). Therefore, dry fine grinding alternatives are applied to enhance the overall energy consumption of mineral processing plants: high pressure grinding rolls (HPGR) and vertical roller mills (VRM).

Jan 1, 2019

By Jaana Romppanen, Satu Jyrkönen, Tiina Ranki, Peter Björklund, Markku Lahtinen, Kaj Eklund, Päivi Suikkanen

Outotec is continuously developing our existing process equipment and new equipment solutions to enhance the Flash Smelting process. Thanks to the long operating history of the Outotec Flash Smelting process feedback from the numerous operating references are available and is utilized. The general goals for development work are to improve equipment performance, thus realizing savings in Smelter plant operation costs by increasing the process efficiency and online availability. Digitalization also opens new possibilities for the feeding equipment and furnace operation monitoring. These solutions will improve the safety and performance of the smelter, and provide process and equipment related information which has not been available earlier. INTRODUCTION The year 2019 marks the 70th anniversary of Flash Smelting. The technology was operated on industrial scale for the first time at the Outokumpu Harjavalta copper smelter in Finland in 1949. The Flash Smelting technology, is now owned and developed by Outotec Oyj and the first plant, is now owned by Boliden Harjavalta Oy. The two companies have been evolving throughout history by optimizing the process for various feeds and raw-materials, as well as through developing the equipment and operating practices. Even though sustainability was not a hot theme/topic during the first days of Flash Smelting, it has nevertheless been the key principle in guiding the development. This is well proven by the wide adoption of Flash Smelting for the processing of copper and nickel concentrates, mostly due to its ability to fulfil the economic and resource efficiency criteria demanded by its operators. Along with the process technology development, also development of the equipment has taken place over time. Outotec is continuously working on developing our equipment to better suit the changing need of our customers in the continuously changing operational environment. Orebodies are getting more challenging with lower ore grades and more impurities. Achieving high recoveries for all valuable elements becomes more difficult with high slag quantities and with the need to tackle the high impurity concentrations. There is a need for higher capacities in greenfield and brownfield smelters. The role of the Loss-in-Weight Feeder, the Air Slide and Concentrate Burner is to ensure even feed into the reaction shaft of the Flash Smelting Furnace, and to enable controlling the process well, thereby enabling the best performance for the customers smelter. The design of the Flash Smelting Furnace aims for high availability, long campaign and safe operation.

Jan 1, 2019

By H. Henao, E. Kohnenkamp, L. Rojas

The slags generated in the copper conversion process are mainly composed of Cu2O-Fe2O3-SiO2 with the compounds CaO and Al2O3 in concentrations up to 10 wt%. The present work contributes to the knowledge of the conversion process, generating experimental data for the diagrams of phases Cu2O-Fe2O3- SiO2-Al2O3 and Cu2O-Fe2O3-SiO2-CaO. The experiments were carried out in a tubular furnace at temperatures of 1150°C and 1200°C under a condition of saturation with tridymite. Once the equilibrium was reached, the samples were fast quenched in water. The phases in the samples were observed in a Scanning Electron Microscope (SEM) and the elemental composition of the phases analyzed by means of Energy-dispersive X-ray spectroscopy (EDS) detectors. The addition of Al2O3 and CaO into the Cu2O-Fe2O3- SiO2 system resulted in an appreciable displacement of the liquidus lines, corresponding to an expansion of the liquid in the tridymite primary phase field. INTRODUCTION The conversion process of copper consists of oxidizing Fe and S present in mattes with 60 to 65wt% Cu (up to 16wt% Fe). This process is separated into two stages: 1- Slag blowing: Fe is oxidized, the addition of a flux such as SiO2 (silica) forms a second liquid phase called slag, this phase is removed from the furnace; 2-Copper blowing: in this stage, the matte with low concentration of Fe (<1% w/w) is again oxidized to remove S as SO2 in the exhaust gases. The product of these two processes is the formation of Copper Blister (> 98wt% Cu) (Schlesinger et al., 2011). Unlike the aforementioned conventional processes, in most Chilean smelters, conversion Peirce- Smith Furnaces are loaded with high copper matte (70–75wt% Cu) (Henao & Moyano, 2016). Due to the low concentration of iron in these matte (up to 5wt%), it is considered that separating the conversion process in two stages is neither operational nor environmentally convenient. Therefore, the process is carried out in a single stage (Pradena et al., 2006), generating a slag phase with a high percentage of Cu2O (wt%Cu>40).

Jan 1, 2019

By Paul E. Mather, Matthew J. M. Krane

Anode or fire refining is the final pyrometallurgical step in the production of copper anode. Part of this process purifies liquid copper by reducing its dissolved oxygen with a natural gas-steam mixture. Until now there have been no transient models of this process coupling the injected gas jet mass transport with its chemical reactions. A transient, 1D flow, chemical reaction model was made to estimate the time-dependent behavior of anode copper composition, soot formation, and the transient gas jet composition along its height. Model estimates were made for reduction rate, soot emission rate, and exergy loss and destruction distributions for two melt temperatures and a range of steam addition rates. It was found that increases to melt temperature and steam addition rate increased reduction rate and decreased soot emission, while having little effect on exergetic performance. Estimates for reduction histories were compared to industrial data. INTRODUCTION Anode/fire refining is the final pyrometallurgical step in the production of copper anodes; it is essential for removing dissolved gases which cause porosity in cast anodes. Despite its significance, the open literature appears devoid of any transient models of the entire process; furthermore, there are very little published process data with which to validate any models made. This dual dearth of modelling work and process data inhibits studies of the tradeoffs between process and performance changes, desirable for decreasing reduction time and soot formation as well as quantifying changes in the exergy losses and destructions of the process. This work introduces a reduced-order, transient model of reduction during fire refining, examines performance trends with operating conditions, and compares model estimates with industrial data. Overview of anode refining The purpose of anode refining is to produce liquid copper which can be cast with minimal gas porosity, which disrupts the downstream electrorefining process. Dissolved sulfur is removed first, then oxygen, by reactions with different injected gases. The removal of oxygen (the reduction step) is the subject of this proceeding and is effected by the bubbling of natural gas, typically mixed with steam, through the melt from tuyeres. A typical refining run reduces dissolved oxygen from 3000 ppm to 300 ppm in 2–3 hours (Schlesinger, King, Sole, & Davenport, 2011). The refined copper is then cast as anodes. Figure 1 shows a schematic of the furnace vessel.

Jan 1, 2019

By Damian Connelly

The metallurgical heart of the majority of copper oxide processes is the heap leaching operation. Fresh low grade sulfide ores is a far greater challenge.The success of this unit operation is so important that operators need to understand the ramifications of their decisions or non-decisions and how they could affect the downstream processing. Heap leaching is an operation that can be described as a scientific art whereby principles of science can be used to guide experienced personnel in attaining their goals. Recent advances have been made based on better understanding the ore characteristics. The success of a heap leach operation, or otherwise, is dependent upon a number of factors, notably: The type of ore to be treated The extent of testwork completed to define the process The interpretation of the testwork results Ore preparation prior to stacking Agglomeration and curing requirements Other issues are: Compliance with the ’smaller’ requirements of environmental authorities Adequate and timely drainage of solution from the base of a leaching lift The degree of saturation in the pads Heap porosity – coarser or finer ore, which is better? Higher or lower irrigation rates – which would produce a better result? Laying out irrigation pipework for ease of operation and maintenance The addition of water, raffinate during agglomeration where needed The heap leaching of sulfide ores, including chalcopyrite, via enhanced bacterial leaching is discussed. INTRODUCTION Over the last twenty years, production of extremely pure copper from solvent extraction and electrowinning (SX/EW) has become more common in a market of real declining prices for copper metal. This paper touches on a number of heap leach operations and experiences. These projects were subjected to extensive engineering design and resulted in low capital cost, efficient operations with a number of lessons learned. The key to these operations was the performance of the heaps and associated fluid collection systems rather than the plants themselves.

Jan 1, 2019

By B. R. Maas

Processing material at a consistent rate through the continuous countercurrent decantation (CCD) thickeners presented a major bottle neck to unlocking additional value from one of the post-flotation streams at the Kansanshi processing plant. The manual operation of the thickeners making up the CCD train resulted in frequent imbalances and process upsets across units. The automation of CCD trains is notoriously tricky as the available manipulated variables are outnumbered by the parameters requiring regulation. The implementation of an advanced, auction-based, control philosophy to manage the movement of both slurry and solution inventory through the train addressed this parameter imbalance and lead to the stabilisation of the circuit. Since the commissioning of this control strategy: an additional 7 200 dmt/day (+36% throughput) of material can reliably be processed through the train, the number of monthly downtime events has reduced, and a saving of $354 000/month in reagent cost has been achieved. INTRODUCTION CCD operation Agitated leaching is a common method used in hydrometallurgy to extract a metal from its host ore. The host ore is initially finely ground to liberate the surfaces of the valued minerals and improve the kinetics of the leaching process. The ore is then contacted in an agitated tank with a lixiviant to dissolve the desired metal into the aqueous phase. The resultant slurry from the leaching process comprises of a solution pregnant in the metal salt and a barren ore. The first purification step taken after leaching is to wash the pregnant liquor solution (PLS) from the depleted ore. On the industrial scale, a set of between two to ten thickeners arranged in a countercurrent configuration is often used to carry out this separation (Perry & Chilton, 1973). The slurry is introduced at the head of the train and a wash solution at the tail. The two streams are pumped through each thickener countercurrent to one other. At each stage the residual PLS in the slurry is mixed and diluted down with the countercurrent overflow solution from the downstream thickener. The diluted slurry is fed into the thickener where the solids separate out through gravity sedimentation. The settled solids are channelled towards the underflow of the thickener by a rake mechanism and pumped downstream to the next thickener in the train. The outcome is the recovery of a PLS from the overflow of the lead thickener and a slurry of washed solids from the underflow of the tails thickener.

Jan 1, 2019

By M. G. Beukes

"In South Africa most of the large gold mines operate between 1500m and 4500m below surface where reef is accessed initially through a vertical shaft system then via a network of tunnels and mined in either a longwall, sequential grid or scattered mining configuration. Due to the complexity of the ventilation networks used to ventilate these mines and the potential disastrous consequences associated with underground fires, it is of utmost importance that these mines are managed in such a way that underground fires are prevented. However, if they do occur the fires are managed to firstly prevent the loss of life and secondly protect the infrastructure and viability of the mine. The aim of this paper will be to: • Discuss current SA mining legislation regarding underground fire prevention and control. • Examine these fires from a risk management perspective by means of a bowtie assessment. • List and discuss the major Threats and Consequences as determined by the bowtie assessment. • Discuss the various prevention and consequence controls for deep level underground fires. • Examine how to effectively run an emergency control room. From this, a practical way of designing, implementing and managing an underground fire management system is explored. Lastly, the paper identifies new technology and ways of thinking and how these can be used to combat underground fires. INTRODUCTION The orebodies of South African gold mines are generally narrow tabular structures that vary in thickness between 0.8m and 1.2m with an inclination of between 200 and 700. This, coupled with depths of between 1500m and 4500m, as well as the unpredictable geology, creates unique challenges and significantly impacts on mine designs and mining methods. In general, gold bearing reefs are accessed initially through a vertical shaft system then via a network of tunnels and mined in either a longwall, sequential grid or scattered mining configuration (Figure 1). Mining is very labour intensive with very limited mechanisation opportunities and this increases the risk to human life if an underground fire occurs. On 16 September 1986, one of the worst mining disasters in SA mining history took place when 177 mineworkers were killed at Kinross Mine. An acetylene tank sparked flames that swept through the mining tunnel igniting plastic covering on the wiring and the flames also set fire to polyurethane foam. The burning plastic combined with polyurethane and the toxic fumes that filled the shafts caused the miners death. This incident was a stark reminder of the serious consequence that underground fires can have on human life as well as the crippling financial and asset impact for the mining companies. Over the past thirty years, the SA mining industry reduced the number of mine fires significantly by replacing normal timber support with fire retardant treated timber, alternative support systems such as backfill and elongate support and many other fire prevention initiatives. Although the number of fire incidents and number of fatalities due to fires does not show a direct correlation because of various factors, the controls put in place against fires has had an impact on the number of fire and explosion fatalities (Figure 2)."

Jan 1, 2019

By Beatrice Pierre, Juan Carrasco

Altonorte began as a concentrate roasting operation in 1988 under the name of Refimet. In 1993, a copper smelter was built with a design capacity of 203,000 tonnes per annum of concentrate. Since 2001, many technological advances have been made in Altonorte, where the biggest Noranda Reactor in the world is installed being the first Noranda Reactor reaching above one million tonnes of copper concentrates processed per annum. In 2013, Altonorte was acquired by Glencore. Recently due to various new environmental regulations in Chile, Altonorte has evolved to new standards of operation in order to reach the vision of becoming a World Class Smelter. This paper describes the path followed to improve safety, environmental performance, process capacity, reliability, and productivity. The foundation for the growth and success in Altonorte is our People. Employee engagement and branding of our cultural journey is what allows Altonorte to face the future with the certainty of becoming a World Class Smelter. INTRODUCTION Altonorte is located in Antofagasta, the mining capital in the north of Chile and is the last smelter built in Chile practically completed with second hand equipment. The biggest technological change in Altonorte occurred during the phase 3 expansion in 2003, where the old Reverberatory furnace was shut down and replaced by the biggest Noranda Reactor installed in the world. The vessel measures 5.3 m × 26m. ºAdditionally, this project contemplated a new rotary dryer, three (3) new Peirce Smith converters, new anode furnaces and a new Acid plant. The nominal capacity was to treat 816.000 tons of new concentrate per year. In 2008, a new expansion phase was implemented where a new double absorption acid plant replaced the oldest acid plant. Bottlenecks such as blowing capacity and oxygen availability were solved installing a new air blower and a new contract was negotiated with our oxygen supplier to increase oxygen availability up to 683 tpd. This improvement defined the current nominal capacity of 1.100.000 ton of new concentrate per year. Current process description All concentrates are received by trucks directly from domestic mines or from the Antofagasta international port in cases of imported concentrates; the concentrate warehouse has a capacity of 25 kt where the blend is prepared to feed the smelter.

Jan 1, 2019

By C. Hudson, D. Tremblay, A. Frey

"A discussion of the design, challenges and successes associated with the commissioning of the gravity recovery circuit at Canada’s newest open pit gold mine - Atlantic Gold’s Moose River Consolidated Project in Nova Scotia, Canada is presented. An overview of the project, its historical significance and overall flowsheet is provided with special focus given to the design and selection of the gravity circuit equipment including the scalping screen, gravity concentrators and the novel intensive leaching technology selected for the project. The performance of the gravity circuit is benchmarked against the feasibility study process design specifications and the outcomes are discussed. Challenges encountered during commissioning are also presented, including the use of third-party automation and the effects of screen sizing on overall gravity circuit performance. Mechanical modifications made to the Sepro Leach Reactor for the Moose River project are also discussed. A detailed technical review of the mechanical and operational aspects of the Sepro Leach Reactor is provided with key operational data on leach times, recoveries, reagent usage, solid-liquid separation, pregnant solution quality and its influence on bullion purity.INTRODUCTION Atlantic Gold Corporation’s Moose River Touquoy Mill in Nova Scotia, Canada was commissioned in the fourth quarter of 2017 with commercial production declared in March of 2018. The 2 Mtpa process plant uses a conventional, gravity-CIL process. This site was previously mined in the 1870s. Interest waned in the early 1900s but resumed in the 1930s and the mine was brought back into production in 1935 until an underground mine collapse in 1936. This mining district became famous after CRBC radio commenced a ground breaking, around the clock, broadcast of the rescue operations. Over 100 million people listened to the broadcast from Canada, the United States and the United Kingdom. These broadcasts changed radio, transforming it from a medium for music to on the spot, breaking news reporting. The mill was constructed by Ausenco on a fixed price EPC contract in the historic Moose River gold mining district, 95 km north-east of Halifax by road. The mill will process ore from the adjacent Touquoy pit for the first 5+ years of operation; after the Touquoy reserves are exhausted, the mill will process ore trucked 37 km from the Beaver Dam deposit for an additional 5 years."

Jan 1, 2019

By A. A. Wessels, D. P. Allison

"Mine hoists are built to handle a certain nameplate capacity; they are specified and designed according to the required duty. However, as production capacity increases in other parts of an operation, the hoist capacity can become the critical constraint. Such a situation occurred at Lundin Mining’s Neves-Corvo operation. This paper examines how each component of the existing hoisting system was examined and optimized. Through a combination of engineering study and hoist simulations, the annual hoisting capacity was improved by 24% through increases in payload capacity and available hoisting time combined with a reduction in cycle time, while no changes were made to the hoist motor, drum or headframe. The additional payload capacity was achieved by reducing the mass of the hoist ropes and skips, and improving load monitoring systems. The cycle time was reduced through the shortening of the creep distances and increased availability through the installation of a shaft collar safety platform, alternative guide rope bushes, and superior liners for both the skips and underground measuring flasks. Enhanced cooling of the hoist electrical system was also incorporated to increase hoist availability by reducing downtime during hot summer months. The changes will increase the capacity from the current 4.5 mega tonnes per annum (Mtpa) to a planned 5.6 Mtpa and are being implemented over a 2-year period whilst maintaining the mine production during the upgrade work. INTRODUCTION Neves-Corvo Mine Neves-Corvo is primarily a copper and zinc mine producing copper, zinc and lead concentrates. The operation is owned and operated by Somincor, the Portuguese subsidiary of Lundin Mining. Located in the Alentejo district of southern Portugal, the operation is situated approximately 15 km southeast of the town of Castro Verde, where summer temperatures can reach as high as 45ºC, and approximately 220 km southeast of Lisbon. The principal means of mine access is via a ramp from surface, with the vertical shaft used to hoist ore and waste from the 700 m level, while conveyors descend from the 700 m level to transport ore and waste up from the deeper levels of the mine. The mine is highly mechanized and several different stoping methods are employed, with the most significant being bench-and-fill and drift-and-fill. The Neves-Corvo mine currently exploits five orebodies: Neves, Corvo, Graça, Zambujal and Lombador for copper and zinc-lead ores which are processed in one of two plants. All the orebodies are currently exploited over their full elevation with the exception of Lombador which is only mined down to the 220 m level, approximately the top 50% of the orebody, known as Lombador Phase 1."

Jan 1, 2019