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Improving the Sustainability of Primary Metal Production - The Need for a Life Cycle Approach

Sep 13, 2010

By Jey K. Jeyapalan

A characteristic common to most tailings dam failures caused by earthquakes or excessive rain storm is that the tailings tend to liquefy and flow for substantial distances as a viscous fluid, with the potential for extensive damage to property and life. Failures of El Cobre, Chile (1965), Mochikoshi, Japan (1978), Aberfan, Wales (19661, Buffalo Creek, West Virginia (1972) are examples of such catastrophic incidents. In these four incidents more than 400 lives were lost, and the loss of property was approximately $200 million. In order to be able to assess the potential for damage in case of such a failure, it is necessary to predict the possible extent of flow slide movement. This paper discusses simple procedures for performing such analyses. Also, in order to illustrate the use of these analysis procedures in tailings dam design, two case histories are analyzed.

Jan 1, 1982

By A. T. Harris

Ground quartzite, known in the industry as amorphous silica, is produced from a quartzite deposit near Honey Brook, Pa., by George F. Pettinos, Inc., of Bala-Cynwyd, Pa. The quartzite is mined by the open pit method and processed in a mill at the mine. The operation regularly produces five standard grades of sand and one grade of crushed stone; however, the company accepts special orders and will produce material to meet the customer's specifications. Beneficiation (chiefly crushing and screening) is controlled by laboratory screen tests on samples taken during preparation of the sand. The chief uses of the sand are for foundry operations, furnace lining, concrete aggregate, and Other specialized uses. The quartzite in this deposit is of uniform composition and does not require control by chemical analysis. However, for special purposes, analysis will be furnished.

Jan 1, 1965

THE following employment items ore made available to AIME members on a nonprofit basis by the Engineering Societies Personnel Service, Inc., operating in cooperation with the Four Founder Societies. Local offices of the Personnel Service ore at 8 W. 40th St., New York 18; 100 Farnsworth Ave., Detroit; 57 Post St., Son Francisco; 84 E. Randolph St., Chicago 1. Applicants should address all mail to the proper key numbers in care of the New York office and include 6c in stamps for forwarding and returning application. The applicant agrees, if. placed in a position by means of the Service, to pay the placement fee listed by the Service. AIME members may secure a weekly bulletin of positions available for $3.50 a quarter, $12 a year. MEN AVAILABLE Graduate Mining Engineer, 31, married. Six years' engineering experience, mining and construction, U. S. A. and Alaska. Underground metal mining, production, development, geology, mine engineering. Engineering on airfield construction, earthwork, location work, mapping, topography, road location; office work. Commercial pilot license. Desires position mining or construction. Available 45 days. Prefer Latin America. M-676-477-E-8-San Francisco. Mining Engineer, 42, married, one child. Fourteen years' mining with much supervisory experience in developing and operating metal mines; also mine safety engineering. Familiar with many large and small mines in the western U. S. and Mexico. Excellent references. M-677.345-E-1¬San Francisco.

Jan 1, 1952

By Jean-Pierre Côté, Alexandre Noiseux

"Hatch and ArcelorMittal Mines Canada have combined their expertise to develop a dynamic model of the latter’s Iron Ore Pellet Plant in Quebec, Canada. This model was used to predict the benefits of different expansion projects, as well as asses the best implementation sequence.Two modelling tools were used: a discrete-event simulation software used to develop the dynamic model of the Pellet Plant and an in-house process simulator. The latter was based on operational data and known behavior of the process, and was calibrated with historical data gathered under different operating conditions.The results of the process simulator were used as input values for the dynamic model, which included all of the operation steps of the pelletizing process, from concentrate beneficiation to baking of the pellets. The model has been validated by assessing its capacity to represent adequately the operation of the plant during a 20-month operating period. It was able to reproduce the plant capacity within a precision of 1.2%.Simulated “what-if” scenarios allowed quantifying the production increase associated with the addition of new equipment such as ball mills or balling discs, implemented individually or in combination. Results revealed a potential 10% increase in the annual plant production by adding additional equipment in the two most limiting sectors of the plant, grinding and agglomeration. The simulation results made it possible to quantify the synergistic effect of two projects on plant throughput; the model showed that the combination of two projects resulted in a greater production increase than the sum of the same projects evaluated individually.Now that it has proven reliable, the simulation tool can readily be used by ArcelorMittal Mines Canada process engineers to perform simulations for equipment optimization, and to evaluate the impact of various operating parameters such as equipment availability and tonnage, product mix or concentrate quality. This work showed that a reliable model can be developed based on known parameters in combination with the proper integration of the process knowledge."

Jan 1, 2010

By Göran Bäckblom

The Swedish mining companies LKAB and Boliden, the equipment supplier Atlas Copco, the general contractor NCC and the specialist company Reflex joined forces in 2005 to advance the field of rock technology for the purpose of mining and underground construction. The creation of the company Rock Tech Centre is part of the strategy developed by the Swedish mining industry to strengthen co-operation with industry, academia and society. This paper outlines the current R&D strategies developed for the industry in general, discusses what focus areas are selected and provides some details on the current RTC project portfolio, especially faster and better drifting.

May 1, 2006

By E A. G Marques, P M. Dight, T A. V Costa, K Mercer

Brazilian banded iron formation (BIF), known as ‘itabirite’, is the main host rock for iron ore in the Iron Quadrangle mines, Brazil. Their geneses are controversial and it is agreed that diagenetic, metamorphic and tectonic events, as well as weathering processes, were responsible for the iron concentration. In addition, it is understood that weathering processes are mainly responsible for reducing the original high intact rock strength, and for generating deep weathered profiles with low strength rocks commonly observed in Vale’s mines.A considerable amount of work has been done to correlate the macro and micro aspects of the itabirites as physical, chemical and geotechnical characteristics that directly or indirectly affect the intact rock strength; however, it is not yet clearly understood what effects the weathering processes have on the strength reduction of these rocks and its associated impact on pit slope stability. This forms a key focus of the lead author’s current research work.This paper presents a review of the geological, geotechnical and weathering characteristics of the itabirites, and early results for the evaluations of fresh itabirites from the PhD thesis research being undertaken by the authors at the Australian Centre for Geomechanics, School of Civil, Environmental and Mining Engineering, The University of Western Australia, sponsored by Vale SA.The results showed that to evaluate the density and unconfined compressive strength (UCS) correlation, not only the porosity but also the geological features should be considered, as they are responsible for data dispersion; however, the presented data suggested a trend that provides the confidence to develop advanced studies and a data population increment to establish proper correlations to support a reliable UCS method.CITATION:Costa, T A V, Dight, P M, Mercer, K and Marques, E A G, 2015. An overview of the weathering process, preliminary density and unconfined compressive strength correlations for fresh itabirites in vale mines on the western side of the Iron Quadrangle, Brazil, in Proceedings Iron Ore 2015, pp 241–254 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Emmanuel V. Manlapig

The variables involved in a complex process like flotation can be classified as follows: a. Disturbance variables - which are undesired properties of the process input which affect the value of the process output but which are not subject to adjustment. They are the result of changes in the properties of the feed, like changes in head grade, flow rate, fineness of grind, etc. b. Manipulated variables (sometimes referred to as process variables or control variables) -which are those that are adjusted - reagent addition, aeration, pulp level - in order to compensate for the disturbances in the properties of feed. c. Performance variables (sometimes referred to as controlled variables) -which are those whose values measure the performance of the process. They are properties of the process output such as grade and recovery. The function of a control system is to maintain the process performance equal to the control objective in spite of the disturbances by adjusting the manipulated variables. Attempts at developing automatic control systems for mineral processing operations date back to the thirties and in many of these attempts the results were not surprisingly poor and un-stable. The poor results brought indifference and suspicion towards automatic control on the part of operators and management. The reasons for the apparent failure of these attempts were two-fold: a. the lack of adequate understanding of the behavioural responses of the process from the control point of view, and b. the lack of reliable control instrumentation which could withstand the harsh environment in mineral dressing plants. Many operators had accepted the fact that control of mineral dressing could be best conducted manually. In the case of flotation circuits, control had been virtually based on the skill and experience of operators particularly their ability to identify and rectify poor flotation performance aided by results from the laboratory (chemical) analysis of regularly collected samples from strategic points in the circuit which are at best, hourly collected samples.

Jan 1, 1978

By Thomas P. Meloy

There is much interest in the automation of entire comminution circuits, At the present technological level it is possible to automate a circuit but to date it has not been done, To successfully automate a circuit, a number of problems must be solved. Not all of them are engineering problems. The purpose of this paper is to discuss some of these problems, as certain the implications of these problems and indicate solutions to them. In this paper the term "automation" is used loosely but in the popular sense. Namely, that a plant is automated if a computer is used to control the basic flow of the materials as well as setting the critical parameters in the process. Specifically, the discussion will concern itself with the control of comminution circuits from the dumping of the ore into the primary crusher until the final interface between the comminution circuit and say, the flotation mill in the case of a sulfide ore.

Jan 1, 1965

By S H. Algie, D P. Taplin, S G. Doig

"Suboptimal performance of clusters of hydrocyclones (cyclones), relative to the performance of the individual cyclones that comprise the cluster, is a common phenomenon. The primary cause is well known: uneven distribution of the slurry feed into the individual cyclones. The direct result of uneven distribution is that each cyclone in a cluster performs somewhat differently. Hence, some, if not all, of them do not work at their intended operating points, and the classification is not as sharp as intended. The impact on grade, recovery and milling efficiency will vary depending on the duty of the processing circuit, but the most immediately apparent consequence of uneven distribution is a difference in wear rates in the individual cyclones; this exacerbates the problems of unequal performance of the individual cyclones. In severe cases, and as differential wear proceeds, flows from the individual cyclones may become visibly different. Uneven distribution, once the phenomenon was identified, was seen to be a significant issue in the high-solids hydrocyclone cluster in the ball mill recycle section of Evolution Mining’s Edna May Operation (EMO, Westonia, Western Australia) gold processing plant. In 2012, a FloCEP® hydrocyclone feed distributor system was installed to alleviate the problem. Over the next four years of operation, this innovation has proven its value in the metallurgical and maintenance areas. Individual cyclones now wear at the same rate, greatly reducing the need for operator intervention, as well as increasing overall plant availability through minimising unplanned maintenance. The costs of the installation can be justified by savings in maintenance alone, though the greatest value, as is described in this paper, is in allowing the plant to produce consistently closer to its operational design limits. The FloCEP® system is a low maintenance, readily installed retrofit, based on two patented devices that are combined with complementary proprietary design methodology allowing customisation for specific flow rates and slurry particle properties. Together, these devices produce and distribute a pseudo-homogenous slurry flow without moving parts.Citation:Taplin, D P, Doig, S G and Algie, S H, 2016. Experience with FloCEP® Slurry Flow Conditioning at Evolution Mining's Edna May Operation, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 251–260 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By Kíssia Carolina Bertoluci Cardoso

Para a fabricação de peças de grande porte, o forjamento em matriz aberta é o processo mais utilizado. Porém, se seus parâmetros não forem bem estabelecidos, defeitos metalúrgicos poderão surgir; esses, em sua maioria, provindos do material bruto de fusão, como rechupes e vazios. Para sanar tais defeitos, a deformação imposta na peça deve ser a mais homogênea possível. Neste estudo, a simulação numérica foi utilizada para verificar a relação entre a largura de contato matriz-peça e a espessura da parede de peças vazadas, com o objetivo de analisar o conceito de razão de mordida para esse tipo de geometria. Utiliza-se um billet cilíndrico inicial de 450 mm de comprimento, 360 mm de diâmetro externo e 120 mm de diâmetro interno, de material AISI 4140. As razões de mordida estudadas variam entre 0,2 e 1,4, sendo impostas variações de tempo em cada processo. Após análise, pôde-se verificar que as geometrias que apresentam distribuições mais homogêneas de deformação utilizaram razão de mordida de 0,4.

Aug 16, 2017

By Walter Jr Duke

The security of explosive materials is a vital concern to every mine, quarry and contractor engaged in blasting. Proper construction of magazines and sufficient locking mechanisms are the fundamental means of maintaining secure storage. The object of this paper is to review the proper methods of construction of storage facilities for explosives as defined by the Alcohol, Tobacco, and Firearms regulations. Subpart K subsection 55.208 and the Institute of Makers of Explosives recommendations.

Jan 1, 1991

By Lucas Coelho da Silva

Também chamado de PRFV, esse tipo de material é usado em diversos segmentos da indústria e a escolha por esse material é devido ao aprimoramento de suas características ou propriedades se comparados com os metais, cerâmicos ou polímeros isoladamente. O tempo médio de um incêndio foi estimado fazendo-se um levantamento de incêndios de média a grandes proporções e esse tempo usado para calcular a temperatura média do incêndio para materiais hidrocarbonetos. O tubo tem sua temperatura limitada em 200ºC, temperatura de degradação do polímero. As amostras foram envelhecidas no forno a uma temperatura próxima da deterioração e depois resfriadas à água e ao ar. Foi comprovado através da análise da transferência de calor que quanto mais perto o material estiver da fonte de calor, maior vai ser a energia incidente sobre o material. O estudo foi feito considerando uma fonte pontual de calor. Além disso, é feita uma análise do tempo que uma estrutura feita do mesmo material levaria para atingir a temperatura de degradação, descartando seu uso posterior.

Aug 16, 2017

By Mike D. Adams

Testwork was conducted on loaded carbon samples from a small gold mine in South Africa. It was shown that a 75% saving in reagent consumption in the Zadra elution circuit could be achieved by adopting a cyanide-free elution approach, i.e. by cutting back the NaCN level from 1 % to nil, and the NaOH level from 3% to 1 %. This process change was also shown to result in a 20% improvement in the elution kinetics. Furthermore, it was also shown that a 50% enhancement in elution rate over the current situation could be achieved by use of an eluant containing 0.5% NaOH and 0.15% NaCN, corresponding to an 84% saving in reagent consumption. A further improvement in elution kinetics was found to occur by increasing the NaCN level to 3%, but this would lead to a concomitant increase in reagent consumption, due to the decomposition of cyanide at high temperatures. The presence of base metals loaded onto the carbon was also found to have a significant effect on the elution. Copper tends to adsorb as Cu(CN)2- during the adsorption stage, and acid washing converts this species to CuCN. Copper in this form is not eluted during cyanide-free elution, whereas it is eluted during a conventional cyanide elution, consuming the initial cyanide in the process. The elution data was analysed and the fit to a simple model was verified.

Jan 1, 1995

By Rossana Bezerra de Azevedo Vasconcelos Seabra de Melo

O presente estudo apresenta um método de avaliação de desempenho de operadores na análise de ferro via úmida baseada na Norma ISO 2597-2, utilizando dados de carta de controle do processo como fonte de informação. A partir do Processo Analítico Hierárquico (AHP), definiram-se pesos que refletem o desempenho dos operadores quanto à produtividade, precisão e veracidade, indicadores estes que são combinados posteriormente num indicador geral de desempenho (IGD). Dados da carta de controle do Laboratório Químico do Terminal Marítimo de Ponta da Madeira (TMPM) foram utilizados para alimentar o IGD e gerar uma classificação dos operadores, possibilitando tomadas de decisão, tais como a dedicação exclusiva dos melhores operadores na análise de ferro e a realocação dos demais para outras atividades, e a identificação dos pontos fracos de cada operador com inferior desempenho, de forma a direcionar capacitações. Além destas melhorias diretas, verificou-se a possibilidade de utilizar o desempenho no IGD como critério para promoções dos operadores, servindo estas como incentivo para a equipe na busca contínua de melhoria em sua habilidade analítica, assim como o aumento da produtividade.

Aug 2, 2018

By Charles L. Parsons, R. B. Moore, S. C. Lind, O. C. SCHAEFER

Early in 1912, from information received by the Bureau of Mines, it became evident that quantities of valuable radium-bearing ore from Colorado were being exported for manufacture in foreign coun- trics and that at least part of the manufactured product was being returned to this country and sold at a price entirely incommensurate with that received by the miner and the prospector. Consequently, in line with its efforts to increase efficiency in the mining and treat- ment of mineral resources, the Bureau of Mines undertook an inves- tigation of conditions. Results of this preliminary investigation were published, in the summer of 1913, as Bulletin 70, which gave an out- line of the radium deposits of the West, the conditions of mining, the wastes involved, and the status of the production of radium from its ores. At about this time newspapers and medical journals were publish- ing statements regarding the value of radium in cancer therapy. These reports, although many of them were exaggerated, brought out clearly the remarkable virtue of the gamma rays for the treat- ment of cancer and other malignant growths. In view of the fact that the largest known supplies of radium ore in the world are in the States of Colorado and Utah and on the public lands of the United States, it was deemed highly important for the Bureau of Mines to study the production of radium in detail. Such study, it was hoped, would enable the prospector and miner to obtain a fairer price for the ores and would furnish information necessary in case Congress appropriated funds to develop methods for extracting radium from ore on the public lands under Government supervision, to be supplied at cost to the hospitals of the Army, Navy, and Public Health Service.

Jan 1, 1915

By José Arango

El presente texto describe la aplicación del sistema MIMS en las estadísticas de producción de la Sociedad Minera Cerro Verde S.A. El sistema fue instalado inicialmente para el control de mantenimiento de los equipos, movimiento logístico, y contable. Posteriormente, se realiza el cambio del sistema de información manual a un sistema computarizado, donde se analiza los problemas cotidianos del sistema de información antiguo y se los compara con los cambios experimentados. En ese sentido, el objetivo de este sistema es facilitar el alcance de sus metas a la organización mediante el uso eficiente de todos sus recursos disponibles: personas, información, equipos, tecnología, y materiales diversos. La eficiencia de la utilización del recurso de información es medida por la relación del costo para obtenerla y el valor del beneficio derivado de su uso.

May 25, 1998

By R. Mukherjee

Consistency of Run-Off-Mine (ROM) quality plays an important role in mineral processing which is not very often talked about. The major impediment is limitation of sampling ROM ore, which makes processing plants to run without any realtime feedback on ore quality that comes in. The process of direct determination of Run-Off-Mine (ROM) ore quality is expensive and time consuming as drawing and preparing representative samples from blasted muckpiles are constrained by large sample size and inherent heterogeneity in terms of size and chemistry. In absence of techniques for direct measurement of quality, monitoring and control of ROM, feed to the processing plant at Joda East Mine, like all other iron ore beneficiation plants worldwide, is largely based on blasthole sampling and subsequent chemical analyses of blastcone chips. While such indirect methods proves to be more accurate for representing whole of a mining block or blasted muckpile (~30-50KT/blast), it is indeed a challenge to ascertain and predict day to day input quality for a part there off. This eventually leads to a gap between predicted and actual ROM quality, resulting in difficulties in process control, in turn, and leading to wide swings in product quality. Hence, it is imperative to bridge the gap between predicted and actual ROM quality by arriving at means, which ensure consistent plant feed grade to deliver consistent output. The paper discusses an efficient and affordable alternative for effective prediction of ROM alumina which has been developed by integrating blasthole quality database in GPS based Truck Dispatch System (GPS-TDS) at Joda East Mine. Initially, GPS-TDS has been installed for optimizing production parameters only, but this development has helped in further utilization of GPS-TDS for real time quality monitoring by improving ROM grade prediction and scheduling from several ore blocks in active mining areas. Keywords:run-off-mine (ROM), blast hole, feed grade, GPS-TDS

Sep 1, 2012

By E. S. Moore

In order that a logical conclusion may be reached regarding the possible occurrence of commercial iron deposits in Canada it is necessary to consider some important producers found elsewhere on this continent. A study of such deposits reveals the fact tl:~at a number of distinct types are producing large tonnages of ore. These types may be classified according to origin and occurrence as follows: (1) Bedded sedimentary deposits. (2) Contact metamorphic deposits. (3) Residual ores. (4) Lenses in metamorphic rocks and m some cases of uncertain origin. In addition to the types listed there are other deposits which have contained or do contain considerable ore and they either have not been worked on a large scale or they have been nearly exhausted. These include the following types: (1) Magmatic segregations. These are mostly titaniferous magnetites. (2) Dikes of magnetite of igneous origin. (3) Bog and lake ores in glacial drift. (4) Black sand placers.

Jan 1, 1925

By Rodrigo Citrangulo Daniel Luiz

Este trabalho tem como objetivo demonstrar por meio de estudos técnico- científicos e de casos, como foram eliminadas as falhas devido a quebras dos elementos de proteção de sistemas de transmissão de torque (pinos de cisalhamento) no trem Laminador 2 (TL2) da Arcelormittal Piracicaba. A quebra de pinos de cisalhamento no TL2 são uma constante desde o inicio da operação do Laminador 2, sendo que diversas tentativas foram feitas no sentido de eliminar as quebras porem sem sucesso, o que demonstrou a necessidade de uma abordagem metodológica do problema. Este estudo, baseado na analise dos projetos dos equipamentos envolvidos e das praticas de manutenção adotada, orientou o redimensionamento dos elementos de proteção do sistema de transmissão de torque e o desenvolvimento de um novo sistema de proteção, utilizando o drive do motor para fazer a segurança do sistema de transmissão além da revisão e implantação de novas rotinas de manutenção nos equipamentos. O resultado obtido demonstrou a importância do profundo conhecimento tanto do projeto do equipamento quanto da avaliação e conhecimento empírico da manutenção de campo, conjunto este de informações que é indispensável para se garantir o desempenho dos equipamentos permitindo uma produção livre de imprevistos.

Jul 30, 2018