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By John (Jack) D. Young, Frank M. Wheeler

Metallurgical plants are typically large, complex facilities. Their design is a multidisciplinary activity with a wide range of inputs, based on: the business case; metallurgical and process requirements; and the main processing equipment selection. Many constraints limit what can be achieved. Appropriate phasing of the design and development, and clear go/no-go decision criteria, are critical to successful implementation of a plant design project. Risk management concepts are used as a framework for successful project development, working from the business case, through project development, to implementation and startup, paying constant attention to technology, safe design, and sustainability. 1.1 INTRODUCTION The subject of “Metallurgical Plant Design” is the design of metallurgical plant facilities in the broadest sense. Plant design represents the culmination of many multidisciplinary activities: knowledge of process metallurgy is applied to design facilities to manufacture useful, economical, metal-based products. In the field of metallurgy, plant design is often overlooked, and its unique requirements are commonly not well understood, let alone appreciated. This book is a contribution to remedying this situation. The focus is the specifics of the metals industries, because an extensive literature already exists on the general topic of plant design.

Jan 1, 2015

By J-F. Magnan, M-A. Thibault, R. Boulianne, C. Gauthier, J-P. Gagné, G. Dufour

During the production of aluminium in smelters, the anodes used in electrolysis cells have to be replaced frequently. Anode butts are usually placed on anode trays for transportation and cooling, a practice during which Hydrogen Fluoride (HF) is emitted in large quantities. Covers developed in 2000 by Alcoa Deschambault to fit on the anodes trays were implemented, resulting in significant reductions of HF emissions. However, the covers are expensive to maintain and use short-life consumable parts. In January 2004, STAS and Alcoa decided to develop a more efficient design of cover, with lower maintenance costs and no need for consumable materials (like soft cushions). This paper presents a summary of the work performed to develop the new design as well as a summary of the test results.

Jan 1, 2006

By L. Li

Backfill is increasingly used in underground mines, as it can help reduce the environmental impact from mining operations. However, the primary objective of backfilling is to provide safe working space for miners, by improving ground stability conditions. As cement is often added to the backfill, a critical issue is the determination of the required backfill strength (cohesion) due to the binder. This value is usually obtained from a solution proposed by Mitchell and co-workers, in the early 1980?s, for stopes with an exposed backfill face. This paper presents a brief review of the Mitchell et al. solution, with some of its main limitations. Some of the recently developed solutions for backfill design are then summarized and discussed.

Aug 1, 2013

Phelps Dodge has recently operated a commercial scale, super fine grinding circuit of copper concentrates for use in a medium-temperature pressure leaching process. Two 355 kW vertical stirred mills were installed in series, targeting a grind of 80% passing 7.5 µm and 98% passing 15 µm as outlined in Phelps Dodge's concentrate leaching patent portfolio. This paper details the operation and results of the test program at Bag dad, as well as some of the operating challenges encountered.

Jan 1, 2007

By L. Tafaghodi, A. Hosseinpour

"Silicon is considered as the most appropriate semiconductor material for manufacturing solar cells because of its natural abundance and being nontoxic. The transferable knowledge and technology from the electronics industry and the long history of silicon-based semiconductors are also assisting the domination of silicon as the most common semiconductor material. Developing an environmentally and economically viable process for producing solar grade silicon has been one of the main challenges in the silicon industry in the past few years. Metallurgical refining processes have received significant attention because of their high productivity and low cost. Slag refining is one of the purification methods which is based on oxidation of the impurity elements, followed by its dissolution into a slag phase. This article presents a review of various slag refining processes that have been employed for purification of silicon and silicon alloys. SiO2, CaO, CaF2, CaCl2, Al2O3, MgO and Na2O are the major components of the slags used for silicon refining. These slags can be classified into three main categories including binary, ternary and quaternary slags.INTRODUCTION Silicon can be categorized into three different grades based on its application or purity: metallurgical grade silicon (MG-Si) with purity of ~98 %, solar grade silicon (SoG-Si) with purity of ~99.99999 % and semiconductor grade silicon (SeG-Si) which has the purity of 99.9999999 % (Johnston & Barati, 2010; Krystad, Tang, & Tranell, 2012; Tang, Øvrelid, Tranell, & Tangstad, 2009). Producing SeG-Si is carried out through an energy-intensive and complicated process named Siemens. This purification process is relatively slow and involves using toxic and corrosive reagents (e.g. Trichlorosilane). At present the majority of SoG-Si is produced via Siemens or Siemens-like processes and there is very limited production via processes dedicated to SoG-Si. Because of the difference in silicon specifications required in microelectronics and photovoltaic industry, and the cost and energy associated with the Siemens process, an interest has emerged to develop technologies dedicated to producing low cost SoG-Si (Istratov et al., 2003; Johnston, Khajavi, Li, Sokhanvaran, & Barati, 2012; Mitrašinovic, D'Souza, & Utigard, 2012; Wu et al., 2012)."

Jan 1, 2017

By R. K. Mishra, A. Kula, X. Jia, M. Niewczas

The mechanical properties of Mg-Gd and Mg-Y solid solutions have been studied under uniaxial tension and compression between 4K and 298K. The results reveal that Mg-Gd alloys exhibit higher strength and ductility under tension and compression attributed to the more effective solid solution strengthening effect and grain boundary strengthening. Profuse twinning has been observed under compression, resulting in a material texture with strong dominance of basal component parallel to compression axis. Under tension, twining is less active and the texture evolution is affected mostly by slip. The alloys exhibit pronounced yield stress asymmetry and significantly different work-hardening behaviour under tension and compression. Increasing of Gd and/or Y concentration leads to the reduction of the tension-compression asymmetry due to the weakening of the recrystallization texture and more balanced twinning and slip activity during plastic deformation. The results suggest that under compression of Mg-Y alloys slip is more active than twinning in comparison to Mg-Gd alloys.

Jan 1, 2015

By Claudio Rocha Rosales

"Peñoles is a mining group with integrated operations in the smelting and refining of non-ferrous metals, and is also a chemicals producer. Peñoles is the world’s foremost producer of refined silver, metallic bismuth and sodium sulphate and is the leading Latin American producer of refined gold, lead and zinc. The Met-Mex Peñoles Zinc Plant commenced operations in 1973 with an annual production capacity of 105,000 t/y. Year after year the production has been increased, and at present, the production capacity is 240,000 t/y. In this paper, the leaching process,particularly the operation of the jarosite circuit is reviewed ,specifying process improvements to treat high iron calcines.INTRODUCTIONThe purpose of the leaching process is to recover the metals, mainly zinc,through a series of extraction stages with sulphuric acid solutions, which progressively increase the zinc recovery. After the series of acidification stages,the solution, which is rich in iron, is sent to the jarosite circuit to separate the zinc from the iron (Garcia & Valdez, 1996).The first step of the leaching process is the neutral leach circuit which produces a zinc sulphate solution that is sent to the purification section for the removal of impurities such as cadmium, cobalt and copper, after this solution is sent to the tankhouse to feed the electrolytic cells."

Jan 1, 2016

By M. A. Halim, V. I. Lakshmanan, Z. Jankovic

An innovative mixed-chloride process for the separation of iron from lateritic ore is described. The separation of Fe(III) from leach liquor is an important process step for the recovery of nickel and cobalt. The patented process of Process Research ORTECH Inc. uses a lixiviant containing hydrochloric acid (HCl) and magnesium chloride (MgCl2) for the leaching of lateritic ores/concentrates followed by the selective solvent extraction step of Fe(III) over other value metals such as Ni and Co. The use of MgCl2 increases the activity of the hydrogen ion in the lixiviant, which reduces the consumption of HCl in the leaching stage and enhances the formation of HFeCl4-, thereby increasing the solvent extraction efficiency of Fe(III) with ketone. The process produces high purity iron oxide (Fe2O3) and regenerates HCl by the pyrohydrolysis of the FeCl3 rich pregnant strip solution. The developed process flowsheet is in closed loop, economically attractive and environmentally friendly.

Jan 1, 2015

By M. Reda

Erosion corrosion is acceleration in the rate of corrosion attack in metal due to the relative motion of a corrosive fluid and a metal surface [1]. The increased turbulence caused by pitting on the internal surfaces of a tube can result in rapidly increasing erosion rates and eventually a leak [2]. Engineers and scientists in different disciplines have worked for many years on methods of complete protection from flow induced corrosion or partially reducing corrosion of this type, and they have proposed or applied different countermeasures [2]. The accident at the Surry-2 nuclear power plant (USA) and other similar incidents have once again disturbed the scientific-technical community. This has forced the plant operating personnel and the management to undertake wide-ranging measures in order to discover on time, assess, and monitor such cases. In these extreme cases, protective coating and even metallic bulk material coating (the substrate itself) may suffer considerably from mechanically induced damage [2]. At high velocities, the "leaching out" dissolution reaction of particular, for example, steel elements at the solid-liquid interface become the rate determining step. One practical example for the difference between erosion corrosion and flow induced corrosion is the famous steam eruption from a Japanese [3, 4] nuclear power plant cooling system at the pressurized water reactor (PWR), turbine and in the condenser-steam generator connecting pipe. The rupture occurred in the carbon steel pipe connecting the condenser and steam generator. The damage occurred in the easily eroded/corroded carbon steel at a vulnerable location downstream of an orifice plate, In general, when there is significant reduction in pipe thickness through erosion/corrosion, distinctive patterns are visible, but those patterns were not observed in this case, Thus one can speculate that another phenomenon is possibly controlling, Fluid flow within pipes reduces the pipe thickness leading to an eventual rupture, The thickness reduction mechanism is erosion/corrosion, One example is "cavitations corrosion", Erosion and corrosion occur at the same time, and it is difficult to determine which one is dominant, Therefore, the term, "erosion/corrosion," is used [5]. In the atomic energy field, the terms "Flow Accelerated Corrosion" and "Flow Induced Corrosion" are also used. It is the purpose here to show that during flow induced corrosion a different mechanism may possibly be operating and in some cases it can be different from the well known erosion corrosion. Another example is fretting failures in early Canadian nuclear steam generators which was thought to be due to excessive vibration caused by high.

Jan 1, 2010

An optimized long-term mine planning determines the best order of material extraction, so that the Net Present Value (NPV) becomes maximum. In the case of oil sands surface mining, one of the key constraints in NPV maximization is the volume of tailings slurry that will be generated downstream. Specifications of tailings slurry are also important from environmental perspective. Moreover, most of the material that will be used for the reclamation of tailings ponds in later periods is generated in extraction and processing of oil sands. In this paper, an integrated optimization framework is proposed to maximize the NPV of the produced oil sands, with respect to tailings capacity constraints and reclamation material requirements. A mixed integer linear programming (MILP) model is developed to find the optimal solution for long-term mine planning problem. The proposed model is coded in Matlab and has been run using CPLEX for verification. The results for real-case oil sands dataset show that the optimal production schedule meets material requirements for reclamation, tailings volume is within tailings capacity range in all periods and the production schedule follows the predetermined horizontal direction.

Aug 1, 2013

By Hans Lundberg

During the last few years, geophysical methods have been introduced to aid mining geologists and mining engineers in locating mineral deposits. These methods have been developed as the result of investigations of various physical characters of minerals and rocks. In prospecting for ore-bodies, electrical methods have proved most successful. These methods are based on the great differences in electrical properties, and especially in conductivity, between ore minerals and rock minerals. The electrical resistance of the common minerals, rocks, and ores in ohms per cubic céntimeter is given in the following table: [ ] The first attempts at electrical prospecting were based on observing currents of polarization around certain ore bodies, which currents it was possible to measure. This method has been developed by Prof. Schlumberger and has been utilized by him successfully. He is represented on this continent by Mr. Sherwin Kelly, who has successfully operated the method here.

Jan 1, 1926

By P. E. Davidson

The management of solid waste is known to be a large and increasing problem in high-population areas throughout the world. It is not necessary here to add further definition to the nature and magnitude of the problem. Instead, it is the purpose of this paper to describe a new process, called the Andco-Torrax System, which will be of use in converting municipal solid waste into useful energy forms and a granulated slag by-product. The paper includes a description of the first commercial plant for the process.

Jan 1, 1977

By Brian C. Asbury

Gold-bearing quartz veins with auriferou pyritic wall rock alteration haloes at the Komis deposit near Waddy Lake in northern Saskatchewan occur in fractured Archean intermediate volcanic rock flanking a plutonic felsic intrusion. Three ore zones totalling 1.5 million tonnes grading five g/t gold have resulted from a combination of patterns of high density of fracture-filling quartz veins created by contrasting competencies of four predominant rock types and preferential gold deposition in magnetitebearing andesite host rock. Pre-glacial surface weathering remobilized gold from a nearby pyritized intermediateto- felsic dyke to form the EP Zone with a wide variety of supergene accessory minerals. Much of the EP Zone wa eroded by glacial action to forn1 a highly anomalous gold-bearing till dispersion train which facilitated its di covery.

Jan 1, 1986

By S. Parkash, A. J. Szladow

Vigorous agitation of suspensions of coking coals in water (or light mineral oils) will often result in catast rophic loss of caking properties. It is shown that this deterioration is not a consequence of oxidation of the coals (by dissolved oxygen), but that it can be qualitatively connected with internal "solid-state" reactions which appear to derive their activation energies from cavitation of the liquid.

Jan 1, 1971

By M. J. S. Innes

Abstract This paper is an account of an investigation made by the Dominion Observatory with a gravity meter and magnetometer over sulphide concentrations at East Sullivan, Val d'Or, Que., in June, 1947. The topographic relief over the area does not exceed 20 feet. The overburden varies from 0 co 50 feet. The west orebody had been outlined by extensive drilling. The average density contrast between the sulphide body and surrounding rocks is 0.5. Two hundred and sixty gravity and one hundred and ninety magnetic stations were observed. The results are shown on contour sketches. A derailed account is given of the methods employed to reduce the gravity observations. The survey shows that both gravimetric and magnetic methods are useful in delineating sulphide deposits under the conditions in which they occur at East Sullivan. The results indicate that the buried contact of the syenite intrusive southeast of the orebody could be traced with the gravimeter and chat the magnetometer was of little value for that purpose. Gravity anomalies due to the varying depths of overburden are negligible as compared to the magnitude of the total anomalies. Introduction The project was first suggested at a meeting of the Associate Committee on Geophysics of the National Research Council in September, 1946. At that time it was pointed out that the accuracy and speed of operation of the new gravity meters made them of special importance for geophysical prospecting and it was highly desirable to have an objective test of the performance of an instrument of this kind in delineating an orebody of known dimensions and density characteristics. Several years ago, a private company did some work with a gravimeter over the Amulet deposits, near Noranda. Unfortunately, the topography there is rather rugged, with hills and ravines exceeding 100 feet, so that the topographical effects rendered it impracticable to distinguish between anomalies due to the sulphides and those due to surface irregularities. An orebody of a typical nature, where the disturbing topographical corrections were not excessive, was therefore sought.

Jan 1, 1949

By Harold L. Gibson, Don H. Rousell, Ian R. Jonasson

"Abstract - The Sudbury Structure consists of three major components: 1) the Sudbury Basin; 2) the Sudbury Igneous Complex which surrounds the basin as an elliptical collar; and 3) an outer zone of shatter-coned and intensely brecciated footwall rocks. Although the Sudbury Event which formed the structure may be unique, the area has, in fact, been shaped by a series of tectonic, magmatic and mineralization events which can be considered in terms of two Wilson cycles of continental extension and closure. The first cycle, from 2500 to 1700 Ma, included the following events: doming (uplift of Levack Gneiss Complex); NE-SW extension (Matachewan dikes); N-S to NW-SE rifting (faults, mafic intrusions, sedimentation, and Ni-Cu-PGE and U mineralization); NW-SE extension (Nipissing diabase, and Ni-Cu-PGE, Ag, Co mineralization); and NW-SE and NE-SW closure (Penokean Orogeny, 1900 to 1700 Ma) with superimposed meteorite impact (1850 Ma, Ni-Cu- PGE, Zn-Cu-Pb deposits). The second cycle, from 1700 to 1000 Ma, included: N-S extension (alkali metasomatism, Au); N-S extension (hornblende diabase dikes along the Murray fault set); NNESSW extension (olivine diabase dikes); NE-SW extension (Fecunis Lake fault set); and NW-SE closure (Grenvillian Orogeny).The rich and diverse Ni-Cu-PGE and subordinate Zn-Pb-Cu and Au mineralization of the Sudbury region is related to endogenic and impact-triggered crustal extension and magmatism. The Sudbury Structure apparently was the site of a triple junction or hot-spot. The Sudbury ores, although located within an impact structure, are analogous in terms of age and tectonic setting to Ni-Cu-PGE and Zn-Pb-Cu ores elsewhere in the world. Meteorite impact accentuated on-going ore forming processes and magmatism at Sudbury."

Jan 1, 1997

By J. P. Harrison, M. Grenon

"This paper summarizes the results of numerical studies on drift stability in moderately jointed rock masses. It investigates the relative pertinence of geomechanical factors such as joint orientation, spacing and stress regime. This is undertaken using a distinct element model and a series of parametric studies. IntroductionIn evaluating the stability of drifts in jointed rock, it is often necessary to compromise by employing models that capture the complexity of the rock mass, but which are still simple enough to allow for their routine implementation. The distinct element method can arguably provide an eloquent method to accomplish this. This paper explores the applicability of the method by means of a parametric study aiming to identify the dominant factors that influence the stability of drifts in moderately jointed rock. To this end a commercially available 2D distinct element numerical model was used. A series of techniques are presented in an effort to quantify the results of any instability predicted by the model.This paper also demonstrates a case study where a 3D joint network model was integrated into the distinct analysis software package. The advantages, as well as the current limitations of this approach, are discussed."

Jan 1, 2001

By Harold L. Gibson, Don H. Rousell, Ian R. Jonasson

"The Sudbury Structure consists of three major components: 1) the Sudbury Basin; 2) the Sudbury Igneous Complex which surrounds the basin as an elliptical collar; and 3) an outer zone of shatter-coned and intensely brecciated footwall rocks. Although the Sudbury Event which formed the structure may be unique, the area has, in fact, been shaped by a series of tectonic, magmatic and mineralization events which can be considered in terms of two Wilson cycles of continental extension and closure. The first cycle, from 2500 to 1700 Ma, included the following events: doming (uplift of Levack Gneiss Complex); NE-SW extension (Matachewan dikes); N-S to NW-SE rifting (faults, mafic intrusions, sedimentation, and Ni-Cu-PGE and U mineralization); NW-SE extension (Nipissing diabase, and Ni-Cu-PGE, Ag, Co mineralization); and NW-SE and NE-SW closure (Penokean Orogeny, 1900 to 1700 Ma) with superimposed meteorite impact (1850 Ma, Ni-Cu- PGE, Zn-Cu-Pb deposits). The second cycle, from 1700 to 1000 Ma, included: N-S extension (alkali metasomatism, Au); N-S extension (hornblende diabase dikes along the Murray fault set); NNESSW extension (olivine diabase dikes); NE-SW extension (Fecunis Lake fault set); and NW-SE closure (Grenvillian Orogeny).The rich and diverse Ni-Cu-PGE and subordinate Zn-Pb-Cu and Au mineralization of the Sudbury region is related to endogenic and impact-triggered crustal extension and magmatism. The Sudbury Structure apparently was the site of a triple junction or hot-spot. The Sudbury ores, although located within an impact structure, are analogous in terms of age and tectonic setting to Ni-Cu-PGE and Zn-Pb-Cu ores elsewhere in the world. Meteorite impact accentuated on-going ore forming processes and magmatism at Sudbury."

Jan 1, 1997

By J. Dubinski

Underground mining of copper ore in the Legnicko-Glogowski Copper District basin generates a number of seismic events, whose energy often exceeds 108 J (Butra, 2010). The number of tremors and their location shows that the area of rock mass involved in the deformation and failure processes significantly exceeds the area of mining operations. Locations of seismic foci of high energy tremors, as well as the aftershocks that accompany them, extend hundreds of metres, confirming that processes to restore the energy balance of rock mass occur in a short amount of time and over a wide area. Thus, an area of similar size should be considered in predictive analyses of the tremor?s position. It should be emphasized that a large portion of the rock mass still has a level of freedom resulting from the way the rock mass is held together and its geometric continuity. This level of freedom is dependent on the scale and duration of mining, the number and size of natural structures, and rock mass pressure, including gravitational pressure constricting individual fragments of rock mass in the area (Burtan, 2012). It can therefore be assumed that in real conditions, areas where mechanical strength of the layers has been exceeded may be located a considerable distance from each other and do not necessarily need to coincide with the working area location. In this sense, a rock mass influenced by mining exploitation is essentially a rock mass in which numerous fragments with concentrated energy exist simultaneously. Energy will be released within these rock mass areas each time rock mass strengths are exceeded by the induced stress changes related to mining operations. This paper presents a discussion on how to predict the location of seismic activity areas based on a change of position of seismic energy equivalents. This parameter is calculated for a given set of seismic tremors with defined foci coordinates. For a given set of seismic tremors, the location of seismic energy equivalents may be used for predicting the location of high-energy seismic events.

Aug 1, 2013

By Deepak Bhadouriya, Saurabh Singh, Aditya Raj Suman

"An experimental study of chemically enhanced filtration and dewatering of fine coal slurry with and without additives was carried out. The experiment involved determination of effect of slurry concentration, additives (cationic, anionic and nonionic), filter area, filtration velocity, particle size and cake resistance on dewatering and filtration using vacuum filtration cell. Finally, the rate of filtration and dewatering and optimum amount of additives used were determined under suitable filtration condition. Overall, it was found that the filtration and dewatering characteristics were enhanced by increased slurry concentration, larger filter area and larger particle size. In addition of additives, the kerosene was found to be best for enhancing the filtration which yielded cake moisture reductions of approximately 17% by weight. At optimum dosages, the final cake moisture contents were reduced by 3.6% and 5.8% by weight using the appropriate surfactant and flocculent, respectively.INTRODUCTIONFor India, it is estimated that coal constitute a principal source of energy for the next several decades. It is majorly used at thermal power plants to generate electricity and also to a great extent in steel and cement industry. It has been observed that its consumption is increasing so as to meet the energy requirements of the country. It has been found that in a coal preparation plant; approximately 20-25 percent coal is of the mined coal of the range below minus 0.5 mm (28 meshes). Generally, this fine fraction is discarded due to its high cost of processing and further utilisatisation is very minimal. But with ongoing research and development for advanced clean coal technology, various new techniques have been evolved to maximize the utilization of available coal. In recent time technologies such as column flotation, cleaning of fine size coal to lower the ash content and low pyretic sulfur is feasible at high recovery value. But in various researches it is found that one of the biggest hurdles in utilization of fine coal cleaning technology by the coal industry is the economic dewatering of the fine clean coal product. Thus, until an economical and practical solution to dewatering of fine clean coal is achieved, the efforts devoted to developing fine clean coal technology will be wasted. In this paper an effort toward enhancing and developing the optimum technique of dewatering and filtration of fine coal slurry has been made."

Jan 1, 2016