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By J. H. Archibald

"In mines employing cut-and-fill stoping (sand fill), ore passes are built as mining progresses upward. These ore pass raises are generally made from timber and form a vertical ""chimney"", like a very tall log cabin. Traditionally the chimney, or raise, is square in shape and is constructed from square timbers with stepped ends as shown in Figure I. The timbered raise is thus surrounded by sandfill on its outside, leaving the centre open for passing ore down through it. Each layer consists of four timbers and rests flush on the layer below. The corners are frequently pinned or spiked.Under certain conditions in sandfilled stopes large horizontal loads may be transmined to the raise cribbing timbers, or the ""chimney's"" walls. In deep mines, where rock bursts are a problem, it can be shown that one of the conditions for rockbursts to occur is that the burst zone be stiffer and weaker than the surrounding rock(l). This allows a strain energy build-Up in the rock surrounding the burst zone, and the rate of release of this strain energy is known to be related directly to the over-all strength and stiffness of the rock in the burst zone. In stopes that are sandfilled, attempts are, therefore, usually made to increase the strength of the sandfill by the addition of large-sized waste rock and Portland cement. These measures usually achieve the desired strength of the sandfill and, consequently, the severity and frequency of rockbursts can be reduced.Problems may arise when the now chunky sandfill transmits high loads to the raise cribbing along with relatively large move- merits. This leads to heavily stressed and strained cribbing timbers the Coeur d'Alene district in Idaho, raise cribbing failures are common. A typical mode of cribbing failure is shown in Figure 2. One learns in statics that a structure shaped like the crib in Figure I is inherently unstable , at least from a structural standpoint. The crib has pivoted, in Figure 2, into a rhombi c shape and supports very little load. Soon the four-foot square raise cribbing made from 5 in. by 5 in. timbers will no longer pass ore."

Jan 1, 1991

By M. Sider, D. L. Piron

"The cost of energy is a growing factor in the cost of zinc production. Electrowinning from sulphate solutions with periodical reverse current or from acidic chloride or alkaline solutions could be the way to lower costs. A comparison of the energy consumption for electrolysis shows that the alkaline solution may be considered the most promising alternative. IntroductionZinc electrowinning from sulphate solutions is a very energy intensive process (typical specific energy usage : around 3.1 kWh / kg zinc). This energy consumption represents 35% of the total cost of electrolysis and is the most important cost component.In order to lower costs, the energy efficiency of the sulphate process should be improved or alternative processes should be developed. In this laboratory, that objective has resulted in research on electro winning in sulphate solutions with the use of periodical reverse current (PRC) and in acidic chloride and alkaline solutions.Some of the results obtained in this laboratory and already published and new experimental results reported in this paper make it possible to present a more critical comparison of the energy consumption of the three processes mentioned.ExperimentalThe experiments at constant current were carried out as described previously. Specific conditions are indicated in Table I. Current efficiencies were obtained by weighing deposits.ResultsThe best energy consumptions for electrolysis obtained in this laboratory for the three media are presented in Table I. More detailed results can be found in the papers already mentioned."

Jan 1, 1988

By B. Misra, B. S: Sastry, Kollu S. Rao

"This paper reports the results of a finite element study of the geothermal heatflow into dry mine airways. For isotropic and unsteady state conditions the heatflow into mine airways is studied for a range of surface heat transfer coefficients between rock and air, and age of the airway. Dimensionless temperature gradient values are presented in tables for different values of Boit and Fourier numbers and the results are compared with Starfield tables and Gibson algorithm. It is found that Starfield tables have consistently over-predicted the G values with errors ranging from 2% to 10%. The differences between results obtained from the finite element study and the G values calculated from Gibson's approximation method are mapped. The small error values over a large range of Fourier and Biot numbers confirm the suitability of Gibson's algorithm to rapidly calculate G values for estimating the heat transfer from surrounding rock to mine air.IntroductionIn many underground mines heat is a major problem, and the provision of acceptable working conditions requires considerable expenditure on ventilation systems. The rational design and operation of these systems depend upon an understanding of the various sources of heat in the mine. The natural source, i.e. geothermal heat, contributes up to 80% of total heat added to mine air and it is difficult to analyze and predict the heat owing to a number of influencing variables. The problem of geothermal heat flow has been studied by many investigators (Goch, 1940; Starfield, 1966; Hemp, 1987; Amano et al., 1982; McPherson, 1986).The primary concern of this paper is to develop a better ready reference dimensionless transient temperature table for estimating heatflow at any stage of mine airway life."

Jan 1, 1994

By Walter Valery, Sergio Vicuna, Roberto Valle, Hamer Arevalo, Ben Burger, Lui Vargas, Alex Jankovic, Jim Seidel, Eduardo Nozawa

This paper describes the design, the first three years of operation and optimization of a large, single stage SAG mill at Minera Yanacocha’s Gold Mill facility located in northern Peru. The Gold Mill was commissioned in March 2008 with a 32’ x 32’ EGL, 16.5MW single stage SAG mill, to process 5 million tonnes per annum high grade oxide Au/Ag ore. Operational control, feed size distribution, grinding media, mill liner, grate and pulp lifter optimisation have allowed the mill to operate 15-30% above design throughput rates, but with a product P80 coarser than design. As part of the optimization, full grinding circuit surveys were conducted. Historical operating data and survey data were analyzed and used to evaluate possible circuit changes and determine alternative operating strategies. A number of changes were implemented which allowed the SAG mill to operate similarly to a large ball mill and achieve finer mill product that was closer to design. This paper summarizes life to date data analysis and improvements made by Minera Yanacocha as well as the grinding circuit optimisation study conducted by Metso Process Technology and Innovation.

Jan 1, 2012

By Robert B. Parsons

"Income tax legislation is not keeping pace with federal and provincial environmental legislation. There is a vast array of new environmental regulations at various stages of implementation across the country. Unfortunately, there are serious concerns about the deductibility of significant payments which mining companies will be required to make under these new rules, and the Department of Finance seems to be reluctant to act on these concerns. IntroductionWhile the federal and provincial governments are racing ahead with obvious fervour to introduce new envirorunental laws, the tax rules relating to envirorunental costs are being allowed to lag far behind. In a nutshell, the tax treatment of envirorunental costs is not keeping pace with the new envirorunental legislation.One of the most serious concerns of the mining industry is the deductibility of mine reclamation or closing costs. The producing provinces are well advanced down the road toward mandating upfront deposits, bonds, or similar financial guarantees to protect the envirorunent from the operation and eventual closure of a mine. These requirements are not small. In some instances, they can amount to tens of millions of dollars. And, if there is no tax deduction for these sums when they are set aside by the mining company, then the costs have to be paid out of the company's after-tax earnings."

Jan 1, 1991

By Akiyoshi Horiuchi, Manabu Kanno, Shigeki Sato, Taro Aichi

"AKITA ZINC Co., Ltd. (Iijima Zinc Refinery), jointly owned by DOWA METALS & MINING Co., Ltd.(DMM), has used the company’s own hematite process for iron control since the beginning of operations in 1971. The hematite process consists of reductive leaching with SO2 gas and iron removal in autoclaves by high temperature hydrolysis. This process enhances not only zinc recovery but also the recovery of gold, silver, copper, lead and rare metals, which is carried out at another DOWA metallurgical plant. All by-products produced in the hematite process are marketed and sold. This paper presents an overview of the hematite process and the recent process improvements made.INTRODUCTION DMM carries out mining and smelting activities for precious metals, PGMs, rare metals and base metals such as copper, lead and zinc. It owns KOSAKA SMELTING & REFINING, producing copper and lead, and the AKITA ZINC Co., Ltd. (AZC) in Akita Prefecture. DOWA is a specialized smelting company which has established a metallurgical complex for copper, lead and zinc, including a recycling business. AZC was established in 1971 at a production capacity of 72,000 t/y zinc; it is jointly owned by DMM and five other non-ferrous metal companies. AZC has increased its capacity continuously and now produces 210,000 t/y of zinc. Figure 1 shows the changes in zinc production and capacity at AZC."

Jan 1, 2016

By William H. Pomroy, Kenneth E. Hjelmstad

An underground mine fire can seriously threaten the lives of all personnel in the mine. This fact makes fire emergency planning a high priority in the mining industry. A fire emergency plan includes a means of warning miners of the existence of a fire, and the need to evacuate or retreat to a place of refuge. The warning alarm must be fast and must reach all miners, regardless of their location or work activity. Means of fire warning are varied, and include such methods as stench, flashing lights, telephones, and word-of-mouth (messengers). Unfortunately, none of these methods are entirely satisfactory. Stench can be slow and seldom achieves total mine coverage, especially in high-back room-and-pillar mines with low ventilation velocity. Telephones are effective only where personnel are close enough to hear the phone ring. A novel fire warning alarm system has been developed by the U.S. Bureau of Mines which enables instantaneous warning of all underground personnel. The warning alarm is sent by an electromagnetic signal which penetrates through mine rock from a transmitter to small person-wearable receivers. Each miner's cap lamp battery could be equipped with a small receiver and when a fire or other emergency occurs the miner could be alerted to the danger by a blinking of the cap lamp. Testing of prototype equipment has demonstrated that the transmitted signal is capable of penetrating through over a mile of mine rock and activating the receiver. This paper describes the theoretical basis for through-the-rock ultra-low frequency electromagnetic transmission, design of the prototype transmitter and receiver, test results, and status of commercial development of systems utilizing this technology.

Jan 1, 1994

By Peter C. Jones

Owing to the inadequacy of the ore transport system at Cassiar in the late 1960's, a new facility was required. This paper traces the various alternatives considered and gives a description of the tram line as installed. The problems encountered, changes made and future modifications are discussed in detail, together with the effects these have on maintenance and operations.

Jan 1, 1978

By W. Jomaa, V. Songmene, O. Mechri, Laval Université, P. Bocher, J. Levesque

"A 2D finite element modelling (FEM), based on pure Lagrangian approach, is developed for studying the serrated chip formation during high speed machining (HSM) of 7075-T651 alloy. The solution was achieved using a commercial software package, ABAQUS/Explicit v6.13. The Johnson-Cooke (JC) constitutive equation is used to describe the work material behaviour. Moreover, the JC damage equation is implemented into the FEM to take into account for the shear localization during the serrated chip formation. Modified Coulomb friction model has been used to characterize the sliding/sticking effects on the tool-chip interface with the friction coefficient and shear flow stress determined by force calibration and machining data, respectively. The proposed FEM is validated using experimental data obtained in HSM of 7075-T651. The FEM was able to predict accurately serrated chip morphology. The intensity of chip segmentation was found to increase with cutting speed.INTRODUCTIONHigh speed machining (HSM) is one of the most used processes for manufacturing aircraft parts with aluminum alloys. For aluminum alloys, the use of HSM increases metal removal rate and reduces the formation of built up edges and burrs. However, it was found that serrated (also named segmented or sawtooth chip) and discontinuous chips can be produced during HSM of some high strength aluminum alloys, such as 7075-T6 alloy (Rao & Shin, 2001). Many parameters were found to affect the segmented/discontinuous chip formation during the machining of aluminum alloys.There are two cases in which the serrated chip can forms: the first is when machining hardened materials (Morehead, Huang, & Luo, 2007), and the second, when machining ductile materials with a cutting speed higher than a critical value (Barry & Byrne, 2002). Different theories and models were developed in order to explain the formation mechanism of such kind of chips. According to Astakhov (2006), the segmented chip formation is attributed to variations in stress and plastic deformation states, and resulting temperatures on the cutting zone. Liyao et al. (2013) stated that the segmented chip formation was mainly attributable to adiabatic shear instability/catastrophic strain localization. Others (Vyas & Shaw, 1999) suggest that the fracture/crack propagation mechanism is at the root of chip generation."

Jan 1, 2016

By M. Hozayen, Q. Ni, E. S. Radwan, P. Nawrocki, A. Jebbouri

"A major geomechanical study was conducted for one of the UAE onshore oil fields with the purpose of studying reservoir rock properties and stress distribution, based on which a 3D coupled reservoir geomechanical model was built. This model was later used for wellbore stability analysis and for analyzing the effect of fractures on future reservoir production performance, including fracture deformation and permeability evolution occurring due to reservoir depletion and resulting changes in local stress field. The subject of this study was a complex fractured Upper Cretaceous carbonate reservoir characterized by high degree of heterogeneity, both vertically and laterally. Wellbore instability related drilling problems were encountered while drilling the wells in this field. The problems were mainly in drilling the horizontal wells, including breakouts and mud losses. Experimental results of laboratory tests used in this study are summarized in Part I of this paper whereas wellbore stability analysis and formulation of a3D geomechanical model that was built for that purpose is summarized herein.A 3D geomechanical reservoir model was developed, which included natural fractures. The mechanical properties of the reservoir rock, such as Young’s modulus, Poisson’s ratio, UCS, friction angle and tensile strength were populated based on the correlations established in Part I of this paper and the developed model was then used to simulate the 3D mechanical-property distribution and the evolution of the in situ stresses in the field due to depletion from 1983 to present-day. Based on the full field model, mud weight cubes were developed to predict the safe mud weight windows in different drilling directions. In addition, well stability prediction for two planned wells was performed using a 3D near-borehole model. Firstly, the computed stress state and mechanical properties simulated in the full field model were extracted along the well trajectory of an existing horizontal well which was drilled recently and then, a3D near-borehole model was constructed along the well trajectory. The wellbore stability analysis along the well trajectory, including stress state, strain distribution and displacements, was performed to identify the instability events along the well trajectory. It has been seen that the presence of natural fractures is closely related to the recorded borehole instability incidents. The computed plastic strains which indicate the wellbore failure were consistent with the recorded wellbore instability events in the FMI image logs, what provide further verification of the developed model. Then, this 3D near-borehole model was applied to two planned horizontal wells and the wellbore stability analysis for the two wells was carried out.The results showed that drilling vertically in the reservoir is safer than drilling horizontally. However, the drilling mud weight window in the vertical direction is narrow, being as narrow as 18.7 pcf or 0.299 sg locally. Drilling horizontally is less stable towards the maximum far field stress direction than towards the minimum far field stress direction. The mud weight cubes were used to identify the optimal well placement and well trajectory. For planned well trajectories, this technology can also be used to determine the optimal mud weight."

Jan 1, 2015

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.

Jan 1, 1994

By Dillon. Patricia

Business Growth ?Coal ?Targeting 30 million tonnes by 2013 compared to 19 million tonnes produced in 2009 ?Expanding Energy Business unit (Oil Sands) ?Copper -Strong growth potential for existing operations and development projects ?New gold strategy recently launched ?New markets for zinc Need to retain existing and attract new employees to support growth Engaged Employee ?Has a positive attitude towards the organization and its values ?Is a person who is fully involved in, and enthusiastic about, his or her work Engaged employees are more likely to stay with the organization.

May 1, 2010

By Thomas S. Falk, Nils G. Lindberg

The first industrial COBO (Cold Bound) pelletizing plant began operation in May 1975 at Trollhiittan, Swede n. A technical description of the process, together with operational experience with the plant, forms the basis of this paper.

Jan 1, 1976

By A. Mellek, M. Pischtschan, M. Perrucci

ABB has received an order for one of the most challenging mill drive projects in its history. With one SAG mill and one ball mill to be added at an iron ore mine in Sweden, the customer’s plant managers wanted to have the most efficient solution for driving their mills but had the budget limitations typically faced by the majority of mining companies during periods of market downturn. To find the best balance between cost of acquisition and highest performance throughout the lifetime of the plant, ABB was selected to deploy a synchronized bypass solution, in which only one drive system is used for two different mills in series. However, being one of the first grinding mills in the world with such a solution was not the only challenge the ABB team faced: The inclusion of some mill application functions - e.g., frozen charge protection, automatic positioning and creeping mode - brought the demands on the engineers to another level. With only one frequency converter and one mill application controller available, the configuration logic and interlocks had to be meticulously designed and thoroughly tested to ensure a smooth and safe startup. The solution offers a footprint reduction and more operator flexibility at a reduced investment as each mill can be run in both directions, and wear on the mechanical components can be greatly reduced due to ABB’s premium ring-geared mill drive (RMD). This paper will describe the details of the project, the configuration developed and the tests performed to guarantee correct software functionality. Mill startup is scheduled for January 2016.

Jan 1, 2016

By H. Kalsi

"IntroductionRoyal Oak Mines Inc. is currently operating the Parnour No.1 mine located 10.5 miles east of Tinunins, adjacent to Highway No. 101. The operation produces gold ore at a rate of 3300 tpd. A variety of mining methods including bulk open stopes with ITH drilling, narrow vein panel, longhole and open pits contribute to produce 1.2 rnillion ore tons annually. The milling process requires water at an average rate of 1 rnillion gallons per day (700 U.S. gpm). The Pamour No.1 mine has historically had two major problems with regard to water control. The flfSt is the underground pumping system's inability to handle excess inflows of water generated from spring thaws. When the thaw takes place over a short period of time, large inflows of water are created which quickly migrate underground and sometimes result in the loss of the lower loading pocket. During the spring runoff the pumps at Parnour No.1 work continuously for 24 hours at a rate of 1200 U.S. gpm. The system was further taxed in 1991 when the Hoyle mine was connected to the Parnour No. 1 mine and whatever excess capacity the pumping system had for the spring runoff was taken up handling the inflow of mine water generated by the Hoyle.The second problem facing the mine was the lack of water for the mill during the severe cold winter months and dry summer months. At those periods inflows of water into the mine decline and the underground water normally pumped to the mill is severely decreased. In times of dry spells mill personnel increase the water diversion from the Three Nations Lake in order to meet water demands and maintain tonnage throughout. In essence, the mine was going through an annual ""feast or famine"" situation and a solution was needed.A number of options were considered but were narrowed down to the two most practical. The first was to modify the existing pumping system and increase its capacity in order to handle the excessive runoff during spring thaw. This involved a heavy capital expenditure and would have caused additional operating costs (i.e. increased hydro). The option chosen by the management was to divert the spring runoff into an unused section of the mine called The West End. A bulkhead placed at the 2400 level would provide an ultimate underground water storage potential of 150 million gallons. This would also cut down the load on the existing pumping system, save electric consumption in pumping and provide water storage which could be used for milling during the two dry spells. Pumping stored water from the mine could be scheduled for off peak hours to take advantage of lower power rates. To meet these objectives an underground bulkhead capable of withstanding high water pressure up to 2000 ft head (866 psi) was constructed in the spring of 1992. The bulkhead site was at the 2400 level at the Pamour No.1 mine. A major consideration was the requirement to construct a safe bulkhead and to minimize water leakage from the bulkhead.Figure 1 shows the bulkhead location."

Jan 1, 1994

By Chris Blain

"Abstract - Based upon an extensive database, this paper analyzes the record of modern mineral exploration success and establishes the 50-year trends in discovery. The record clearly shows that the overall discovery rate rose during the 1950s and 1960s, peaked in the 1980s, and fell during the 1980s and 1990s. By commodity and ore-type target, the pattern of discovery is not continuous. Typically, it is episodic as a series of waves with minor resurgence. The waves reflect the order of the so-called discovery booms, led by uranium, then nickel, and copper, polymetallic base metals and gold. With the possible exception of gold, the discovery booms appear to be independent of metal price, although favorable perceptions of the price outlook may well have initiated the boom or led resurgence. Although difficult to quantify, an emerging trend in modern discovery is the integration of several detection techniques into the search process. No doubt, this trend will continue as orebodies become more and more difficult to find. The record of the past two decades shows that greenfield discovery rates have progressively fallen even though the level of investment in exploration has risen to an all-time high. This trend reflects increasing discovery risk. Several factors are contributing to this trend. Perhaps the two most important are: (1) deteriorating economics as increasing real costs and decreasing real prices continue to raise the economic hurdles for minimum acceptable exploration targets, and (2) increasing exploration maturity in many search terrains, particularly those in the traditional regions of North America and Australasia. To succeed cost-effectively in this new environment of increasing discovery risk will require extraordinary creativity, innovation, and technical skill coupled with commercial discipline."

Jan 1, 2000

By Pierre Beaudoin, Michel Bourassa, Robert Lanthier, Samir Chéfaï

"Mine Doyon, in collaboration with CRM's Process Control Division, improved the control strategy at the SAG mill I Ball mill grinding circuit. The project aimed at increasing operation stability and throughput. First, a needs analysis was achieved in order to define the control philosophy and to upgrade the process control equipments and instrumentation. The stabilizing control strategy has been developed and implemented successfully using single loop PID controllers. The monitoring feature as well as the rule based supervisory control strategy were implemented on 486PCs running Process Vision and COMDALE/C softwares. Main features of the control strategy are described in this paper while results are presented and discussed.RésuméLa Mine Doyon, en collaboration avec le service de contrôle des procédés du CRM, a optimisé la stratégie de contrôle au circuit de broyage. Les objectifs du projet étaient !'amélioration de la stabilité de !'ensemble de !'opération et la maximisation du tonnage usiné. Une analyse de besoins a été réalisée pour concevoir la philosophie de contrôle et déterminer les ajouts a apporter a I 'instrumentation et au systeme de contrôle. Une stratégie de contrôle à deux niveaux, integrant stabilisation et supervision, a été developpee et mise en opération. La regulation est réalisee par une combinaison de contrôleurs Moore de type PID. Le monitoring et la stratégie de contrôle a base de règles soot implantés sur des micro-ordinateurs de type PC/486 avec les logiciels ProcessVision et Comdale/C. Les principaux aspects de Ia stratégie de contrôle sont décrits dans cet article et les résultats obtenus soot présentés et discutés."

Jan 1, 1995

By Arsenio Enriquez, Adrian Deneys, Ryan Walton, Jenny Esker

NOx emissions at the Rio-Tinto Kennecott Copper (RTKC) smelter, near Salt Lake City, Utah, are regulated to a compliance emission limit at the Main Stack of 15.9 kg/hr on an annual rolling average. The paper discusses RTKC efforts and improvements, particularly related to the anode furnace operations, since the Smelter modernization in 1995 to comply with the air quality approval limit. This includes replacement of gaseous ammonia to Steam-Gas Refining (SGR) system during the copper reduction stage, upgrade anode furnace oxygen-fuel burner from Praxair’s Stabilized Jet (S-J) to Jet Lance (J-L) technology, development and implementation of operational best practices and continuing to investigate and evaluate NOx control technology and strategy in the industry. In early 2016, changes to Praxair J-L Burner technology on both anode furnaces, utilizing wider lance spacing, was adopted and further improved NOx emission levels well below the compliance limit. INTRODUCTION Since the establishment of the Clear Air Act in 1970, the Environmental Protection Agency (EPA) has been regulating emissions of nitrogen oxides (NOx) to reduce impact on public health and the environment (USEPA, CAA, USEPA, NAAQS). As a requirement of the Clean Air Act, the EPA evaluates the standards for NOx and criteria pollutants on a periodic basis and as a result, standards have been revised and ultimately reduced over time (USEPA, CAA, USEPA, NAAQS, UDAQ, SIP). To remain competitive with changing regulations and in conjunction with Rio Tinto environmental standards for continuous improvement, the RTKC smelter has been motivated to research and implement NOx control strategies. NOx health and environment impacts NOx refers to a group of seven compounds including the most common, nitrogen dioxide (NO2). (USEPA, NO2). The EPA enforces both short-term (1-hr average) and long-term (annual average) standards for NO2 to protect against associated respiratory system impacts. Short-term exposure of elevated NO2 concentrations can aggravate respiratory diseases and lead to symptoms such as coughing, wheezing or difficulty breathing while longer exposures may contribute to the development of asthma and potentially increase susceptibility to respiratory infections. (USEPA, NO2) Additionally, NOx is necessary in the formation of ozone and particulate matter less than 2.5 microns (PM2.5). Ozone concentrations can negatively impact lung function and in some cases, contribute to chronic obstructive pulmonary disease. (USEPA, Ozone) The particles associated with PM2.5 can reduce lung capacity and aggravate heart conditions. (USEPA, PM2.5) For all NOx related pollutants, children and the elderly are generally at greater risk for the health effects. (USEPA, NO2, USEPA, Ozone, USEPA, PM2.5)

Jan 1, 2019

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 Rodrigo Serna, Nora Schreithofer, Zoltan Javor, Kari Heiskanen

"Mineral floatability is a function of mineral properties such as size, liberation, shape, surface composition, reagent coverage on the surface, level of oxidation on the surface, etc.; pulp chemistry: Eh, pH, temperature, DO, reagent type, etc. and hydrodynamic conditions: turbulence, gas dispersion, D32, etc. The biggest challenge with predicting the floatability of an ore is finding a measurement method that would take into account the effect of all of the variables on the floatability of the minerals. The particle-bubble attachment time measurement is considered as an alternative way to predict the floatability of minerals instead of using expensive and time consuming flotation tests because it takes into considerations both surface chemistry and hydrodynamic parameters present in the froth flotation. The existing particle-bubble attachment time method is suitable for studying some significant flotation variables such as pH, temperature, particle size, reagent type and concentration. Nevertheless, measuring the attachment time as a function of collector coverage or surface oxidation is much more challenging. This paper introduces a new induction timer designed to measure the effect of galvanic interaction on the attachment time of particles. The new setup employs an array of needles to create 6 bubbles with the average size of 2.1 mm. Imaging system is used to set the initial distance between the particle bed and the array of bubbles. The attached particles are collected and sent for further analysis. One of the main benefits of the new experimental setup is that the attached particles can be physically separated from the unattached particles therefore many of the particle properties can be analysed and evaluated.INTRODUCTIONSchumann (1942), and Tomlinson and Fleming (1963) proposed that the flotation rate constant is dependent on four probabilities: particle-bubble collision (PC), particle-bubble attachment (PA), particlebubble aggregate stability in turbulent environment (PE), and particle-bubble aggregate stability in froth phase (PF). Any change in any of these probabilities will affect the overall flotation rate constant. All of the above-introduced probabilities are influenced by stream- variables and mechanical variables but their extent of influence vary. The stream variables are particle properties that have been shown to affect flotation rate constant such as size, shape, liberation, mineralogical composition, reagent surface coverage, surface oxidation, etc. The mechanical variables are the direct and indirect properties of the flotation unit affecting flotation rate constant such as cell and impeller geometry, air rate, impeller speed, air holdup, bubble size, residence time, hydrodynamics, froth depth, etc. For instance, the probability of collision is affected by many mechanical variables (bubble size, hydrodynamics, bubbles holdup etc.) but only one stream variable (particle size) has a major effect on it. On the other hand the probability of attachment is affected by much more stream variables: particle size, shape, liberation, surface composition, particle surface oxidation and collector coverage, Eh, pH, etc."

Jan 1, 2016