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By William A. Napier

The Mantaro Phosphate Property is located ~ 250 km east of Lima, Peru in the Andean altiplano near the city of Huancayo, Junin District. The Mantaro deposit is a mineralized zone of phosphatic rock currently defined by surface outcrops, trenches and drilling extending over a strike length of more than 30 km and a width of more than 5 km covering ~27,700 hectares. Mineralization is exposed as three roughly parallel exposures (?mantos?) trending in a northwest-southeast direction along the Mancaspico syncline. Estimated mineral resources1 contained in Manto 1 of the Property (4% P2O5 cut-off) as of February 21, 2010, are: Measured 5.548 million tonnes @ 10.8% P2O5 Indicated 33.975 million tonnes @ 9.9% P2O5 Measured + Indicated 39.523 million tonnes @ 10.0 % P2O5 Inferred² 376.265 million tonnes @ 9.0% P2O5 1Tonnes rounded to the nearest 1,000 and grade to 1 decimal place. 2Inferred material reported with no cut-off and an assumed grade. There is considerable potential to expand the resource base. Mantos 2 and 3 of the deposit have been geologically mapped and exhibit surface mineralization widths similar to Manto 1. Given that the deposit is of marine sedimentary origin, it is reasonable to infer that comparable grades and depth of mineralization are present within Mantos 2 and 3. Based on this assumption, the potential mineral deposits within Mantos 2 and 3 are estimated to be approximately: Manto 2 425-435 million tonnes @ 9% P2O5 Manto 3 280-290 million tonnes @ 9 % P2O5 These potential quantities and grade are conceptual in nature, there has been insufficient exploration to define a mineral resource and it is uncertain if further exploration will result in these targets being delineated as a mineral resource. However, should such conceptual resources be confirmed by trenching and drilling, the Mantaro Phosphate Property would rank as one of the most significant phosphate deposits in the world.

May 1, 2011

By D. A. MacFadyen, J. J. Brummer, C. C. Pegg

"The first record of a kimberlite found in Canada (1946) was the identification of thin dykes intersected while drilling for gold in Michaud Township, Ontario.Sampling of the Munro Esker (1964) in the Kirkland Lake area, Ontario, by the Geological Survey of Canada identified the occurrence of detrital grains of pyrope garnets along a length of 35 km of the 113 km tested. A search for the source of the garnets resulted in the identification (1968) of a narrow subsurface kimberlite dyke in the Upper Canada Mine. This discovery resulted in a staking rush. Unfortunately, subsequent work did not identify the source of the kimberlite indicator minerals.During 1978 the Ontario Geological Survey started a multi-discipline study of 29 townships (2560 krn2) in the Kirkland Lake area, to encourage exploration for gold, base metals, and kimberlites. Back-hoe sampling (1979 to 1982), where the overburden was thin, and reverse circulation drilling, in areas of thicker drift, yielded samples of the till. These were analyzed for several elements and a mineralogical identification of the heavy minerals was completed. Pyrope and chrome diopside grains were identified.Studies of the Pleistocene geology indicated only the most recent direction (167 degrees) of ice advance (Matheson) and the associated deposits, out of a possible three advances known to occur in the general region straddling the Ontario-Quebec boundary, is present in the immediate area of Kirkland Lake. Contouring the distribution of pyrope grains (1990) showed a concentration centered over an area of 616 km2 extending down-ice from Gauthier Township. This included a smaller area containing chrome diopside grains. Kimberlite boulders were identified (1981) in gravel pits on the Munro and Misema River Eskers located within this anomalous area. The next step would be to use the airborne geophysical data to locate the kimberlite pipes which yielded the indicator minerals and boulders. The source area is likely to be in the northern half of the Ontario Geological Survey study area."

Jan 1, 1992

By W. Díaz, R. A. Parra, L. E. Arias, C. A. Toro, M. Marin, E. Balladares, V. Parra, G. Reyes, S. N. Torres, D. Sbarbaro

This work presents visible-near infrared (VIS-NIR) spectroscopy measurements, and signal analytical techniques to characterize minerals and relevant pyrometallurgical process variables for the copper extractive industry. Data signal processing techniques such as baseline correction and numerical analysis are used to estimate the continuous and discontinuous spectral components. Such spectral components are used to estimate the process temperature, and patterns such as the integrated radiation. Also, metal combustion emissivity calculation are depicted. Our findings suggest that VIS-NIR spectroscopy may be a suitable technique to assess the process condition state, appearing as an interesting sensing alternative. INTRODUCTION Although the flash smelting process is one key stage in the copper extractive industry, representing about 40% of copper matte production worldwide (Cantallopts, 2017), few attention is dedicated to develop sensing solutions to assess process variables, such as mineralogical composition and temperature, in the feeding and bleeding stages, compared to the steel industry (Strakowski, et al., 2014). In this process and other industries, e.g. the thermoelectric power generation one, combustion and particularly the generated flame are the production chain’s heart. Since the flame is a highly radiative emitting process where chemical and physical transformations take place, many works had been dedicated to characterize the combustion state by sensing its radiation using optical and photonic technologies (Ballester & García-Armingol, 2010). In this context, this work aims to contribute with visible-near infrared (VIS-NIR) spectroscopy and pyrometry techniques to retrieve relevant information from a laboratory scale flash smelting process. On the other hand, since photonic instrumentation allow us to perform contactless measurements of emitted, absorbed, transmitted or scattered radiation, it appears as a suitable technique for sensing process properties in harsh environments, e.g. high temperature processes. One of these techniques is the Visible- Near Infrared (VIS-NIR) spectroscopy, which provides information about the spectral radiation intensity distribution, in this work, the emitted flame’s radiation. It is well known in combustion research that the spectral emission from a flame is composed by a black body continuous radiation background, molecular emissions, elemental emissions and additive noise features (Arias et al., 2011). To make sense of such information signal processing techniques are needed, here we propose to analyse the continuous and discontinuous spectral components separately.

Jan 1, 2019

By T. Gerritsen, R. MacRosty, R. Pula

For several years Hatch has been installing fibre optic temperature sensors on the copper cooling elements of smelting furnaces to improve monitoring capabilities in critical locations. The metal/matte tapblock is a key area to monitor in the furnace as it undergoes severe wear from the molten material repeatedly drained through it. The high wear rate around the tapblock means downtime is necessary to perform refractory repairs. A good understanding of the tapblock condition allows the operation to maximize safety and production; consequently the metal/matte tapblocks have been the focus of this study. Fibre optic technology allows the installation of numerous sensors in locations that are very sensitive to refractory thickness, thereby providing information previously unavailable with traditional measurements. The transient nature of the thermal response to tapping and the three-dimensional geometry of the tapblock confound the interpretation of refractory thickness from temperature measurements. This paper focuses on the analysis of both plant data and thermal modelling simulations and details the progress made in relating the temperature measurements to the refractory thickness in front of the copper tapblock.

Jan 1, 2014

By David L. Anderson

This paper explores the financial impact of the initial version of the Saskatchewan Potash Reserve Tax; first, a one; and second, in conjunction with the other taxes affecting the industry's profitability. A though the introduction of the Reserve Tax is shown to lead to a substantia increase in a hypothetical firm's effective tax burden, the more unusual outcomes frequently attributed to this levy on y occur after the imposition of other non-provincial tax rulings. Despite this qualification, the results obtained suggest that the Reserve Tax undoubted y acted as a catalyst in the polarization of attitudes during the ear y period of industry/government confrontation

Jan 1, 1979

By K. H. Singh, J. N. Szuck, J. A. Riddell

"Hydraulic rock drilling equipment has been in use at Falconbridge over the past two years in both production and development situations. This paper deals with the experience gained in the application of hydraulic drilling in the company's mines and discusses the benefits and problems encountered during their use. The paper primarily focuses on technical, operating, maintenance and economic aspects of the machines, and does not attempt to compare the performances of different machines from the various manufacturers.IntroductionThe Sudbury Operations of Falconbridge Nickel Mines Limited are comprised of five operating mines and two mines under development. All the production comes from underground mines, mostly at depths below 1000 metres. The company, faced with increases in operating costs and difficult mining conditions, has continued to seek solutions with the help of new mining technology.The development of electric-hydraulic drilling machines in Europe had been pursued with great interest and, in 1979, a decision was made to test these machines to prove their technical and economic viability under operating conditions. Since then, a number of electric-hydraulic machines have been evaluated in different situations and currently nine hydraulic machines are being used in the company's various mines. These machines are comprised of two-boom drilling jumbos for development, one-boom machines for longhole drilling and a large-hole-diameter drilling rig for blasthole drilling. One hydraulic jumbo has also been used in a cut-and-fill stope."

Jan 1, 1982

By D. M. Slavich

"In today's operating and investment climate, project evaluation is both more important and more difficult. It is more important because economic and financial analyses of a proposed project provide a basis for judgment of a project's commercial viability by equity participants, lenders and, in some cases, other participants such as off takers and governments. It is more difficult because these analyses must, of necessity, be based on estimates, projections and evaluations which must be made in a period remarkable for its economic and political uncertainty.Project evaluation starts with the analysis of the engineering, commercial and financial information available. Beginning with the preliminary design and capital cost estimates, alternative financing plans can be developed outlining possible sources of funds, terms and security arrangements. Pro-forma financial statements can also be developed, including sources and uses of funds, cash flow schedules, income statements and balance sheets. With these results, various profitability measures can be determined.Subsequently, in an effort to deal with uncertainty, these results can be tested by measuring the impact on project viability and profitability of changes in project and external variables such as product process, mining and processing rates, operating and financing costs, currency exchange rates and other factors.The results are a number of financial projections reflecting different assumptions for key project parameters. The projections can be used to structure the project to achieve the maximum financial performance. Projects, the financial viability and profitability of which can be demonstrated under varying market conditions, will be the most competitive in capital markets."

Jan 1, 1982

By G. D. Just

"Extensive mechanization of underground mining operations, improvements in blasting technology and the development of simulation models for systems evaluation has now made it feasible to optimize rock fragmentation and materials handling operations. Methods of achieving these objectives are described in this paper, with particular emphasis on the need to obtain precise field data measurements. Techniques are illustrated with reference to the sub-level open stoping system of mine production. IntroductionThe primary objective to be achieved in any mining system is to deliver a specified grade of ore to the mineral processing plant at a planned delivery rate and at the minimum total mining cost. Design and management of such a system is complicated by the large number of unit operations and the often unknown inter- relationships between the different unit processes. This particularly applies in underground mines, where planning restrictions and unit costs are much greater than in comparable tonnage sur face mining operations. These difficulties can often be resolved by the application of judgment based on extensive experience, but the costly trial -and-error methods required for new technology discourage innovation.Most modern medium- and large-scale mines are now extensively mechanized. Consequently, the performance of each unit operation by individual items of equipment should be predictable for a given set of conditions. An essential prerequisite is that quantitative performance data are available from field measurements. Such information can then be used to optimize the design and management of the complete mining system to achieve the minimum tot al mining cost. One of the most significant factors influencing all unit costs is the degree of rock fragmentation. The importance of this variable is indicated by the fact that opt imization of rock fragmentation implies minimization of tot al mining system costs."

Jan 1, 1980

By F. T. Manns, G. Harper

"The Swayze gold mine is an Archean vein deposit in northern Ontario. The veins are superimposed on a conjugate joint system and are contained within an anastomosing alteration envelope in a metadiorite body. Reserves were estimated on the basis of fire assays of channel samples and car load samples from underground mine openings, surface and underground diamond drilling and surface trenching. A semi-variogram constructed from channel samples along one of the drifts yielded a horizontal, regionalized influence of approximately 9.0 m. Common industry practice has been to use 6.1 m for similar deposits in Ontario. Proven ore was defined from underground openings. The maximum extrapolation distance for proven ore along strike and dip from a data point is taken to be 6.1 m. Probable ore is extrapolated 7.6 m from a data point in a mine opening or from a drill intersection. Possible mineralization is based on geological continuity one-half the distance to a neighbouring data point.The mineral inventory estimate of 1.45 million tonnes at a grade of4.8 g Au/tonne gives an excellent outline of the geology of the deposit. The deposit contains 313 000 tonnes of ore reservesat a fully diluted grade of6.9 g Au/tonne. These figures include dilution for several reasons: (I) a 2.1 m mining width is used rather than the more typical 1.5 m width to allow for over break because of the shallow dip of some vein zones; (2) over break is allowed for adjacent to major unmineralized dykes; and (3) grams of gold are deleted from estimates to allow for the mining of unavoidable minor dykes.A personal computer with off-the-shelf software was used to compile 712 geologically defined ore blocks and sort them into a number of revealing categories. The computer was used to perform grade sensitivity tests, as well as to evaluate depth potential. Hopefully, the reiterative aspect of the method has randomized the errors and helped to cancel their effects."

Jan 1, 1987

By D. A. Trotter

"This paper traces the main advances in mine lighting from neolithic times to the 1960s. The earliest lights consisted of reeds or strips of wood soaked in grease. As man's knowledge increased, the oil lamp, the candle, kerosene, acetylene and finally electricity have allowed him to see where no natural light could penetrate. These advances in technology, however, did not come easily. Many false starts were made and great dedication was required by a few lighting pioneers to overcome the many technical difficulties that were encountered. The lighting of coal mines in particular caused unique problems, as there was the ever-present threat of methane explosions. Advances in mine lighting will continue, but these advances are only possible because men like Davy, Wolf, Marsuat and Edison paved the way.IntroductionMan's first efforts at mining consisted of merely picking rock off the surface of the earth. The sun was his only source of light. The early mines of the Neolithic age were simply vertical pits, 5 to 8 m deep. In order to follow an orebody, miners began to dig horizontally from the bottom of these pits, and as work progressed the need for additional light became apparent. With the discovery of the light-giving properties of fire, man was no longer dependent on natural light. Figure 1 gives an impression of the earliest artificial mine lighting used.Early Evidence of Mine LightingCarbonized residue from wood chips which had been inserted into rock cracks can be found in early Neolithic workings. The mines at Krzemionki Opatowski in Poland contain very narrow low tunnels that were lit in this fashion and were worked from 2300 to 1800 B. C. The wood had to burn downward to provide light and because wood burns poorly in this position, the chips were probably soaked in animal fat to make them burn more easily."

Jan 1, 1982

By J. Elderton

"The combination of A C induction motor and flu id coupling, of either the fixed or variable filling type, constitutes a simple, low cost, highly reliable drive unit, with many applications in the mining field.The paper will, however, concentrate on the variable filling fluid coupling in three principal applications-conveyor starting, infinitely variable speed control for slurry and slimes pumping and dewatering pumps for deep mines. Fluid couplings can be used with standard or custom-built control gear equipment, ranging from the most simple, time-based open loop types, to those having the latest microprocessor techniques.IntroductionThe first industrial applications of fluid couplings included their use in the mining field as hydraulic slip regulators for flywheel generating sets. These installations, usually rated at around 1700 to 2500 hp, were located at mine shafts where the electrical grid transmission lines were not strong enough to cater for the peak power demands of the cage winding cycle. In Canada, the first two significant examples of variable filling fluid couplings for mining were on conveyor drives, at Steep Rock Mines Limited, closely followed by the major iron ore handling term inal on the St. Lawrence River at Sept-Iles. Successful and reliable operat ion of the fluid couplings at these two sites set the pattern for use on many subsequent mining projects throughout the Canadian Continent."

Jan 1, 1986

By F. Logsch, H. Pempel, J. Markowski, P. Ay

"Due to the European Directive 2000/53/EC on end-of-life-vehicles, from 2015 on more than 95% of car materials have to be recycled. In order to recycle the materials back into the economic cycle, it is necessary to produce products with high quality and purity.Plastic components in cars, which are coated with metals by vapour deposition or electroplating, have a wide circulation (e.g., as cladding panel or trim strip for interiors and exteriors). In the end-of-lifevehicle recycling process, these plastic-metal composites are not considered in usual technologies (car shredder) and are not separated from Automotive Shredder Residue. These parts can be separated by optical or HF-detection sorting and then introduced to a specific treatment.Experiments with a specially developed bioleaching configuration showed that the thin coatings, which consist mainly of copper, nickel and chromium, can be removed efficiently from the polymer base materials by a bioleaching solution with Acidothiobacillus ferrooxidans as a leaching agent. The solution used was produced in special fermenters with a 9K-nutrient salt media. During the bioleaching process at 35°C maximum temperature, most of the copper is dissolved and the other metals accumulate as metal sludge. The bacterial cultures based on A. ferrooxidans are robust and resilient.After a 48-hour bioleaching period while the composites were stirred regularly with ventilation, the plastic particles were completely free from metallic coatings. The metal components are separated for further use: undissolved components (mainly Ni and Cr) are separated by decantation of the solution; dissolved copper recovey is carried out by cementation of copper. The cementated solid contains ~98% Cu, along with small amounts of other metals.With the bioleaching process, good separation and re-utilization of the metallic coatings is possible. The cleaned plastic parts were prepared by compounding for new applications with injectionmoulding."

Jan 1, 2016

By L. Cáceres, G. Leinenweber, P. Bustamante

"Given the severe scarcity of fresh water sources in Northern Chile the use of seawater has become the only alternative to allow mining expansion. This option however poses several technological challenges as a result of the high concentration of natural salts that promote various forms of metal corrosion. Therefore the steel piping protection has been a constant challenge for design engineers responsible for solving the problems of corrosion. Known protection alternatives are varied and expensive, a few of them are rubber coatings, protection based centrifuged concrete, extra wall thickness of pipes in combination with corrosion inhibitors, extra wall thickness of pipes without using corrosion inhibitors, and the use of highly corrosion resistant steel materials.In this framework the aim was to study the corrosion kinetics of carbon steel pipe API 5L X70 under electrochemical and weight loss testing. The test conditions include a range of seawater velocities between 0.2 to 3.0 m/s.For electrochemical experiments the API 5L X70 steel specimen was a 4 mm diameter disk embedded in an 8 mm diameter Teflon rod and exposed to seawater. Duplicated coupons were placed in a standard test apparatus that was built according to the standard ASTM D 2688 – 94.The main results were: a) corrosion mechanism explained in terms of the counterparts partial processes which are the hydrogen evolution and oxygen reduction reaction; b) for the test specimen a corrosion band like feature that suggest a lateral dispersion of aggressive solutions from corrosion pits; c) a range of corrosion rates between 1 and 1.96 mm/year for flow rates between 0.2 and 3.0 m/s; and d) a convenient inhibitor dose between 20–25 mg/L for optimum inhibition efficiency to obtain a maximum value of 80% for corrosion efficiency."

Jan 1, 2016

By Dougla McDonald, Richard Poulin

"Most mine managers in Canada today will agree that one of the keys to mining efficiency and productivity is their human resources. A5 a result, many mines develop some sort of incentive designed to tap their employees' capabilities to the fullest extent. Historically, the most common plans used have been ""piece-rate"" plans, where individual or small groups of miners are paid a financial bonus based on some measure of their productivity. Recently, however, incentive plans that take a more team-based approach have been developed in some Canadian mines. One such plan will be defined in this paper, and its popularity in the industry today discussed.Gainsharing PlansThere are two primary components to a gainsharing plan. The first is a cash incentive, which is paid to all employees and based on factors that are highly correlated with employee productivity, and key to the profitability of the mine. For example, the typical gainsharing cash incentive is based on the cost/unit of metal produced. Management (in consultation with employees in some cases) will establish the budgeted cost per tonne, and any savings in this amount is shared between the company and the employees. The second is a management philosophy and associated communication network, which is designed to foster an environment that encourages information exchanges, communication, participation, and trust between employees and management. The typical gainsharing communication network consists of two tiers of committees. The first, operational committees, include all employees working in the same department or departments which frequently interact. The employees meet monthly with management personnel to discuss problems encountered and brainstorm for solutions. In most cases, these committees will nominate a person in the group to structure the meeting to maximize its efficiency. The second, the screening committee, is a single group consisting of representatives from the various operational groups, whose primary job is to ensure that the plan is effective, and the objectives and results generated by the plan remain consistent with the mine objectives. In short, gainsharing plans tell employees that their bonus depends upon performance and then gives them the opportunity and incentive to affect that performance. The opportunity is provided by a communication network and positive management practices, and the incentive comes in the form of ""intrinsic"" rewards of participation and the ""extrinsic"" rewards of the bonus payments. Figure I will clarify the relationship between the intrinsic and extrinsic rewards."

Jan 1, 1995

By G. R. Sadowski

"Large subhorizontal joints have been found in the foundation excavations in basalt and granite of Brazilian Dams. Some spread for hundreds of square meters showed slickensides—polished surfaces plus striations—and laminations interpreted as related to shear displacement, what substantially reduced their shear strength and imposed special reinforcement measures against the potential sliding of overlying concrete structures. The geological characteristics of these discontinuities have raised speculations related to their origin, be it related to mechanisms of bulging, cambering or to some tectonic or primary geological event.Several geologists and engineers from the northern hemisphere including Terzaghi already showed to be concerned with their role in granite foundations while in the southern regions Brazilian authors have found similar occurrences but also affecting individual lava flows of continental flood basalts in the foundations of major dams of the Parana Basin, which they designated under the particular name of “fault-joints”. This double-standard designation is self-explanatory of the difficulties involving their origin and related geomechanical properties: faults or just shear joints?Recently, similar features were encountered in the foundations of large dam constructions in anorogenic granites inserted in the realm of the Brazilian Amazon, where some of these discontinuities exhibit features common to tectonic thrusting combined with deep tropical weathering.The evidence of preshearing along the surfaces of such fractures, also associated to products of deep weathering, reduces their geomechanical strength substantially, suggesting values of ultimate phi spanning 12 to 28°. The detection of these descontinuities during initial investigation phases continues to be a major complex task in geological risk evaluations surveys. Trenching associated to some geophysical exploration techniques, although considered to be very basic exploration techniques are still the suggested methods for their forecast and previous determination."

Jan 1, 2015

By Desmond M. Levins, Reginald K. Ryan

"Removal of radium from uranium tailings would substantially lessen their environmental impact because it would eliminate, or greatly reduce, the hazards arising from radon emanation, leaching of radium, dust dispersal and gamma radiation. A process is described to extract radium from tailings by leaching in 3M Nael solution. The radium can be rapidly leached at ambient temperatures by either multi-stage contact in agitated vessels or washing on a tailings filter cake. Extraction efficiencies ranging from 80 to 94% have been measured for tailings derived from a number of Australian ores.Methods for radium recovery from the leach solution by precipitation, ion exchange and adsorption have been examined. Precipitation as barium/radium sulphate appears to be the most suitable approach. A possible flow diagram for the process is proposed which involves recycle of the saline leach liquor.IntroductionDisposal of mill tailings is the most contentious environmental issue facing the uranium mining industry. The conventional approach to managing tailings is to store them in a dam above ground. Attempts have been made to stabilize some tailings piles by physical or chemical methods. In a few cases, the tailings have been covered with earth and revegetated. However, most tailings piles from abandoned mills are in a neglected state and subject to the erosive and dispersive forces of nature. The cost of remedial action is high. The United States Department of Energy (DOE) has estimated that it will cost up to $130 million to rehabilitate abandoned mill sites in the U.S .A..Environmental authorities are now insisting that uranium mining companies improve their methods of tailings disposal. In the United States, the preferred approach is burial, either in mines or in specially excavated pits. Tailings retention systems as operated in Canada are regarded as storage facilities until an acceptable method of disposal is found. In Australia, the Fox Commission recommended that tailings from the Ranger project should be returned to the open-cut mine. Returning tailings to the mine has considerable merit, but it is not always a viable option. In many underground operations, it is not physically possible to fit all the tailings in the worked-out mine. In other cases, the groundwater hydrology of the mine may be unfavourable."

Jan 1, 1980

By V. G. c Papangelakis, M. Huang

A conductivity cell, developed previously, was employed in an effort to investigate the inter-relation between electrical conductivity and acidity of sulphuric acid - metal sulphate solutions at high temperatures. The measured solutions include the H2SO4-H2O, MgSO4-H2O, H2SO4-MgSO4-H2O, H2SO4-MgSO4-Al2(SO4)3-H2O solutions. All solutions reported in this paper were measured from 15 to 250 °C at equilibrium vapour pressure. The maximum measured concentrations of H2SO4, MgSO4 and Al2(SO4)3 were 0.45 m, 0.30 m and 0.10 m, respectively. It was found that, from 15 to 250°C, there is a linear relationship between H2SO4 concentration and electrical conductivities for acid concentration up to 0.45 m. At 250 °C and constant H2SO4 concentration, the solution conductivity drops with the increase of MgSO4 concentration. Lt is suggested that this drop is caused by a decrease in the concentration of H. Finally, an empirical model was developed based on the available measurements. This model has been tested against real laterite leach solutions where sulphuric acid and metal sulphates are dominant electrolytes. The average difference between the estimate acid concentration from this model and the one from titration was less than 5%.

Jan 1, 2004

By G. Girard, A. Larouche, J. Colbert, G. Doyer

"The Direct Chill (DC) casting process uses water to extract heat from molten aluminium and helps to control the solidification process. Many factors such as the water flowrate, water distribution around the mould and water impingement angle have significant impacts on the solidification process. It has been noted that the chemistry variation of the cooling water is also an important factor that has a major impact on the presence of defects on the ingot. A significant change in the water quality can produce defects on the ingots such as cracks, bleedouts, or runouts. Understanding the impact of water quality variation on ingots is therefore essential to ensure good ingot production and reduce defects. This paper aims at describing a new approach to follow the variations of process water quality over time. It is an original and innovative method, which is still under progress. A water quality and stability index (WQSI) is under development to evaluate changes in the water composition based on water physico-chemical parameters. The index is calculated by comparing each of the actual parameters with historical values previously modeled by a statistical law. It is a dimensionless number having an adjustable weight factor for each parameter. The positive or negative contribution of each parameter, with respect to the water cooling capacity, is taken into account to calculate the WQSI. The current selection of parameters is based on knowledge from the literature as well as on empirical experience. When the developed tool will be mature, it could be used to track water variations upon time and anticipate problems, enabling proactive actions to ensure good ingot production.INTRODUCTIONFor many years, the impact of water chemistry on heat transfer, during DC casting, has been of great interest in the aluminum industry. Several papers have been published to demonstrate the correlation between water chemistry and heat transfer (Yu, 1985), (Gildemeister, 2014). Although numerous studies do present the effects of water parameters (i. e. hardness, conductivity, oil, and grease…) on cooling capacity under controlled experimental conditions, they do not reflect the strong interactions between the parameters and variations present in a casting center. Wells and Cockcroft also demonstrated that laboratory based studies are not fully representative of real heat transfer in an industrial casthouse, there are too many factors involved (Wells, Li, & Cockcroft, 2001). In this context, it becomes very difficult to obtain a quantifiable relationship between the capacity of water to cool the ingot and ultimately the performance of the cast."

Jan 1, 2016

By T. Holmes, S. Davison

"The Special Standard Surge bin at Agrium’s Vanscoy Potash Operations (VPO) has been plagued with flow problems and wear, and corrosion issues for it’s entire working life. Investigation showed that the carbon steel construction, bin geometry, and resultant funnel-flow pattern were directly responsible for production losses and disproportionate maintenance and capital costs. Potash enters this bin at between 140°C and 165°C, but the stagnant potash outside the active flow channel was much cooler, allowing moisture to migrate toward the outer regions, which caused corrosion of the walls and reduced live capacity as the potash in this area hardened and built up on the walls over time.A 2013 inspection revealed holes and paper-thin areas in the lower cylinder wall sections and in the conical hopper. The only thing preventing major leaks and even a potentially catastrophic failure was the buildup of stagnant hardened product on the cone walls. It was concluded that the cone had reached the end of its life and required replacement. VPO’s original plan was to replace the cone in kind and repair the cylinder as necessary; however, a failure-mode and bin-performance investigation combined with a lifecycle- cost analysis indicated it would be better to redesign the hopper.For success in retrofit projects, it is essential at the design stage to consider the bulk solid flow properties and the operating environment involved. Because education in this area is not offered at a university level, engineers often do not fully appreciate the effects of the flow properties of bulk solids on bulk material handling equipment.Jenike & Johanson conducted flow properties tests on samples of potash and using the data, redesigned the bin and the feeder. After the modifications, VPO’s surge bin provides safer, more reliable operation with a much longer predicted working life. Using this retrofit as an example, we aim to provide a general understanding of bulk solids flow theory and highlight the importance of customizing the design to the appropriate flow properties in the cost effectiveness, reliability, and safety of a bulk material handling system."

Jan 1, 2016

By D. M. Aloi

In today's evolving and globalized world, mining companies are being pressured to move beyond compliance towards long-term sustainability and sustainable development. Companies are expected to "engage" with communities and measure the success of these engagements without a clear understanding of "how" to do this. This move, away from "Corporate" Social Responsibility (CSR) and compliance, develops more of a focus on "Community" Social Responsibility and sustainability. This shift in focus leads to the development of world-class projects that provide sustainable development for people, reduces the incidence of costly delays, and promotes good global citizenship for corporations. The process of "engaging" communities in mining project design and development leads to a stronger license to operate and sustainable development. To create this mutually beneficial relationship between communities and companies, communities must be "engaged" in the mining process as early as possible, preferably during the exploration or the concept phases. How to create this "engagement" remains elusive. How to measure the progress of this engagement is also problematic. The quantitative and qualitative metrics needed to measure both positive and negative impacts of the mining and community relationship will be discussed.

Jan 1, 2007