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By Jerry Handford

Investing in the Development of our Future Workforce ?Collaborative partnerships with educational institutions, industry associations, governments and other businesses. ?Programs: »Co-op / Discipline Student Program »Trades Development Initiatives »Operator Training Programs »General Student Program »Careers Next Generation / Community Careers Co-operative

May 1, 2006

By C. Díaz, A. D. Dalvi, C. E. O'Neill

"Roast-reduction smelting (RRS) of nickel concentrate, combined with flash smelting of copper concentrate, was one of the process options that Inco considered as a means of meeting its 1994 sulphur dioxide abatement target at its Copper Cliff operations. RRS involves deep roasting the nickel concentrate in fluid bed roasters. The roaster off-gas is treated in a sulphuric acid plant, and the low sulphur calcine is reduction smelted with coke in an electric furnace to yield a sulphur-deficient matte. The latter material is converted to Bessemer matte in Peirce-Smith converters, with minimal evolution of sulphur dioxide, and the converter slag is reverted to the electric furnace. Excellent nickel and cobalt recoveries (Ire obtained. This paper discusses the development of RRS, including extensive commercial scale testing at Inco's Thompson Smelter, and its key operating parameters. IntroductionReduction of sulphur dioxide emissions has been a long-standing endeavour at Inco. At the company's Ontario Division, as shown in Figure 1, sulphur dioxide emissions were reduced from about 2 million to 685 000 tonnes per year over the period 1970-1985. Most of this impressive improvement was the result of a sustained research effort which led to increased rejection of pyrrhotite from the ore during milling while maintaining an acceptable nickel recovery. Between 1970 and 1985, the combined grade of the separate nickel and copper concentrates feeding the Copper Cliff Smelter increased from about 10070 to about 'lIJ0J0 Cu +Ni and the combined S/(CU +Ni) ratio decreased from about 2.8 to 1.65."

Jan 1, 1994

By A. Mcdonald

"An X-Met Analyzer was purchased from Outokumpu in late 1983for use in the Hudson Bay Mining and Smelting smelter. Its first use was in the fuming plant to give zinc assays of each charge of slag tapped from the fuming furnaces. This quickly told the operators exactly when each charge had reached its economic tap-out point, and gave supervision a fool-proof method of identifying good operation. These and other factors led to major improvements in coal utilization in the fumers and to major increases in zinc oxide production. A second unit was later purchased for the reverberatory furnace to give silica and iron assays of the slag, and these were used to make adjustments in the feed composition to maintain the desired SiO2:Fe ratio in the slag. Since purchasing the units for the furnace, the oil consumption and copper content of the slag have dropped significantly. IntroductionSmelters have lagged far behind concentrators in process control by mean s of rapid product analysis. The on-stream X-ray analyzer was developed about seventeen years ago, and soon concentrators around the world were getting assays of the incoming ore, .concentrates and tailings every fifteen minutes, and using these to control reagent additions and other process variables. Almost always, the concentrate grade and recovery improved.In smelters, product streams are solids or molten materials, not the more easily handled slurries, and until seven years ago no inexpensive equipment was available to provide rapid analysis of this type of material. In approximately 1980, several companies developed instruments based on irradiating solid samples with low-intensity gamma rays from radio-isotope sources, and measuring the secondary X-rays emitted from different elements in the sample to provide an analysis of the elements desired.The smelter staff had a close look at what was needed and listed the following points as being critical:1. ability to provide Zn assays of a sample of slag within 15 minutes of taking it, in order to achieve optimum fuming times (zinc fuming , being a batch process, had the greatest potential benefit from rapid slag analysis);2. ability to give Cu and Fe assays on the slag, and on other smelter products, such as matte and converter slag;3. ability to give Si02 assays since the SiO2 content of the slag has a strong effect on fuming rate; and4. ability to stand up to an industrial atmosphere such as exists in the fuming plant."

Jan 1, 1987

By Hyumng Sup Choi

The role of the interfacial electrical 'Condition on the adsorption of col-lectors on mineral surfaces has been studied by electrophoretic mobility and adsorption measurements made on zircon. From the investigation of the electrokinetic properties of zircon, H+ and OH-are seen to act as potential determining ions, thus controlling the electrical nature of this mineral. The isoelectric point of zircon occurs at a pH of approximately 5.0, and it is evident, therefore, that the zircon surface would be positively charged below a pH of 5.0 and negatively charged above this pH. The adsorption of collectors therefore de-pends strongly on the pH of the solution; anionic collectors are adsorbed on positively charged surfaces and cationic collectors on negatively charged surfaces. This, in turn, de-fines the effective flotation condition, with respective collectors, for this mineral. The above results have been correlated with the flotation behaviour obtained by the simplified flotation test using a modified Hallimond tube.

Jan 1, 1963

By Ferrin Prince

New Gold?s New Afton mine is an 11,000 tonne per day block caving mine, located 8 km west of the city of Kamloops, British Columbia. The reserve is estimated at 52.5Mt with grades of 0.65 g/t Au and 0.93% Cu. Block caving requires a considerable amount of infrastructure development before production can begin. Each excavation had its own challenges, often further complicated by interactions with the caving stresses and fault structures. The main areas of interest were: the production crusher complex, the surface to underground infrastructure, and the footprint interaction with the faults. The ore zone at New Afton is bounded by two very weak fault zones, with large fault affected areas and associated splays. The resulting rock mass rating (RMR) is 35-50, with some areas significantly weaker due to clay infill. These conditions created a unique and decidedly difficult environment in which to develop New Afton?s infrastructure. Despite these difficulties, the mine began production on schedule in July 2012. The main production crusher for the mine is a gyratory crusher that allows for direct truck dumping, with a smaller jaw crusher in series to facilitate the initial development and production. The crusher chamber was redesigned several times to minimize the chamber volume, resulting in a 40% decrease in volume without losing functionality. After drilling and geotechnical testing, the location of the crusher was changed to eliminate the threat of fault affected ground in the area; the entire complex moved a short time before mining began on the chamber. The mining techniques used enabled tight control of the crusher pocket excavation, while also allowing for the timely completion of the chamber. The locations of the surface to underground infrastructure were tightly constrained by geology, surface infrastructure, and an existing open pit. The VR5 raise was drilled and abandoned part way through the reaming process when the drill string became stuck in fault gouge material. It was relocated and successfully completed. The VR7 raise hit a region of poor rock strength and deviated more than 11 m. Poor ground conditions caused a 130m section of the raise walls to fail. An innovative rehabilitation program was undertaken to re-establish the raise for ventilation. A surface to underground slick line was also installed to ease the material movement underground. A layout of the Extraction level was changed from herring bone to straight through drawpoints that resulted in a net reduction of 1.3 km of development. The Apex level was added to aid in the breakage over the major apex pillar and allow for geological mapping. A portion of the caving footprint is located within the footwall fault. The low strength, high clay content, and small joint spacing of the material resulted in blast-hole cut-off and drift deformation. Drift rehabilitation was a key factor in the successful development of the cave footprint. Innovative drilling and loading techniques were used to keep the holes open and to impede movement along the joint structures.

Aug 1, 2013

By U. Troncoso

Mantoverde is a heap leach-SX-EW operation that was commissioned in December 1995 at a production rate of 42,130 ton of copper per year and 5.4 million ton of ore per year. Copper production has been steadily increased to reach 62,000 ton in 2005. The forecast copper production for 2006 is 60,300 ton for an ore treatment rate of 9.5 million ton. A first dump leach operation was started in 1999 at a production rate of 1,922 ton of copper. A second dump leach operation was started in early 2002 at a production rate of 2,805 ton of copper. Dump leach production will be increased over time to as much as 24,000 ton of copper. Several improvements in the heap leach process have been implemented to cope with the higher ore throughput and copper production. However, the solvent extraction plant has remained unchanged which has resulted in a lower availability of raffinate solution and, as a consequence, in longer leach cycles. Different studies have been undertaken in order to optimize the solution management system at Mantoverde, including column test work aimed to reduce the leach cycle and solvent extraction plant modifications aimed to increase the raffinate solution availability. The test work program and the economical evaluations carried out, as well as the conclusions and recommendations obtained, are discussed in this paper.

Jan 1, 2007

By H. E. Lake

VERY EARLY in the initial stages of underground development work at Eldorado's Beaverlodge operation, the decision was made to use mill tailings as a backfill product. Mining and milling commenced in June, 1953, using locally available sand as backfill, while test work and installation of a plant was carried out to prepare ?and deliver the tailings to the mining areas. The first use of tailings was made in February, 1954, a sandslime separation being carried out with hydraulic cyclones. To date (January. 1956), approximately l 40,000 tons of fill have been used in the stoping areas, providing very effective support in a 50 deg. Vein system of cut-and-fill mining. The recoverable portion of the mill tailings amounts to 40 to 45 per cent, which has resulted in a product giving a percolation rate of 6 to 10 inches per hour. Owing to the fact that Eldorado has milled from 15 to 2 5 per cent more ore than it has mined, through the purchase of custom ore, the degree of control on the sand-slime separation has not been as critical as it might normally be when the filling operation must depend only on the tailings from ore mined. A description of the conditions involved and of the plant as finally installed is given below. It might be mentioned here that, with the impending increase in milling capacity from 700 tons to 2,000 tons p.er day, the present plant will be considerably altered within the ensuing year to handle the increased tonnage and distribution.

Jan 1, 1956

By J. N. Cram

"The comments given are to help allay generally accepted ideas that the handling of arsenic as arsenic-trioxide (As2o3J in and from off gas pyrometallurgical operation fumes is difficult, hazardous and expensive. It need not be any of these things if the basic and rather unique chemic3l and physical properties are understood and taken care and advantage of through present day technologies. These particular characteristics are:-(1) As2o3 sublimes and re-condenses, at a relatively low temperature;(2) As2o3 is, for practical in-plant purposes, insoluble in water at ambient temperatures and quite soluble in water just below the boiling point;(3) residual suspended and dissolved As 2o3 can be removed from water by complete dissolution with very little sulfuric acid, followed by the addition of small amounts of ferrous sulfate and calcium chlorate, with oxidation to the ferric and arsenite state and precipitation of an insoluble ferric calcium arsenate, thereby lowering the As2o3 content of solutions to acceptable levels. Even lower levels of non-toxic forms of arsenic solids and residual As2o3 in the water solutions can be attained by also using phosphate, and lime, along with the above.A background re past arsenic processing methods, present day operations, plus predictions re future trends, and hazards, are outlined."

Jan 1, 1979

By E. Poiate, P. A. L. P. Firme, D. Roehl, M. A. Carrion, A. M. Costa

Drilling high-pressure/high-temperature wells in salt rock formations is still a challenge for the energy industry. Creep and solubility is part of the salt rock physical-chemical behaviour, which must be considered in the design of the wells. The stress redistribution caused by drilling, in addition to thermallyactivated processes, triggers creep deformation, leading to borehole closure and the imposition of loads on the casing. The drilling fluid is designed by computer modeling in order to control the creep strain rate to a limit which allows the drilling operations and the casing setting. Depending upon the composition of the drilling fluid, chemical reactions on the salt wall may occur, especially in case of water-based fluids in highly soluble salt rocks. In those cases, cavities by dissolution (washouts) can be generated and the casing column remains uncovered by the cementation and laterally unconfined along the cavity length. This scenario is propitious to the loss of integrity of the casing due to phenomena such as plastic collapse, buckling and non-uniform loading on the casing provoked by the closure of salt formation around it. The casing should remain intact during the wellbore life-time. In this work, a section of a typical well crossing salt formation composed by halite and carnallite is considered. An idealized-cylindrical washout cavity inside a highly soluble salt layer is assumed. The purpose here is to evaluate the effect of the dimensions of the cavity on the integrity of the casing. Several typical diameters and lengths of the cavity are adopted. Numerical analyses are carried out with an in-house finite-element system composed by the pre-processor MTOOL 3D®, the simulator ANVEC 3D® and the post-processor POS 3D®. Salt rocks are modeled as visco-elastic materials. Creep is simulated by the Double Mechanism Creep Law, widely employed in Brazilian salt rock mechanics research. Cement and casing (steel) are modeled as elasto-plastic materials described by the Mohr-Coulomb and the von Mises criteria, respectively. Casing integrity is evaluated with respect to vertical and horizontal displacements. Vertical displacements imposed to the casing can provoke the failure of the column by plastic collapse or by buckling. Besides that, horizontal displacements of salt due to creep closure shall lead to the undesirable contact with the casing. Failure envelopes based on displacements are generated. The results of the simulations have shown that the casing failure by plastic collapse occurs preferentially in short columns, as well as buckling occurs in long and slender columns. The occurrence of both failure modes is more frequent in large-diameter cavities. Additionally, failure caused by contact between salt and casing occurs preferentially in short-diameter cavities.

Jan 1, 2015

By J. Nsasi Bakambu

This paper describes an autonomous platform for exploration and navigation within networks of tunnels, as those typically found in underground mines and caves. In the exploration mode, a remotely located supervisor instructs the platform to move through successive sections of the network, gathering range data that is, then, concatenated into 2D/3D survey maps of the environment. In the navigation mode, the supervisor specifies high-level missions on the previously acquired survey maps. A motion planner, then, translates each mission into a set of consecutive navigation actions, separated by natural landmarks. Mission execution consists of detecting landmarks, self-localizing and performing the planned navigation actions.

May 1, 2003

By D. Mills, W. H. S. Lawson

"The need to make repairs is seldom a major consideration in the design, fabrication and installation of major components of electrical generation plants. Repair welding, however, is a fact of life in the electrical generation industry, for restoration of degradation in service, from cavitation of hydraulic turbine runners, to corrosion and fatigue damage in pressure vessels. In making weld repairs to carbon and low-alloy steels, the largest source of trouble is hydrogen embrittlement and related post-weld cracking. Various strategies have been developed to control problems from this source, including post-weld heat treatment, the use of nickel-base alloy filler metals and the temper bead welding technique. Each of these basic strategies is being applied as circumstances require; each strategy must, however, be implemented in a manner that reconciles weldment structure and hardness, degree of restraint and service environment with the consequences of unsatisfactory performance of the repaired component.IntroductionMajor working components of electric generating plants are specified and installed on the basis that, wherever technically and economically feasible, they will retain functional capacity without major repairs for the twenty-five-plus years of normal plant lifetime. Nevertheless, repairs are often required, and welding is usually an essential feature of the work. Remedial welding may be performed to correct design or fabrication errors which become evident only at the time of component installation. The most common causes of requirements for repair involve corrosion, fatigue or related processes which prove more aggressive than expected during service. Increasingly, our planning for future repair requirements is related to continual improvements which are occurring in nondestructive evaluation technology. As components are periodically reinspected during their service life, fabrication induced defects may be revealed for the first time quite late in the life of the component. When this occurs, repair must be considered wherever inaccessibility of a flaw makes it impossible to prove its inactivity. Finally, there are certain components, for instance in hydraulic turbines, which cannot be economically made or used without the expectation of service induced wear. Here, periodic maintenance welding must be regarded as a normal event."

Jan 1, 1981

By M. K. Walter

"The underground operations of Kidd Creek Mines uses an average of 450 U.S. gpm water during regular operations, and discharges an average of 800 U.S. gpm through consecutive staged pumping lifts of 1200f t.Water is used as a flushing medium for the drilling operations and as a dust suppressant for drawpoint mucking. The water retains an average of 5% suspended solids by weight which is removed underground before being pumped to the surface. This paper outlines the treatment of the mine water for the removal of suspended solids which are chemically treated to settle out as a sludge product of 60% solids by weight. This process reduces the sludge handling operation by 50%. The sludge is systematically disposed into the ore passes.IntroductionThe Kidd Creek minesite, located 27 km north of Timmins, Ontario, produces 4.5 million tonne s of copper, lead, zinc and silver ores annually from its No. I and No.2 underground mining operations. Both mines use a sublevel blasthole stoping method of extraction.Water from the underground operation passes through a series of surface settling ponds, where it is treated to remove heavy metal ions from solution. A blend of the pond effluent with fresh water from Kidd Creek, supply the underground with water at an average rate of 450 U.S. gpm. Water flows from the production zones through coarse sumps and into a main pumping station. There are five main pumping stations underground, three in No. I Mine and two in the No.2 Mine.The No. 2 Mine pumping stations are located on the 4800 level and the 3600 level. All water below the 3600 level to the shaft bottom is controlled from the 4800 pumping station. The water from the 4800 pumping section is combined with water from the remaining levels of the No.2 Mine at the 3600 pumping station. Water from the 3600 pumping station is pumped to the 2400 pumping station in No. I Mine.The No. I Mine pumping stations are located on 2800, 2400, and 1200 levels. All water below the 2400 level to the shaft bottom is controlled through the 2800 pumping station. This water is pumped to the 2400 pumping station. The 2400 pumping station also controls the water below 1600level to 2400 level."

Jan 1, 1988

By K. Iturralde

Dense transport infrastructure areas lack green facilities, they produce annoying noise and they are big energy consumers. As far as there is no free land or space, adding a vegetal covering to existing infrastructures has become a choice in order to get a more pleasant and comfortable environment. Noise barriers are getting spread all over the highways and sometimes they install photovoltaic panels. Is this just a hype or are there real causes? A green acoustic barrier with an energy generator could be interesting for covering the existing urban transport infrastructures. The specific geometry of the infrastructures requires a personalized product. If we measure the infrastructure environment's characteristics, which are humidity, temperature, sunlight and size, we can create an accurate 3D model. This model would be used for various purposes. For instance, it could be a useful tool to design and fabricate the customized prefab acoustic barriers and plant containers. And it would be helpful for adjusting efficiently the future performance of the vegetation and photovoltaic panels. But the insertion of vegetal elements in infrastructure surroundings can be a tough operation. It requires special skills and techniques. Nowadays, those tasks are performed almost manually and they require a big effort. The prefab containers for vegetal elements would ease the robotic assembly on site.

Aug 1, 2013

By G. J. Hamilton

"THE Royalite-Canada Southern Coleville No. 1 gas strike of August 15th, 1951, and the closely following low gravity black-oil strike of August 23rd, were the first of a series of recent oil and gas discoveries in western Saskatchewan. They are in what is now known as the Coleville field, 25 miles north and west of Kindersley and 30 miles east of the Alberta-Saskatchewan border (Figure 1).Gas flows have been recorded in the Viking sand at daily rates of between 5 and 10 million cubic feet, and black oil of 15° A.P.I. gravity is produced from Mississippian sediments of Banff age at a daily rate .of 50 to 100 barrels on pump.Development drilling was carried on during the winter months, with very little attempt at step-out exploratory ventures. This year, however, a step-out programme to the northeast (Figure 2) is •being carried on in order to determine the position of a possible truncation of Mississippian sediments in that direction. Section 30 of the Coleville area has been fully developed on a 20-acre wellsite basis, and structural information is restricted to local rather than regional interpretation. No attempt will be made in this paper to interpret the Coleville area with respect to the regional geology in any but a general manner."

Jan 1, 1952

By R. C. Wallace

Introduction At a time when the mineral-bearing areas in Manitoba are being fi very keenly explored because of the major developments which are now taking place in that Province, it may be timely to give an analysis of the mineralization in the two major types of deposits, with a view particularly to assist in the intensive prospecting to which the mineral-bearing areas in the Province are now to be subjected. As is already well known, there are two principal types of mineral deposits in the territory- copper-zinc and gold; and attention will be confined almost exclusively in this paper to these two types, with some indication of such modifications of the main types as may be found to be of economic value. The details of the paper are drawn from what is yet a small part of the area of the Province available for prospecting. Enough is now known of the types of mineral deposits which are described in the following pages to justify the expectation that these types may serve as criteria in the search in the newer districts. Doubtless new types will also be found as investigations proceed.

Jan 1, 1928

By M. D. Johnson, R. K. Bezys

"The majority of Ontario's limestone and dolostone production comes from a few Paleozoic carbonate units. In eastern and central Ontario, Ordovician rock units, which are the main sources for production, include the Oxford, Gull River, Bobcaygeon, Verulam, and Lindsay Formations. They are predominantly utilized for aggregate and cement manufacturing, with the Bobcaygeon Formation being used as a source of building stone. Along the Niagara Escarpment, the Silurian Lockport, Amabel, and Guelph Formations are sources for the limestone industry. The largest tonnage of rock extracted by the industry comes from these Silurian units, especially the Lockport and Amabel Formations. These units are used primarily for aggregate, although they are also a source for lime. In southwestern Ontario, the Silurian Bertie Formation and Devonian strata, represented by the Bois Blanc Formation, Onondaga Formation, Detroit River Group, and Dundee Formation, contribute to Ontario's production of lime, cement production and crushed stone. The Detroit River Group (Lucas and Amherstburg Formations) is the main source of the lime and cement produced in the province.Northern areas, which may become significant sources for the industry, include Manitoulin Island, the Lake Timiskaming area, and the James Bay Lowland. IntroductionThe Engineering and Terrain Geology Section of the Ontario Geological Survey has undertaken a geological inventory of all active and abandoned limestone and dolostone quarries in Ontario. This geological study, combined with a commercial study of active quarries carried out by the consulting firm of Derry, Michener, Booth and Wahl, will provide an up-to-date report on the industry in the province and will be published by the Aggregate Resources Section of the Ministry of Natural Resources. This report will follow the format and style of D.F. Hewitt's Ontario Department of Mines Industrial Mineral Reports and Circulars (Hewitt, 1960, I964a, 1964b, 1964c; Hewitt and Vos, 1972). Examinations of the quarries were carried out by geologists in the Paleozoic I Mesozoic Geology Subsection of the Engineering and Terrain Geology Section, and include, in addition to the authors, R,R. Wolf, V.A . Mazur, and D.K. Armstrong in the summer of 1986."

Jan 1, 1988

By W. J. Mcgaughey, R. G. McCreary, S. C. Maxwell, R. P. Young

"Seismic tomography is a process for obtaining images or maps of seismic velocity or other seismic properties of a rock mass. Seismic velocity images reveal variation in elastic moduli which, in tum, are related to several properties required in the geological or geomechanical assessment of a rock mass. Seismic velocity is sensitive to lithology, discontinuities, and in situ stress. Spatial or temporal variation of these properties may be indirectly assessed. Tomographic measurements are sensitive to volumes of ground, rather than determinations at points, or along lines or surfaces, as in conventional geological or geomechanical measurements or mappings.Tomography surveys are complementary to conventional measurements as they have the capability to interrogate a substantially larger volume of ground. They are thus useful in discerning trends or patterns in regions between or surrounding conventional ""point"" measurements of lithology, rock quality, stress, or other parameters of interest. Seismic velocity images give broad indications of trends in velocity; their spatial resolution of ground properties is typically on the order of five to ten per cent of the nominal survey dimension.Research in seismic tomography has been carried out for several years, and the capabilities and limitations of the technique in mining environments are beginning to be understood. This report reviews the present capabilities of seismic tomography surveys in mining, emphasizing rock mechanics applications. Six case studies are used as examples to demonstrate the capabilities of the method in assessing lithological variation, density and orientation of discontinuities, and the effects of stress."

Jan 1, 1994

By P. B. Marchant

"Considerable gold and silver values are lost to flotation tailing from both the South ern Tail orebody and the Main Zone orebody,The underlying mineralogical assemblage of the two ore types is quite different. This paper describes the research strategy employed to determine an economical method to scavenge gold and silver from flotation tailing.Much of the unrecovered gold in the Southern Tail ore is associated with arsenopyrite while silver losses are probably as unliberated tetrahedrite and minor silver-bearing sulphosalts. Processing alternatives tested include bulk sulphide recovery by flotation and gravity, selective pyrite-arsenopyrite separation, cyanidation, and oxidation pretreatments such as pressure leaching and bioleaching to enhance cyanidation response. Gold losses in the Main Zone ore are more closely associated with silver-bearing minerals, pyrite, and siliceous gangue and consequently respond more readily to conventional tank cyanidation. The 5 300 tid carbon-in-leach circuit to treat Main Zone flotation tailing is described in detail.IntroductionEquity Silver Mines Limited's open-pit silver mine, a 70% owned subsidiary of Placer Development Limited, is located 37 km southeast of Houston in north central British Columbia. The deposit consists of two major ore zones, Main Zone and Southern Tail (Fig. I). These zones are within a sequence of Cretaceous volcanic and sedimentary rocks striking 015 degree s and dipping 45 degrees west. Feasibility ore reserves were 28 million tonnes grading 106 g A g/t, 0.96 g Au !t and 0.38% Cu a strip ratio of 2.2 to I. A detailed mineralogical description has been presented and a comparison of the two ore zones is shown in Table I."

Jan 1, 1986

By Cy Jordan, Ben Burdett, Adrian Dance, Jack Rainey

"In 1997, EIMCO Minerals installed a knowledge-based control system on one of the five primary grinding lines at Highland Valley Copper. The objective of the system is to maximise throughput without affecting circuit product size or flotation recovery. The system was commissioned in October 1997 on a SAG mill/ball mill circuit following a plant audit and upgrade of the control instrumentation.The system monitors and controls the SAG mill power, bearing pressure and recycle load by manipulating the solids feedrate, water addition and mill speed. The two ball mill and cyclone circuits are controlled through water addition at various points in the circuit as well as the number of operating cyclones.An on-line particle size analyser is used to measure the cyclone overflow quality. Models of the SAG mill charge level and overflow product size are also incorporated. A method of predicting the SAG mill power response to feedrate changes is used to lessen the effect of dead time for improved mill power control. In the future, inferred measurements of SAG feed particle size and hardness will allow changes in ore behaviour to be predicted and compensated for by the system.This paper describes the development of the project -from installation and commissioning to modifications and refinement -along with prospects for the future.BackgroundIn early 1997, EIMCO Minerals was contracted by Highland Valley Copper to install a knowledge-based or expert system control strategy on one of the five grinding lines in the mill. This was to become the start of the Advanced Control Project at Highland Valley Copper (HVC). This paper will review the progress of the Project as well as discuss the prospects for the future.Following a preliminary engineering study (or plant audit) by EIMCO in 1996, it was decided to implement an advanced control system in order to improve plant operations and increase productivity. The study suggested that such a system had a pay-back period of a few months through increased throughput without loss in flotation recovery. Highland Valley already had successfully applied higher level control through their Elsag Bailey distributed control system (DCS) and this was the next stage in process optimisation."

Jan 1, 1998

By W. P. Clement, M. C. Bell

"PT International Nickel Indonesia, a subsidiary of Inco Limited, mines and processes nickel laterite ores for the supply of nickel matte, primarily to the Japanese market. It has large ore reserves and a substantial portion of its energy requirement is supplied from its own hydro-electric plant. Since the early 1980s, the company has increased its production level and has dramatically reduced its unit costs. Projects are in progress to further decrease costs and recently a major expansion - 31% increase in nominal capacity - has been undertaken, consistent with marketing opportunity in Japan. The expansion project, which has a low capital cost per unit of production, is outlined in this paper.IntroductionPT Inco is a fully integrated mining and smelting facility located in Indonesia on the island of Sulawesi, and is based on a very large, world class nickel laterite orebody located 60 km inland from the Gulf of Bone. Construction of a single furnace line plant started in 1973. Complete supporting infrastructure of townsite, hospital, schools, shopping centres, road systems, and an airport, all had to be built. Prior to completing the first phase, the decision to expand the plant to a three kiln-furnace line was made. A major factor in the decision was the ability to develop the hydroelectric potential of the nearby Larona River. This involved construction of a 30 m high dam, and a 7 km surface canal to the generating station. The penstocks drop 150m to three 55 Mw turbines. The power generated is sufficient to supply the entire electrical load for the complete smelting complex and town site. The unique capability to supply the high smelting energy requirements for a lateritic nickel ore by fully captive hydro power, has, over the past decade insulated PT Inco from the large upward swings in oil prices suffered by other lateritic nickel producers.Wet ore is first partially dried to 20% moisture in two co-currently fired rotary driers, screened on an internal trommel, and delivered to two dry ore storage buildings. The partially dried ore is calcined at 750°C and partially reduced in three large 100 m by 5.5 m kilns. Reduction is accomplished by lancing bunker C oil onto the ore bed at the discharge end of the kiln. The kilns are equipped with five air pipes with onboard blowers to gradually bum the combustible gases generated by the lance oil. The kilns were also originally equipped with two side burners to supply additional heat close to the feed end of the kiln. Calcined ore is transferred by 20 ton refractory lined containers to the furnace feed bins at the top of the smelter. Smelting is carried out in three 18 m diameter furnaces powered by 45 Mw transformers. Slag is skimmed at 1550°C through water cooled breast plates and removed to the slag dump by Haulmaster Carriers. Matte of 25% Ni, 1O% S, 65% Fe is tapped at 1350°C into the converter aisle. The iron is slagged in converters to produce a nickel sulphide matte at 80% Ni. Three rotary Kaldo converters were initially installed. The product matte is granulated, dried, and shipped in returnable rubber bags to Japan. Most of the matte is fluid-bed roasted to nickel oxide and then directly reduced in a second reducing fluid bed reactor at our facilities in Japan.The smelting complex was designed to smelt two million tonnes of dry ore per year, equivalent to 34 000 tonne nickel production at an ore grade of 2% Ni. The cost of the entire project including working capital was $900 million."

Jan 1, 1990