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By David Mitchell, Daan Delport, Frik Marx, Mike Shapiro

The use of copper cooling elements to enhance refractory lining life in pyrometallurgical vessels is common in modern furnace design. Copper elements typically incorporate a base panel with cast in cooling passages and an integral extended surface (formed of pins, fins or similar) onto which suitable refractory material is cast. The metallic, conducting parts are located towards the cold face of the lining, with the refractory material interposing between the coolers and the process. The coolers are designed to arrest wear of the refractory material by freezing a layer of slag or partially reacted material onto the hot face, thereby rendering the lining inert to further attack [1]. These coolers have achieved success in new furnaces and relining of existing vessels. The freeze layer is prone to mechanical damage during operational and process instability. The coolers must be capable of extracting the additional heat flux under upset conditions to facilitate rapid self-repair of the freeze layer and prevent further refractory wear in the intermittently exposed areas. However, operational experience has shown that the high heat flux capabilities of the copper coolers have some disadvantages, especially in processes producing vapours which form corrosive compounds when condensing onto the cold surfaces of the coolers. When corrosive conditions develop, the entire composite will fail due to loss of structural integrity, and as a result of leaks from the cooling water passages. This paper describes recent developments in the approach to the design and manufacture of copper cooler panels customized to achieve specified heat fluxes and temperature profiles, thereby reducing the formation of corrosion mechanisms in applications with corrosive gaseous environments and enhancing refractory lining life. Condensation formation prevention is achieved by adjusting the geometry of the cooler and selection of suitable materials of construction.

Jan 1, 2007

By M. Menéndez

Enhanced gravity separation appears to be one of the most promising methods for processing all types of <200-µm coal feeds and tailings. Systems based on this technology are reviewed, and the results of investigations based on C900 Multi-Gravity Separator tests conducted to assess the treatment of <200-µm, extremely difficult-to-wash coal settling pond tailings are presented. Multi-Gravity Separator processing tests of ultra-fine tailings with a high clay particle size content (22.6% <10 µm and 60.1% <40 µm) and a 69.56% ash content show that this material can be effectively treated after desliming (<10 µm) of clay-size particles to produce a coal with a 20.6% ash at a separator combustible material recovery of 69.3%. Desliming is shown to be critical in reducing coal ash content and combustible material recovery. Similar improvements are anticipated in the recovery and separation pro-cesses for other enhanced gravity separation systems from the desliming of feeds. Although not a conventional form of treating Multi-Gravity Separator data, the existence of well-defined polynomial relationships based on the product of drum shake amplitude and shake frequency relative to product coal recovery, product ash content and yields at varying wash water flows is demonstrated. Low-amplitude and intermediate- to high-frequency bed agitation are shown to produce optimum ash reduction results.

Jan 1, 2007

By Y. Wang, S. Sridhar, B. Coletti, G. N. Shannon, S. Vantilt

The final removal of inclusions in the ladle, tundish, and mold in a continuous casting process involves the kinetic steps of liquid film drainage, interface rupture, and absorption of the inclusion into the overlaying molten slag. During this process, oxide inclusions can undergo chemical reactions with the slag. This paper presents recent results on imaging the slag/steel interface and elucidates the evolution of Al2O3and Al2O3-CaO inclusions during their separation from the steel and on their incorporation into the slag. Experimental results, obtained through a Confocal Scanning Laser Microscope, are compared with thermodynamic predictions.

Jan 1, 2004

By B. D. Paphane

Since the commissioning of the Tati Hydrometallurgical Demonstration Plant (HDP), which produces Ni and Cu cathodes as well as Co salt from sulphide concentrate employing Activox® technology for leaching, no kinetic data has been generated from the plant under normal operating conditions, from start-up to steady state. Therefore, this study seeks to determine the rate of reactions in the leaching circuit with a view to obtaining kinetic data for the system under the current operating conditions. Within the five-compartment autoclave operating at temperatures of 105°C to 110°C and 1100 kPa pressure, the extraction of Ni, Cu, and Co ions into solution is achieved through the oxidation of the sulphide concentrate using approximately 50 kg H2SO4 per ton, 10 kg NaCl per ton, and 1.21 kg O2 per kilogram of S2-. The autoclave reactions showed complex kinetics, with the reactions proceeding via some intermediate(s) before the formation of products. The results suggest that the reactions were dependent on the size of the metal ion of interest and the concentrations of the metal ions in the Tati concentrate as well as in chloride leaching. The order of the leaching rate constants was Fe2+ > Cu2+ > Ni2+ > Co2+ in all the compartments studied. The rates of leaching were also found to decrease as the concentrate moves from compartment 1 to compartment 4. For compartments 1 to 3, leaching was observed to be preceded by dilution of the repulp liquor (copper raffinate). The leaching rate for compartment 5 was slightly lower than that of compartment 1 but higher than the rates of compartments 2, 3, and 4 for all the metals studied. Keywords kinetics, hydrometallurgical plant, Activox

Jun 1, 2013

By Viviane Tavares

The technology advance of mobile devices makes consumers of these equipment do more constant exchanges, with this the obsolete devices discarding becomes an environmental problem, due its landfill accumulation. In order to minimize the environmental impacts caused by these equipment there?s the recycling necessity of polymers, ceramic and metallic materials. The main goal of this recycling is to study the printed circuit board of device mobile processing through ore treatment in order to recoup copper. Initially printed circuit boards were processed in a knives mill, in order to liberate the ferrous material, after that it was done the magnetic separation of the reduced residue. With the not magnetic fraction it was done the grain sized analysis and sulfuric acid and hydrogen peroxide leaching analysis. With the chemical analysis results proceeding from the leaching aliquot it was possible to observe that the leaching method with sulfuric acid and hydrogen peroxide presented greater copper recovery.

Jan 1, 2009

By Lon D. Santis

This paper summarizes explosives transportation incident and accident data collected by the U.S. Department of Transportation (DOT) from 1993 to 1998. The paper briefly describes the legislation and regulations that cover hazardous materials transportation. The multimodal incident data collected by the Research and Special Programs Administration (RSPA) contained 86 incidents involving Class 1 materials during transit. Thirty-two occurred on public highways. The Federal Highway Administration (FHWA) data showed there were 8 1 motor-vehicle accidents involving explosives. The FHWA Crash datafile extract contained 649 records categorized as involving Class 1 materials although closer analysis revealed that nearly 90% of these did not involve explosives. In both databases, there were no fatalities caused by the explosive materials although 7 fatalities were the result of injuries suffered during the motorvehicle accident. There were also no serious explosions during any of these incidents or accidents. The paper concludes with an analysis of the risk involved with transportation of commercial Class 1 materials on the highway.

Jan 1, 2000

By M J. Bourassa

In addition to the geologic risk of a particular project, the criteria that an international exploration company (æIECÆ) utilises when making an investment decision in a particular country should also include a critical analysis of the political, judicial and fiscal regime of the host country. A key investment criteria of an IEC is mineral tenure and the security and continuity of that mineral tenure under the host countryÆs existing legal system as well as the host countryÆs overall legal, political and fiscal framework, the latter of which can affect the projectÆs overall economic viability in a number of ways. The authors, Steve Vaughan and Michael Bourassa of Aird & Berlis, Toronto, Canada, have taken the position that developing an understanding of a countryÆs legal tradition is a crucial first step in analysing the mineral regulatory regime of a particular country. This paper continues their efforts to overview the most recent legal trends affecting the worldÆs mineral industry and attempts to analyse, categorise, compare and contrast differing legal systems, cultural backgrounds and economic philosophies relating to the development of mineral rights in Pacrim countries and the resulting commercial, legal, and political framework which ultimately drives the relevant mineral legislation. For the convenience of organisation of this analysis, the authors have divided the Pacrim countries into four smaller groups, firstly, on the basis of their legal tradition and, secondly, by their geographic location:Common Law Countries: USA, Canada, Australia and New Zealand; Spanish Civil Code Countries: Mexico, Central America (Panama, Nicaragua, El Salvador, Guatemala), South America (Chile, Peru, Ecuador, Colombia). Communist or Former Communist Countries: Mongolia, China, Russia. Countries of the Pacific Southwest: Phillippines, Indonesia, Malaysia, Indo-China (Vietnam, Laos, Cambodia, Thailand), Papua New Guinea. The discussion starts with an analysis of the various types of legal regimes, attempts to classify or categorise them, reiterates the necessity for the rule of law and those factors which encourage mineral exploration and development and discusses and recommends the expansion of a practical country competitiveness rating system developed by the Fraser Institute. In addition to the fundamental issue of mineral tenure û what it is and how secure it is û the paper discusses how different legal systems have shaped different approaches taken by individual nations to attract foreign mineral investment. The paper analyses the best practices and experiences accumulated in different Pacrim countries with varying legal traditions and identifies a practical country competitiveness rating system which the authors believe should be expanded to cover all minerally endowed countries. This rating system will permit countries to identify their mineral regime weaknesses and adjust their legal systems to better attract mineral investment and will also permit exploration and mining companies to compare their jurisdictional choices with those selected by their competitors.

Jan 1, 1999

By Mostafa Mossaad, Ali Helwa, Manal Salem

Support of excavation (SOE) design practice tends to model SOE elements using two-dimensional (2D) analyses to avoid the complexity associated with three-dimensional (3D) analyses. Such practice overlooks soil arching in the horizontal plane and prevents designers from accounting for elements such as capping beams as part of the statical system. This study simulates square excavations supported by cantilever slurry walls in dry cohesionless soil using 2D and 3D finite element (FE) models. First, side support wall behavior is compared from 2D and 3D FE models for variable excavation length to depth (L/H) ratios. Second, the effect of slurry wall lateral bending stiffness on wall behavior is studied by modeling the wall using plate element with isotropic and anisotropic wall stiffness. Finally, the sensitivity of cantilever wall behavior to the presence of capping beam is illustrated. The study concludes that unbraced excavations with L/H ratios greater than 5 almost resemble plane-strain conditions. Slurry walls are better simulated in 3D FE models by dividing the plate element into discrete panels or by assigning anisotropic bending stiffness to the plate element. Finally, the presence of capping beam affects the behavior of cantilever walls resulting in reduction of deflections and redistribution of bending moments. INTRODCUTION Support of excavation (SOE) design practice ranges in complexity from conducting simple hand calculations to performing three dimensional numerical modeling depending on several factors among which is the geometry of the design problem. This paper addresses walls that are designed using numerical modeling, and discusses the factors governing the choice of the most suitable modeling approach. It has been believed for a while that modeling excavations using 2D numerical models would lead to a more conservative solution, which turned out to be incorrect in specific cases. This paper attempts to describe cases where 2D finite element modeling could be on the conservative side and other cases where it could be less conservative than the more complex 3D modeling.

Jan 1, 2018

By Dennis R. Jr Bell

Before beginning any site development or mineral extraction activity, it has been well documented that it is first prudent to gain an understanding of the prevailing geologic conditions.Whether it’s identifying the depth to type of bedrock, or determining the quality and quantity of the in place mineral deposit, these factors should always be considered in a project’s fatal flaw analysis. In situations where there is limited subsurface information, geologic models have been proven to be one of the most valuable and cost-effective tools used by the developer and/or his consultant.

Jan 1, 1997

By Irwin H. Cornell

BRIEFLY stated, the history of the St. Joseph Lead Co. is the story of how a group of men, working for ten years as officers without salaries and stockholders without dividends, developed a small mine in Missouri into what became a large and prosperous corporation. Their courage and faith in the scattered surface deposits of lead coupled with the management&apos;s engineering vision and sound financial judgment should prove an inspiration to present-day mining operators and investors. In 1717, John Law&apos;s company, known as "The Company of the West," was formed in France and letters patent were granted, for a period of 25 years by Louis XV, for exploration in the Mississippi River Valley. One of the underlying purposes of the expedition, headed by Mr. Renault and Mr. La Motte, a French metallurgist, was development of the lead mines in the area now known as Southeast Missouri.

Jan 1, 1947

A record $18.7 billion worth of metals, non- metals and fuels was produced in the U.S. during 1962, according to a year-end estimate from the USBM. The 1962 total value, based on preliminary statistics compiled by the Bureau, was nearly $600 million more than in 1961. Most minerals gained both in value and volume of production during 1962 according to information collected by the Bureau. All mineral fuels except anthracite showed increases. Among nonmetallic minerals- other than fuels-gains exceeded losses by two to one. Metal production held steady as gains and losses balanced.

Jan 2, 1963

By Gunnar Persson

The borehole pressure/time history of blasting practice is simulated in a twin pendulum apparatus, where the expanding shotfiring gases force two steel slab swingers apart. A pilot installation built at SveDeFo is described. The relevant factors, that govern the use of this test method as a means of classifying explosives with respect to their toxic fume potential, are described.

Jan 1, 1996

By Shane McDonald

Australia produces approximately 84 million tonnes of coal per annum from 30 longwalls in New South Wales and Queensland, operating at an average depth of around 300m. Industry trends and expectations place increasing emphasis on the reliability of these operations; for example, the current average face width is 245m and this is expected to increase to approximately 270m by 2010. In recent years, Beltana No.1 Mine has consistently been Australia?s highest longwall producer, with ROM output of 7.2Mt in YEJ2007. Strata management has become a key feature of the operation of Australia?s longwall mines, as a tool to manage variances in the geotechnical environment. This involves an understanding of the impacts of the geotechnical environment on ground behaviour and the implications for mine design, stability and associated support, interaction and horizon selection. The anticipated ground control impacts of these factors form the assumptions that drive the format of plans specifying both triggers and actions, with quantified, monitoring-focussed experience used to refine the plan in a continuous improvement (ie ?plan-do-check-act?) process. This paper summarises the Beltana No.1 Mine strata management methodology and experience to-date.

Jan 1, 2008

By Swaminathan Srinivasan, Jess A. Schroeder

"Landslide activity along U.S. 50 in Cincinnati, Ohio (USA) has caused roadway damage for decades. After a necessary closure of three lanes due to slope movements, emergency stabilization measures were undertaken to protect the roadway by providing a short-term solution necessitated by The Ohio Department of Transportation budget constraints. The landslide shear plane occurred on a sloping bedrock surface as much as 50 feet below grade. Drilled shafts were installed 40 feet downslope of the roadway shoulder and were heavily reinforced across the shear plane but steel reinforcing did not extend the full length of the shafts and was stopped well short of the ground surface. Instrumentation data has been collected for 11 years after construction has shown these “Stub Piers” have provided much more than a short-term solution and have provided an attractive alternate to conventional deep shafts or tieback drilled shaft options.INTRODUCTIONLandslide activity has occurred along U.S. Route 50 in western Cincinnati, Ohio for many decades. The site is located between North Bend and Addyston, Ohio on the right descending (cutting) bank of the Ohio River. Road distress caused by slope movements required periodic repairs over recent decades. Railroad tracks downslope of the roadway also showed signs of horizontal displacement and periodic repair. Visual evidence in 2005 suggested the shear plane extended below the US 50 roadway and extended out into the Ohio River.A weed and brush-covered slope extended down slope from the roadway at about 3H:1V for a vertical distance of about 20 feet. Above US 50, the hillside continued to rise more than 100 feet. There is a railroad right-of-way at the toe of the slope with the Ohio River bank just downslope of the railroad.In 2005, Terracon Consultants was retained by the Ohio Department of Transportation (ODOT) to perform a geotechnical study that included 17 test borings and inclinometer monitoring at 4 locations. Roadway damage was occurring (see Figure 1). After only a few weeks of monitoring, the inclinometer casings sheared off about 50 feet below grade, near the soil / bedrock interface (see Figure 2). Soon after, the roadway distress worsened, causing ODOT to close 3 of the 4 lanes to traffic and reroute traffic onto the remaining single lane and shoulder. Terracon was asked to develop a stabilization design under emergency repair conditions. However, both limited budget and time-related constraints necessitated a direction by ODOT that the solution be at least “pseudo” short-term (3 to 5 years)."

Jan 1, 2017

By T Smith, J Hatley

With the increased focus on the need for more uranium mines, this paper presents the design process currently underway for the development of the Millennium deposit in northern Saskatchewan, Canada. This deposit, located 630 - 750 m below surface, will be accessed by two shafts and will be mined by blasthole stoping methods at less than 500 t/d. Mining grade will approximate two per cent U3O8 and mine life is expected to be six to seven years. The project is a joint venture between Cameco, AREVA and JCU. This paper discusses in detail methods used to predict worker radiation exposures, the methods used to monitor the work environment and procedures unique to the uranium industry necessary to minimise worker radiation exposures.

Jan 1, 2008

By Michael Olmsted

Inspection of boreholes prior to blasting can result in cost reductions as well as increases in efficiency and safety. Until recently, borehole inspection was performed in two manners. For simple inspections, a flashlight was used to view the upper part of the hole. More thorough inspections were performed with long tool strings developed for oil field applications. Borehole inspection tools developed specifically for mining and blasting applications have now been developed. Video Cameras developed for borehole inspection have been in service for several years. Now measurement tools are available, developed specifically for mining.

Jan 1, 2000

By Colin Hardie, Erik Bartsch, Guy Comeau

"The Xstrata Nickel Raglan Concentrator, located at the northern limit of Quebec’s Nunavik region has been in operation since 1997. Originally designed to process 800,000 tonnes per year of high grade nickel ore, plant capacity is currently approaching 1,200,000 tonnes per year due to an Optimization Project (FAG to SAG conversion) in 2005 and many recent processimprovements.In 2006, the Raglan Metallurgical Group with assistance from the Xstrata Process Support group decided to make SAG control one of its priorities in order to further increase throughput and improve stability. The original primary mill control logic delivered by the Optimisation Project in 2005 consisted of a simple PID loop controlling the mill charge (bearing pressure) through feed rate changes. Due to the multivariable, non-linear and disturbance dominated nature of the SAG circuit it was quickly found that this traditional PID control strategy was not able to adequately control the mill; resulting in poor stability, frequent operator interventions and less than optimum performance.This paper describes the successful integration of advanced field systems such as mill feed image analysis (Wipfrag) and crusher gap controller (ASRi), into a multi-variable fuzzy logic SAG mill controller. The process of how a strategy for control was developed and implemented directly in the existing control system (exploiting standard system capabilities) is discussed. It is also shown how this approach has provided mill automation which is simple, robust (despite erratic feed characteristics), and delivers both an increase in throughput and a reduction of variability.INTRODUCTIONOriginally commissioned as a Fully Autogenous Grinding (FAG) circuit in 1997, preparations to convert the Katinniq Concentrator Mill to SAG had in fact commenced as early as 1999, but were halted owing to alternative process improvements which achieved up to 1Mtpa as early as 2000. Up until this time, plant process controls had remained more or less static; modifications having been limited to those required by new equipment. Primary mill process controls and related measurements were at this stage limited to:"

Jan 1, 2008

By D. Nutakor

Rock joint stiffness is not only a poorly known parameter, but also has no established laboratory measurement procedure. This paper presents methods used to determine the normal and shear stiffnesses of healed joints filled with vapor-altered minerals obtained from the Yucca Mountain site in Nevada. Results show that these joints behave linearly up to 85% of their loading history and are stiff with strengths very close to the strength of the intact rock. Factors that might have contributed to the linear behavior of these joints are discussed and areas requiring further investigation are provided. Joint normal stiffness ranges from 7.16 to 64.77 GPa/mm with an average value of 26.93 GPa/mm, while joint shear stiffness averages 11.41 GPa/mm and ranges from 3.09 to 28.41 GPa/mm. Young?s modulus of the vapor-altered joint infilling was calculated from the stiffness of the healed joint. Young?s modulus of the vapor-altered joint filling material averages 7.89 GPa and ranges from 2.15 to 19.43 GPa. Given the pervasive presence of such altered rock, usually in the form of sub-spheroidal 3-D pockets, this property should be of value in any numerical modeling attempting to describe the mechanical behavior of these tuff formations at the level of detail where inclusions might be a factor.

Jan 1, 2008

By J. I. Schoenherr, G. Schubert, F. Demczenko

The currently known and used plastics and rubber recycling or sorting processes cannot be applied efficiently and economically due to large amounts of fine bulky materials (<3 mm). These wastes are mostly given to specialized landfill sites. Starting out from classical and traditional beneficiation processes a new research project was initiated to work on certain new ways to efficiently separate plastic material mixes. First basic results show that the use of new and improved thermal beneficiation methods is a great implementation in the field of plastics separation. The results can be further increased by a suitable combination with other methods as well. This leads to high-quality and almost pure separated plastics and rubber products, easy to sell on recycling product markets.

Jan 1, 2002

By Xing Jin, Dan Graffi, Glenn MacPherson, Dan Rioux

"The complexity of a modern flotation circuit makes it susceptible to disturbances such as changes in feed, ore mineralogy, equipment degradation, poor measurements and faulty instruments. Good measurements and a robust control system are critical to create and maintain a stable and optimum flotation process.This paper focuses on the development and implementation of process control applications in the flotation circuits at Xstrata Nickel’s Strathcona Mill ( referred to as the mill hereafter ) in Sudbury, Ontario. Following the path of ‘stabilize-improve-optimize’, basic controls to stabilize process variables such as flotation cell pulp level, air and reagent addition rates, cleaning-column feed and wash-water rates have been established. Factors such as best practice in pulp level and valve position measurement, feedforward control and the application of an appropriate control philosophy, have contributed to the significant reduction in process variability. For instance, standard deviation reduction of 79% for the Ni impurity in the column Cu concentrate grade was experienced and is shown. The variability reduction of the flotation circuits’ key process-variables paves the way to further improve and optimize flotation performance. A grams-per-metal unit reagent addition control scheme has been improved upon, particularly for different operating scenarios and better robustness. In addition, following significant stabilization of the primary controls and columns feedrates, Cu/Ni separation cleaning-column bias-control (cascaded to the wash-water rate) and hold-up control (cascaded to air flowrate) have been developed and tested. This strategy – from stabilization to optimization - is expected to achieve a more consistent control of final concentrate grades and improve recoveries.INTRODUCTIONFlotation is considered the most important and value-added process in the milling metallurgical plant and is still undergoing continuous evolution to treat greater tonnage and different ores (Wills, 2006). Starting over three decades ago, with the advent of on-line slurry content analysis devices, flotation automatic control has received persistent interest and a large number of applications have been reported (Thwaites, 1983, 1986 ; Mckee, 1991). Bergh and Yianatos (2011) reviewed different aspects of process control in flotation circuits and have evaluated the applicability of model predictive control to the process. Mckee (1991) analyzed the difficulty in developing lasting/robust process control applications for flotation circuits and stated that the path of stabilization-refinement-optimization would more likely lead to successful flotation circuit process control. Best practice on column process control was discussed by Bouchard, etc. where a multi-layered approach was proposed, provided that the measurement of column process variables ( i.e. bias, froth depth, hold-up, etc. ) are measured reliably (Bouchard & Thwaites, 2008). Wills (2006) stated that the best practice for flotation automatic control starts with fulfilling basic control objectives, such as stabilized flotation cell level, air flow, pH, reagent flow etc., before considering more advanced, or even optimal, control of metallurgical targets, which are more closely linked to economic performance."

Jan 1, 2013