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By G. J. Heferen, A. Pranowo, N. J. Aslin, P. O. Eriksson

Glencore Technology (GT) has over four decades experience supplying stainless steel cathode plates (“cathode plates”) to the electro-refining and electro-winning industry. Cathode plates are typically the single biggest capital investment in a refinery. Refineries may view cathode plates as fixed asset or consumables depending on their operational characteristics. This paper examines the issue of cathode plate life and the strategies and philosophies used by different plants in the management of their cathode plate asset. Some plants operate with their original plates after more than 20 years. Others accept high turnover and regular maintenance as normal operating practice. Reference data are provided on plate life for various operating plants including benchmark plants achieving best-practice plate life and operating cost. The role of the electrode handling equipment on cathode plate longevity is also examined, including latest developments in Cathode Stripping Machine, robotic copper stripping, and full-automation production cranes. The ability to identify and manage the population of plates in service is also critical for maximising plate life and minimising its overall operating cost. This paper discusses a novel and unique RFID system for tracking and managing cathode plate inventory. INTRODUCTION Permanent cathode plates The adoption of permanent stainless steel cathode electrodes in the electro-refining of copper was the most significant process development since the first commercial electro-refineries were built in the late 19th century. It provided significant improvement over the labour intensive and complicated starter sheet system. Copper grows over the permanent cathode blade for a number of days before being stripped, and the permanent cathode can be returned straight back to cells for the next cathode cycle. Glencore Technology (formerly Mount Isa Mines (MIM), then Xstrata Technology) has been manufacturing permanent stainless steel cathode plates from the late 1970s with the birth of ISA PROCESS™, and the Kidd process that came one decade later. Invented and commercialised by Mount Isa Mines, the ISA PROCESS™ was first implemented into Copper Refineries Limited (CRL), Townsville, in 1978. The KIDD PROCESS by Falconbridge evolved in the 1980s and was first implemented into the Kidd Creek Tankhouse, both operations converting from traditional copper starter sheets.

Jan 1, 2019

By M. Al-Khawaja, F. Hassani, F. Mucciardi, N. Razavinia

"In today’s economy many industries are becoming aware of the need to recover some of the waste heat they create. Industrial processes release, on a global scale, over 100 tera-Joules (i.e. 1014 J) of waste heat annually. The recovery of waste heat can lead to a reduction of greenhouse gas emissions and it can also provide a financial benefit which can be obtained by converting some of this excess heat to electricity. At McGill, a research program has been initiated so that low grade waste heat (temperature between 100ºC and 300oC) from process off-gases found in pyro-metallurgical industries is captured and concentrated by using heat pipes and then converted to electricity by a mechanical engine. This paper illustrates the 3 C’s process (capture, concentrate and convert waste heat to electricity). It also provides some preliminary experimental data. INTRODUCTIONThe problematic climate change caused by the use of fossil fuels, the rapid depletion of global reserves and the catastrophic consequences of nuclear power generation call for renewable and safe, resources of energy, for both man and the environment. Extensive researches in the production of energy from renewable sources and improvements in efficiency of current technologies can help us to reverse this trend.The greatest advantages of using renewable energies are that they don’t deplete and they also contribute to a green environment. On the other hand the disadvantage of using these resources is that the energy available from renewable sources is much less concentrated than that provided by fossil fuels and nuclear energy. This makes renewable energy less attractive for large scale industrial uses in most cases. A key target for society for the 21st century is the production of energy from renewable sources at a cost that is competitive with fossil fuels. Fossil fuels represent a concentrated form of energy; usually it is referred to as high grade energy. Nonetheless, there is a vast supply of alternative energy. The sun, wind, water and biomass were the first to be explored. While these are all valid options that warrant concerted efforts and large investments, there is another source of energy that typically is produced by manufacturing industries. This energy is often referred to as low grade waste heat. Most of this energy is simply vented to the environment through the stream of off-gases. In the future it will be necessary to capture and convert some of the low grade heat to a valuable form such as electricity if we are to improve on the efficiency of energy usage."

Jan 1, 2012

By M. Girard, E. Bourricaudy, M. Ashbury, M. Canizares, A. Mezei

Liquid-solid separation and slurry handleability relate directly to commercial plant ramp-up success or lack thereof. The paper provides a well-proven approach for testing, scale-up and commercial application of difficult processes. Emphasis is placed on practical applications of rheological concepts developed both academically and empirically. The cause-effect relationship between the process chemistry and possible physical implications on the metallurgical plant operability is presented in a simple, direct form. Examples include recent results in areas of mineral processing and extractive metallurgy. Technical process risk factors and their mitigation are included in the discussion.

Jan 1, 2011

By A. Gronningsater

Introduction As is well known, the fight between the blast furnace and the reverberatory furnace in copper smelting during the second decade of the century ended with a victory for the latter, a result which must largely be attributed to the introduction of flotation methods. To my knowledge, no new blast furnace has been blown-in at any American copper smelter since the War. As the metallurgy of nickel, up to and including matte smelting, is generally considered a close parallel to that of copper, the introduction of reverberatory smelting in the big new smelter of the International Nickel Company at Copper Cliff, built in 1928-30, seemed a logical adherence to a well established trend. In view of these facts, considerable comment was made when Falconbridge Nickel Mines decided to retain the blast furnace in their smelter built about the same time, in 1929. A presentation of the reasons governing this choice should therefore be of interest. The basic principles underlying the Falconbridge practice, and the considerations guiding the successive steps in the operations, will be discussed in the following. To understand the problems involved, the character and mode of occurrence of Sudbury ore must be kept in mind. Large amounts of disseminated ore are generally present. Although the gangue usually runs only about 50 per cent Si02, the ore hoisted as a rule contains more silica than needed in the smelting operation; until recently this excess was removed entirely by hand picking (in later years supplemented by magnetic sorting methods), a difficult and not very satisfactory method, in which 'the border line between ore and waste is entirely arbitrary, and therefore too much depends on the judgment of the picker.

Jan 1, 1934

By A. Holland, T. Krumins, E. Olin, J. F. M. Castilleja, J. Geldart, C. Fleming, I. Jackman

A flowsheet has been developed to treat the flotation tailings from a copper mine in Mexico to recover gold and silver by cyanidation and carbon-in-pulp (CIP). The plant will treat ~15,000 t/day of a 60:40 blend of current flotation tailings and the mine’s historic tailings. The tailings also contain a significant amount of cyanide-soluble copper, and the economic viability of the project is strengthened by recovering most of the copper and cyanide associated with this process. The solution and solid phases in the CIP tailings will be separated in a counter current decantation (CCD) circuit and the CCD solution overflow will be treated by a SART Process. Copper precipitates as a salable copper sulphide product in the SART Process and the cyanide that is associated with the copper complex is regenerated as free cyanide. After SART, a portion of the SART product solution will be recycled to leach to reuse the free cyanide, while the remaining solution will be used as wash water in the CCD circuit. Incorporation of the SART Process in the flowsheet allows the CIP circuit to be operated aggressively as a gold plant, which means most of the silver in solution passes through CIP to SART. Silver co-precipitates with copper in SART and is recovered very efficiently with the copper sulphide by-product. Incorporation of SART also allows the leach and CIP circuits to be operated with relatively high levels of free cyanide, which enhances silver leach kinetics and helps keep copper from loading onto the carbon in CIP. The flowsheet was developed in the laboratory and successfully demonstrated in a fully-integrated pilot plant in 2018.

Jan 1, 2019

By M. Somppi, Z. Yamak

"Gold producers invest significant effort in mining, processing, and creating an intermediate gold doré product. Nonetheless, equal effort should be extended to the final handling and processing of the doré bar, and managing the high-purity gold produced at the fine-gold toll refiner. This detailed attention to bullion handling and refining provides rigor and confidence that the mine site is achieving, through fair and controlled methodology, the most appropriate value for the final product. With the above in mind, the following study explores the importance of preparing a set of site best-practices for bullion handling and specifically, detailing the peculiarities of sampling methodologies and the impact on assays.INTRODUCTION Gold and silver handling practices are common place at mine sites and refineries. The practices include but are not limited to smelting, ingot casting, weighing practices, and secure transportation. Proper handling and processing of the bullion material ensures that the mine site is achieving the true value of the final product. Various handling aspects can critically impact the perceived value of the bullion. A few of these particulars include weight tracking, scale recertification and calibration, refining and melting practices, melt temperature measurement, sampling, pouring, bar cleaning, furnace technology and crucible selection, and assaying. Nevertheless, this report discusses and focuses on the importance of proper sampling and molten-metal temperature measurement and their potential impact on the final doré bar value. Refining or re-melting operations achieve a proper measure of the precious metal content of its bullion when the sample accurately represents the whole bar. At first this task appears seemly straightforward, however, taking a representative sample can be challenging and is also one of the most important tasks for valuing gold during the settlement stage at the precious metal refinery. Various bullion sampling methodologies exist; including: dip sampling, granulation, drilling, cutting, and vacuum pin sampling. The Royal Canadian Mint (2009) indicated in their technical review of refinery operations that pin sampling is one of the best methods for cases where representative sampling and accuracy are required, e.g. to determine the payable metal content. Pin sampling consists of inserting a sealed glass vacuum tube (Figure 1) into the molten metal; when the molten metal contacts a purposely-designed weak portion of the glass, the seal breaks and the metal is suctioned into the hollow centre (Figure 2)."

Jan 1, 2018

By R. H. Watson

A paper read by J. A. H. Church before the Northern Alberta Branch last February described a method of working thick inclined coal-seams from the dip upwards, with the view to preventing fire risk by using water for the stowage of waste workings, and extinguishing a conflagration should such break out, was favorably received; but there was some doubt as to the cost of such a method, as it involves a retreating system, which might prove too expensive for practical adoption. Let us consider a typical leasehold such as we are familiar with in the Rocky Mountains. The leasehold is crossed at one end by a mountain river, which is cut by the outcrop of a seam of coal, 30 feet in thickness, pitching as shown on the drawing herewith, which also shows the general line of the outcrop in elevation through the leasehold, which is two and a half miles long and contains 1,500 acres. The average lift is about 600 feet above river level and drilling has proved that the coalseam can be tapped at a depth of 1,500 feet, 2,000 feet down the pitch from the outcrop in the river, all as shown in the illustration, which is typical enough of our mountain conditions to serve the purposes of comparison of methods. We take up the leasehold and invest $30,000 to pay for drilling and prospecting; $30,000 more for the price of the lease to locator or holder, and say $100,000 to pay for a railway spur (it might cost twice this sum, but we are only comparing two methods in the same location) and "now we are ready to consider equipment and the cost of development.

Jan 1, 1924

By J. R. Goode

"The Las Cristinas deposit contains about 10.2 million ounces of gold at a grade of 1.3 g/t. The deposit comprises a layer of fully oxidized saprolite (SAPO), a layer of sulphide-enriched saprolite (SAPS), carbonate leached bedrock (CLB) and carbonate stable or un-leached bedrock (CSB). Gold occurs at about the same level in all lithological groups. The bedrock units contain minor amounts of copper (about 0.1%) as chalcopyrite, while SAPO contains virtually no copper it having been leached and deposited in the SAPS zone.A previous owner started investigation of the Las Cristinas deposit in Venezuela in 1991. Over the next seven years, 1174 holes with a total length of 159 km were drilled, extensive metallurgical testwork, including pilot plant operations, were conducted and feasibility studies were completed. Construction was started in 1997 and again in 1999 but was suspended.Crystallex has been producing gold in Venezuela since the early 1990’s. In 1997, Crystallex acquired Inversora Mael which had held two of the claims to the Las Cristinas concessions since 1986. In September 2002, Crystallex entered into a definitive agreement with the Corporación Venezolana de Guayana, (CVG), to develop the Las Cristinas deposit.An extensive program of studies and testwork was started in early 2003 to determine an optimum development plan for Las Cristinas. Mine Development Associates, SNC–Lavalin Engineers and Constructors, SGS Lakefield Research Limited, J.R. Goode and Associates, and Professor A. Laplante at McGill University acted as the main contractors.Because of the potential value of by-product copper, earlier flowsheets used carbon-in-leach for SAPO, but processed all other ore types by flotation to produce a gold-copper concentrate with cyanide leaching of cleaner tailings to maximize gold recovery. Cyanide recovery was necessitated by the high copper content of the leach feed. Initial studies of available data by Crystallex revealed that direct leaching of all ore types would provide about 11% more gold recovery than the previously selected flotation route with reduced capital and operating costs.Bench and pilot scale studies have confirmed that a SAG-ball mill-gravity-CIL route is very effective for all ore types and will give about 89% gold recovery. This paper describes the recent testwork, discusses the proposed plant design, and presents economic data."

Jan 1, 2004

By C. A. Jeffrey, K. Pearson

Abstract - The Croft diorite in central England belongs to a suite of Caledonian igneous rocks collectively known as the South Leicestershire diorite complex. Although the intrusions occupy separate outcrops, they are linked at depth to form a single pluton, buried beneath a cover of Triassic sediments (Le Bas, 1972; 1982, Allsop and Arthur, 1983). Both the Caledonian diorites and the overlying sub-Triassic unconformity have been affected by a complex history of alteration and mineralization which can be subdivided into four stages: (1) deuteric effects, caused by the release of volatiles during magmatic cooling; (2) albitization through sodic enrichment; (3) formation of lowtemperature laumontite, analcime and calcite veins with associated wall-rock alteration to prehnite and pumpellyite; and (4) sub-Triassic unconformity-hosted base metal, manganese and palygorskite mineralization. Zeolite mineralization occured some 200 Ma later than the intrusion itself, during post-Triassic times, as indicated by the presence of a single vein of laumontite and microcrystalline calcite which cross-cuts the sub-Triassic unconformity surface and enters the overlying Triassic sediments. Evidence from fluid inclusion work indicates that two fluids were involved in the deposition of the zeolite veins. One fluid was initially of relatively high temperature (~100°C to 320°C) and low salinity (~0.2 to 5.9 wt% NaCl equiv.), and was probably meteoric in origin, whereas the other was of relatively low temperature (~41°C to 165°C) and high salinity (~0.4 to 16.72 wt% NaCl equiv.), and is interpreted to represent a basinal brine. During Triassic rifting, thinning and fracturing of the crust, with the possible rise of associated magmas (Halliday and Mitchell, 1984), could have increased permeability and heat flow, initiating the circulation of hydrothermal fluids. Triassic unconformity-hosted base-metal mineralization in Central England is similar to other Triassic-Jurassic mineralization in Europe (Mitchell and Halliday, 1976).

Jan 1, 1997

By J. S. Fox

Major-element data for unaltered, unmineralized felsic host rocks from a number of stratigraphically simple, massive volcanogenic Zn-Cu(-Pb) sulphide deposits of low metamorphic grade have been compiled. The petrochemical affinities of these host rocks have been determined (by standard means and by discriminant analysis) and compared. This comparison indicates that volcanogenic deposits in felsic terrains are not restricted to the classical calc-alkaline rock association as previously thought, but can actually be hosted by rocks showing a range of iron content. There is a positive correlation between differentiation trend and are tenor. Zn-Cu ores usually have iron-rich felsic hosts (most Canadian Shield deposits); Pb-Zn -Cu ores have iron-poor felsic hosts (Japanese, Iberian and Tasmanian deposits). This parallels the antipathetic relationship between iron content and background lead levels evident in young, unmineralized, island arcs as well as in many older belts. Correlations between differentiation trend on one hand and massive ore mineralogy and the relative proportions of various rock type (including rhyolite, quartz-porphyry and coarse pyroclastic rocks) on the other are also evident. It is concluded that the recognition of a calc-alkaline differentiation trend cannot be used as a prospecting guide, as has previously been proposed. However, in view of the above correlations, the recognition of a given trend may aid in the formulation of an effective exploration philosophy.

Jan 1, 1979

By C. A. Jeffrey, K. Pearson

The Croft diorite in central England belongs to a suite of Caledonian igneous rocks collectively known as the South Leicestershire diorite complex. Although the intrusions occupy separate outcrops, they are linked at depth to form a single pluton, buried beneath a cover of Triassic sediments (Le Bas, 1972; 1982, Allsop and Arthur, 1983). Both the Caledonian diorites and the over-lying sub-Triassic unconformity have been affected by a complex history of alteration and mineralization which can be subdivided into four stages: (1) deuteric effects, caused by the release ofvolatiles during magmatic cooling; (2) albitization through sodic enrichment; (3) formation of low-temperature laumontite, analcime and calcite veins with associated wall-rock alteration to prehniteand pumpellyite; and (4) sub-Triassic unconformity-hosted base metal, manganese and palygorskite mineralization. Zeolite mineralization occured some 200 Ma later than the intrusion itself, duringpost-Triassic times, as indicated by the presence of a single vein of laumontite and microcrystallinecalcite which cross-cuts the sub-Triassic unconformity surface and enters the overlying Triassic sediments. Evidence from ?uid inclusion work indicates that two ?uids were involved in the deposition of the zeolite veins. One ?uid was initially of relatively high temperature (~100°C to 320°C) and lowsalinity (~0.2 to 5.9 wt% NaCl equiv.), and was probably meteoric in origin, whereas the other wasof relatively low temperature (~41°C to 165°C) and high salinity (~0.4 to 16.72 wt% NaCl equiv.),and is interpreted to represent a basinal brine. During Triassic rifting, thinning and fracturing of the crust, with the possible rise of associated magmas (Halliday and Mitchell, 1984), could have increased permeability and heat ?ow, initiating the circulation of hydrothermal ?uids. Triassic unconformity-hosted base-metal mineralization in Central England is similar to other Triassic-Juras-sic mineralization in Europe (Mitchell and Halliday, 1976).

Jan 1, 1997

By J. W. Matousek

The heat content of the waste slag from a typical smelting operation methods for estimating the thermodynamic properties of smelting slags, to include: -- heats of formation -- heat capacities (specific heats) -- heat contents -- melting temperatures -- heats of fusion The techniques are illustrated with the analyses of a nickel reverberatory furnace slag from Copper Cliff, an iron-making blast furnace slag, and a "lateritic" slag from a ferronickel operation in Colombia.

Jan 1, 2007

By Kenneth L. Norris

Stonegate Agricom Ltd. is currently conducting exploration and development drilling of the Paris Hills Phosphate Project (Paris Hills Project) located in Bear Lake County, southeastern Idaho, 3.2 km west of the towns of Paris and Bloomington, Idaho. The project is located adjacent to a highway and 19 km by paved highway to Montpelier, Idaho where the Union Pacific Railroad system is located. Power and water are available locally. The nearest metropolitan centre is Salt Lake City, Utah approximately 225 km by road to the south-west of the property. The Paris Hills Project encompasses an area of approximately 856 hectares. Property holdings consist of three (3) patented lode mining claims and 16 contiguous fee parcels (some with federal phosphate leases). Active open pit phosphate mining operations are located in surrounding counties in south-east Idaho and are owned and operated by Agrium Inc., Monsanto Company and J.R. Simplot Company. The Paris Hills Project is located near the centre of the Western Phosphate Field which constitutes the most extensive phosphorite beds in the United States. Phosphate beds of the Western Phosphate Field occur within the Phosphoria Formation of Permian age and extend over an area of more than 350,000 km2 including extensive areas of Idaho, Utah, Wyoming and Montana. At Paris Hills the phosphate mineralized beds occur in the overturned limb and the horizontal limb of the Paris Syncline. Grades and thicknesses in both the western overturned limb and the eastern horizontal limb of the anticline are similar. The vast majority of potential mineralization occurs in the horizontal limb which underlies most of the property holdings. Mineralization in the overturned limb has a strike length of over three (3) kilometres and extends from the surface to a depth exceeding 300 m depending on location along the north-trending strike of outcrops. Depths of the horizontal limb range from surface along the north side of Bloomington Canyon to estimated depths of 915 to 1,035 m at Paris Canyon. The property contains an Inferred resource of 109.6 million tonnes at 23.6% P2O5 over two mineralized horizons. The phosphate zones have a strike length of over 3 km and extend from surface to a depth of at least 900 m. Drilling commenced late in the 3rd quarter of 2010 and is planned to continue through 2011. The drilling was planned to target an area of potentially higher grade phosphate mineralization and better define and upgrade the current resources.

May 1, 2011

By H. Warren Newcomen

Assessments of the stability performance of open pit highwalls have traditionally been based on consideration of surface movement rates. Although generally accepted in industry, this approach presents challenges for establishing appropriate threshold values to allow for safe mining operations and does not address the issue of total strain. Surface movement monitoring data from a limited number of open pit mining operations in North and South America has been evaluated in terms of highwall strain, rock mass quality and inferred mechanism of instability. Threshold strain levels for key stages of highwall stability proposed from previous work have been reviewed and are generally endorsed based on evaluation of additional data. An empirical highwall strain criteria for the assessment of highwall stability performance is postulated based on the observed trends in highwall strain data from the case histories presented.

May 1, 2004

By M. F. Goudge

MAGNESIA refractories and magnesium metal are both essential war commodities. The need for magnesium, which had just made its debut as a commercial metal a few years before the outbreak of the present war, is widely known because this new and valuable light metal has already received much publicity. Less widely known but equally important in the war effort are magnesia refractories. They are indispensable to the efficient functioning of the great metallurgical plants producing steel, nickel, copper, and other metals, where, because of their resistance to extreme high temperature and chemical attack, they are used in lining the furnaces, which are operated at a white heat. The demand for refractories in the metallurgical industries rose rapidly upon the outbreak of war, and now, in consequence of the continued great expansion under way in the manufacture of steel, nickel, copper, and other metals, the need for magnesia is greater than ever. Since 1915, part of the Canadian requirements of basic refractories has been supplied from the deposits of magnesitic dolomite in Argenteuil county, Quebec. The products from these deposits are excellent for many uses, but the magnesitic dolomite has too high a content of silica and lime to be used in making a type of magnesia brick required in nickel converters, and in the roofs of reverberatory furnaces used in the copper and steel industries. There is now a large and growing demand in Canada for bricks and shapes for these uses. This demand has always been supplied from the United States. Makers of these products in the United States, in turn, formerly imported most of the necessary high-grade, dead-burned magnesia from Austria and Manchuria. Not only are these sources closed, but refractory chrome ore from the Philippines is no longer available and chrome refractories may have to be in large part replaced by magnesia.

Jan 1, 1942

By J. R. Kadambi, J. Furlan, Kucukal E.

"Hydrocyclones are used in various industrial applications, including mineral processing and tailings management, to separate or classify solid particles and/or liquid droplets from multiphase feed. The fluid flow in a hydrocyclone (used in mineral processing) was investigated numerically and experimentally using particle-image velocimetry (PIV) and refractive index matching techniques. Two turbulence models were used in the calculations: the k–? model and the Reynolds stress model. Particle image velocimetry measurements were taken at various spatial locations along the cyclone. Computational results were validated globally using pressure and flow-rate readings at the boundaries, and locally by comparing the PIV velocity-vector maps and profiles.RÉSUMÉ On utilise les hydrocyclones dans diverses applications industrielles, dont la minéralurgie et la gestion des résidus, pour séparer les particules solides et/ou les gouttelettes liquides de l’alimentation polyphasée, ou pour les classifier. Une étude numérique et expérimentale sur l’écoulement des fluides dans un hydrocyclone (dont on se sert en minéralurgie) a été menée à l’aide des techniques de vélocimétrie par images de particules (PIV, de l’anglais particle image velocimetry) et d’appariement des indices de réfraction. Deux modèles de turbulence ont été utilisés dans ces calculs, à savoir le modèle de turbulence k–? et le modèle aux tensions de Reynolds (RSM, de l’anglais Reynolds stress model). La valeur de la PIV a été mesurée à diverses positions spatiales le long du cyclone. Les résultats de ces calculs ont été validés globalement à l’aide de relevés des pressions et du coefficient d’écoulement d’une extrémité à l’autre de l’hydrocyclone, et localement à des coordonnées spatiales spécifiques en comparant les cartes et les profils du vecteur vitesse PIV.INTRODUCTIONA hydrocyclone is a piece of equipment used to separate and/or classify solid particles or liquid droplets from liquid solid or liquid-liquid feed. Versatile in application, hydrocyclones have been widely used in industrial applications including the food, oil, power generation, chemical, and mineral processing industries. The first hydrocyclone was introduced in 1891 by Bretney to purify various liquids (Bretney, 1891). Hydrocyclones have a relatively simple design with no moving parts, which leads to an efficient separation process."

Jan 1, 2017

By K. E. Harley, M. J. Whiting, T. J. Sabin, E. M. Ryan, J. F. Watts

"Wire and Arc Additive Manufacturing (WAAM) has the potential to enable a very significant reduction in buy-to-fly ratio compared to conventional manufacturing through the ability to build near-net shape components. Components manufactured from AA 2319 by WAAM can exhibit significant levels of porosity. There is also a variation in the physical appearance of the surface deposit sometimes found on such components. This deposit is similar to those observed on aluminium joined by MIG and TIG welding processes. It has been suggested that both the bulk porosity and the surface deposit are caused by hydrocarbon-based lubricant on the feedstock wire. An established correlation between surface deposit and porosity would offer valuable insight into WAAM products and enable early interventions in quality control or process monitoring based on visual examination. The relationship between the nature of the surface deposit and porosity has been studied for AA 2319 WAAM components manufactured using different wire batches. Evidence is presented to support the assertion that (i) there does not appear to be a relationship between surface deposit coverage and porosity, (ii) batch-to-batch variability in feedstock wire affects porosity. This study has led to a better understanding of the cause of porosity in WAAM components.INTRODUCTION There is a high cost associated with conventional, subtractive manufacturing because of the high ‘buy-to-fly’ ratio, a measure of the initial material bought compared to the material found in the finished part (Allen, 2006; Yilmaz & Ulga, 2016). A typical aerospace product may have up to 90% of the purchased billet of forging machined away which is cost inefficient and high in material waste. Wire and Arc Additive Manufacturing (WAAM) has the potential to reduce costs and lead time. Robotically controlled weld torches rapidly deposit feedstock wire in layers to build large near-net shapes with mechanical properties similar to those of conventional manufactured parts (Sequeira Almedia & Williams, 2010; Martina et al., 2012; Ding et al., 2015; Williams et al., 2015). A high level of porosity variation has been observed in aluminium WAAM parts (Cong, Ding & Williams, 2014; Gu et al, 2016) which can result in a range of material properties (Rudy & Rupert, 1970). This leads to difficulties in regards to standardisation and qualification of process and parts. In order for WAAM to be used commercially, porosity will need to be understood, monitored and reduced to a reproducible acceptable level or eliminated."

Jan 1, 2018

By S. Banisi, M. Poorkani, M. Farzaneh, M. Askari

"At the Sarcheshmeh copper mine 40,000 t of ore per day with an average grade of 0.9 % Cu is ground to 70% passing 75 microns. Grinding is effected in 8 parallel lines of 8 x 5 m ball mills in a closed circuit with cyclones. The make-up balls are 80-mm forged alloy steel balls and the average ball consumption is 750 gh of ore ground. In order to optimize ball size distribution inside the mill, based on the previous investigation instead of using only 80 mm make-up balls a combination of 80 and 60 mm (75% to 25% by weight) ball charge was used in one of the mills. To evaluate the performance of three ball types namely forged alloy steel balls (A), ductile cast iron (C), high chromium cast iron (D) and also a combined (80 and 60 mm) charge of forged alloy steel balls (B), four identical parallel mills were charged accordingly. These four mills were sampled during a period of six months. The amount of material finer than 75 microns of cyclone overflows was selected as a criterion for the performance evaluation. It was observed that in a mill with the combined make-up balls the amount of fine produced was 4% higher than the other mills. The consumption of ball types A, C and D were 730, 710 and 534 g/t, respectively. The results of laboratory flotation tests showed that due to an improvement in the production of fines an increase of 1.4% in the overall copper recovery is obtainable. Due to the promising results, the new make-up ball regime was implemented in all mills in the plant.INTRODUCTIONThe Sarcheshmeh copper ore body which may rank as third or fourth largest in the world contains 1 billion tonnes averaging 0.90 % copper and 0.03 % molybdenum. It is located southeast of Iran and has been processing 40,000 t/d of ore since 1982. The mine produces 100,000 tonnes of copper and 2,200 tonnes of molybednite concentrate per year. After three stages of crushing, the ore with a F80 of 12.7 mm is fed to 8 parallel ball mills in closed circuit with cyclones to produce a product 70% finer than 75 microns. The concentrate of the first stage of flotation is reground and the tailing constitutes the main component of the plant final tailings. A concentrate with an average grade of 31% Cu is obtained after cleaning and re-cleaning stages. Total recovery of the plant varies between 83 and 87 % depending on the operating conditions and ore type."

Jan 1, 2002

"As mine head grades decline and orebodies become more complex, traditional mineral processing techniques and flowsheets to achieve saleable concentrate become more difficult to design and construct. Mines with lower quality concentrates or concentrates with penalty elements are particular under threat. The economics of these operations are far more susceptible to metal price, concentrate treatment terms and the availability of other, cleaner concentrates. Additional value may be realised for these orebodies through improved recovery by producing a low grade middling concentrate for further processing, in conjunction with a saleable concentrate.The most cost effective way to reduce impurity levels is to do so as early as possible in the mining value chain. Technologies such as fine grinding and fine particle flotation are well established as effective methods for impurity rejection in mineral processing. What is normally overlooked is how a hydrometallurgical process could also be integrated in the overall flowsheet to achieve higher overall recovery at the mill. In the base metals environment, this is mainly because hydrometallurgical processes are associated with production of metal or use of expensive and toxic precipitating agents once the minerals of interest are solubilised. These processes can be very expensive, particularly with rising power costs and poor economies of scale in capital costs associated with low production rates from middling streams.Glencore Technology (GT) has recent experience in the treatment of middling and low grade concentrate streams as well as tailings streams to compliment a concentrator flowsheet in a refractory gold and base metals setting. The value proposition is the isolation of a low grade middlings concentrate from the primary circuit or the tailings stream for upgrading to an intermediate product with an equal or higher grade than the primary concentrate to allow blending for sale. This allows plants to operate on a more favourable part grade-recovery curve while avoiding the expense of metal production. For existing operations this is particularly attractive since it can be added on with no process interruptions.Two case studies are examined showing flowsheets and costings to arrive at the value proposition of the GT low grade treatment flowsheet."

Jan 1, 2017

By Kim Le Roux

Cemented paste backfill (CPB) is a relatively new material that is increasingly being used in open stope mining across the world. The advantages offered by this high density tailings backfill include: a lower total cost associated with backfill placement, reduction of excess water underground; and the elimination of the need to process the tailings prior to placement. However, almost all backfill design is based on the performance of laboratory prepared samples since it is difficult to obtain undisturbed samples and conduct in situ testing due to the lack of access to backfilled stopes and the safety concerns in accessible areas. The logistical problems associated with conducting in situ testing and obtaining undisturbed samples of cemented paste backfill (CPB) has lead to the reliance in the mining industry on performance data obtained from laboratory prepared CPB samples. The degree to which these laboratory prepared samples represent the actual in situ condition is not well defined, partly because the influence of the mixing, transport and placement process on the material properties it is not well understood. Therefore, there is a need in the industry to understand how the material properties and hence the performance of the laboratory prepared CPB compares with in situ material. This paper reports the findings of an investigation into the in situ properties of CPB at a gold mine in Northern Ontario. A combination of in situ and laboratory testing, conducted on undisturbed samples, was used to quantify the in situ properties and performance of the CPB. These results were then compared to those of a laboratory based investigation of the same CPB. It is evident from this investigation that the bulk properties of the in situ CPB are different from those of the laboratory prepared CPB. The most significant observed differences are that the in situ CPB has a higher void ratio and a lower degree of saturation than the laboratory prepared material. The implication of these differences on the stability and performance of the CPB will also be explored in this paper. 1

May 1, 2002