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By A. Idegami, M. Imamura, S. Heguri, Y. Ozaki

"Nickel powder can be produced by the reduction of a nickel ammine complex solution by hydrogen at high temperature and pressure. To minimize the deposition of fine nickel on the surface of the reactor and other equipment, seed crystals are added to the initial solution to promote nucleation of the nickel powder. Such seed crystals catalyze the precipitation of the nickel particles on the surface of the seed and enhance grain growth. In this study, nickel nuclei were precipitated by the addition of a polymer to the nickel ammine complex solution, resulting in the production of nickel powder. Thus, we herein propose a model that explains the effect of the polymer in the precipitation of nickel nuclei.INTRODUCTIONNickel powder is commonly produced via a hydrometallurgical process from the hydrogen reduction of a solution containing a nickel ammine complex at high temperatures and pressures, and this process was commercialized in the 1950s by Sherritt Gordon (Sherritt International, Canada, Benson & Colvin,1973; The Staff, Research and Development Division, Sherritt Gordon Mines, Ltd., 1958).In the above transformation, upon the injection of hydrogen gas into the solution, nickel is reduced as outlined in Equation(1), ultimately resulting in the production of nickel powder.Ni(NH3)nSO4+ H2?Ni+ (NH4)2SO4+ (n-2)NH3(n:2–6)(1)In this process, seed crystals are added to the reactor to suppress the precipitation of fine nickel (scaling) and to enhance nickel reduction (Benson & Colvin, 1973; Mackiw, Lin & Kunda, 1957). More specifically, iron sulfate and a small amount of dispersant polymer are added, which leads to the formation of nuclei. Upon subsequent hydrogen reduction, the reduced nickel can then be deposited on the nuclei, allowing nickel particle growth to take place. However, this results in iron contamination in the final nickel product, and so the use of pure nickel as a seed crystal is desirable to produce high quality nickel powders."

Jan 1, 2017

By John J. Laffin

"IN THE BOOK that has been rated the best seller of all time, it is predicted that man will earn his livelihood by the sweat of his brow. Apparently man has accepted the statement as a challenge and has been attempting to refute it ever since, as he continues to transfer the workload to his inanimate servants - the many types of machines and other labour-saving devices that are available to assist or perform for him in the normal tasks of the day. The history of the evolution of the use of energy takes us back to primitive man, who existed in a very low energy environment, the only energy available being his own muscle power. Although man took a great leap forward when he discovered fire, which was used for lighting, heating and cooking, he still depended upon his own muscles for power. Early man's greatest achievement was probably the invention of the wheel, which permitted him to utilize the muscle power of animals. While still in a very primitive state when viewed from the perspective of the twentieth century, man, with fire and the wheel, had achieved a standard of life far exceeding that of his predecessors. Looking beyond the very basic elements of human energy, fire and the muscle power of animals, we find the next additions of energy coming from man's mastery of other elements of nature. The Phoenicians utilized the power of the wind and the Romans adapted the energy of falling water to the water wheel."

Jan 1, 1972

By C. A. Rowland Jr

"I. INTRODUCTIONFred C. Bond's ""Third Theory of Comminution"" (1) was published in 1952. The mathematical statement of the Third Theory is the well-known Bond Formula:where W - Kw H per short tonWl - Work IndexP - Product size in microns which 80% passesF .. Product size in microns which 80% passesWork Index, as defined by Fred Bond, "" ... is the comminution parameter which expresses the resistance of the material to crushing and grinding. Numerically, the Work Index is the KwHrs per short ton required to reduce the material from theoretically infinite feed size to 80% passing 100 microns."" (2)Work indices for grinding can be obtained tram Bond grindability tests and can be calculated from plant grinding mill operating data when power consumed per ton of ore ground, the feed size analysis and the product size analysis are known.Work indices obtained tram Bond grindability tests, having been obtained from standard and controlled laboratory procedures, are reproducible and for the sample tested are accurate. The degree of accuracy relative to plant mill operation depends upon how representative the sample is of the total mill feed.The results of the Bond closed circuit rod and ball mill grindability tests (3) are given in grams of product sized material produced per revolution of the test mill. In developing a method to evaluate plant operating data and results from his grindability test, Fred Bond developed the ""Third Theory of Comminution."" In the process formulae were developed for converting grams per revolutionobtained from grindability tests to work index.The standard feed sizes for the Bond grindability tests are:Rod Mill Test ore crushed to minus 1ll inchBall Mill Test ore crushed to minus 6 mesh (Tyler)The formulae for converting grams per revolution to work index incorporate the 80% passing sizes for the feed to and the product produced in the specific test. Therefore, accurate work indices can be obtained from Bond grindability tests when the feed size is finer than standard. To obtain accurate test results, the ratio of reduction should be greater than 6 to 1."

Jan 1, 1972

By Gyan S. Rajhans

"The strategy of fibrous dust sampling is discussed, various sampiing methods are critically reviewed .and their application to coal dust is demonstrated. Fibre counting is described in detail. An attempt is made to explain the basis of determining the threshold limit value of asbestos and other dusts. The paper also discusses such dust control methods as enclosure of the process, effective local exhaust ventilation, segregation, substitution, wet processing and continuous monitoring of the return air for recirculation."

Jan 1, 1970

By W. R. McClelland

GOLD-BEARING ores, representing many types, are found widely distributed through the Province of British Columbia. They range from those which by their nature may be considered as complex, to those whose mineral characteristics are simple. Those in which the gold is associated with metallic sulphides provide particular milling and metallurgical problems, the solution of which involves not only detailed laboratory investigation but also a careful consideration of economic factors. The location of an ore-body may have a deciding influence on the adoption of a method for the metallurgical treatment. Whether the ore should be treated with the object of recovering the gold as bullion or as a shipping concentrate is often dependent on such topographical considerations as the position of the mine at or near tidewater or within a reasonable overland distance of a smelter. British Columbia is fortunate in having the Trail smelter situated in the southern part of the Province, and the smelter at Tacoma, Washington, is accessible for coastwise traffic. Both of these provide a ready market for most types of gold-bearing concentrate. In order that the results obtained by laboratory tests may give a fair indication of what should follow in mill operation, it is essential that the test sample should represent as closely as possible in mineralogical character and in grade the ore that eventually will constitute the feed to the mill. In the early stages of mine development this consideration is sometimes overlooked and samples of a much higher grade than would be representative of run-of-mine ore are submitted. Flotation tests on such a sample of ore high in sulphides may show a low ratio of concentration, bu.t if the actual run-of-mine ore is lower in sulphides the mill operation will reveal a much higher ratio. The recommendations for treatment based on the results of laboratory tests may have been against concentration, when in actual operation this would be the most suitable method of treatment. Recommendations based on laboratory tests are necessarily from the results of work carried out on the sample submitted, modified only by such other economic or topographical information as may be known to the investigator. This paper deals with a few of the gold ores found in the six mining districts of British Columbia and is based on investigations made in the Ore Dressing and Metallurgical Laboratories of the Mines Branch, Department of Mines, Ottawa.

Jan 1, 1937

The negative effects of pyrite and pyrrhotite on thiosulfate gold leaching have been investigated. Possible remedies to reduce some problems are discussed. In a gold bearing pure silicate ore, 92% of gold could be extracted within 3 hours using a solution containing 0.2 mol/L ammonium thiosulfate, 0.9 mol/L ammonia, 30 - 300 ppm copper sulfate and 8.6 ppm dissolved oxygen at pH 10.26. The thiosulfate consumption was 7.1 kg/t under these conditions and could be further reduced to 3.5 kg/t by decreasing the dissolved oxygen to 0.3 ppm. Addition of 16% pyrrhotite or pyrite into the silicate slurry led to a decrease in gold extraction by 2% or 9% respectively and an increase of thiosulfate consumption by 11 kg/t or12.8 kg/t respectively in three hours. Several adjustments, such as increasing copper ion and ammonia concentration and reducing the dissolved oxygen level to 0.3 ppm resulted in increased gold extraction and lower thiosulfate consumption despite the presence of these sulfides.

Jan 1, 2005

By M. C. Bétournay

Under the requirement to define the economic advantages of using hydrogen fuel cell vehicles, a broad-scoped project was initiated to quantify the costs associated with operating fuel cell vehicles and diesel vehicles. While ventilation savings are clearly an advantage for the former, a complete and detailed analysis of this and other operational and capital cost elements was undertaken in order to provide the mining industry with factual information in considering the changeover from one technology to another. This paper outlines the results of the investigations to date defining the costs/benefits associated with capital purchases, operations (electrical/diesel, mine air heating fuel, ventilation, openings, surface and underground infrastructure, maintenance, labour, etc.), delivery of energy, regulatory obligations, and mine production. Considerations are given to the type and size of a mining operation, the depth, and location in North America. Significant ventilation power, equipment, and infrastructure savings are possible with the application of fuel cells for shallower mine applications. At depth, where heat is an issue, there is a reduction in benefit. Specific qualifiers such as minimum air velocities, dust dilution, shaft, and heating system velocity limits must be considered on an individual mine basis. While the capital cost for fuel cell mining equipment is currently higher than diesel versions, the high cost of fuel cells is anticipated to be reduced significantly in the near future with the intensification of manufacturing. In either case, the operational savings would probably be sufficient to balance the supplementary capitalization costs. Comprehensive reports have been issued.

May 1, 2005

By G. Righettini, G. Desrivières, P. Mousset-Jones, R. Lacroix, M. C. Bétournay, P. Laliberté, S. Hardcastle

"Under the requirement to define the economic advantages of using hydrogen fuel cell vehicles, a broad-scoped project was initiated to quantify the costs associated with operating fuel cell vehicles and diesel vehicles. While ventilation savings are clearly an advantage for the former, a complete and detailed analysis of this and other operational and capital cost elements was undertaken in order to provide the mining industry with factual information in considering the changeover from one technology to another.This paper outlines the results of the investigations to date defining the costs/benefits associated with capital purchases, operations (electrical/diesel, mine air heating fuel, ventilation, openings, surface and underground infrastructure, maintenance, labour, etc.), delivery of energy, regulatory obligations, and mine production. Considerations are given to the type and size of a mining operation, the depth, and location in North America.Significant ventilation power, equipment, and infrastructure savings are possible with the application of fuel cells for shallower mine applications. At depth, where heat is an issue, there is a reduction in benefit. Specific qualifiers such as minimum air velocities, dust dilution, shaft, and heating system velocity limits must be considered on an individual mine basis. While the capital cost for fuel cell mining equipment is currently higher than diesel versions the high cost of fuel cells is anticipated to be reduced significantly in the near future with the intensification of manufacturing. In either case, the operational savings would probably be sufficient to balance the supplementary capitalization costs.Comprehensive reports have been issued."

Jan 1, 2005

By F. Malek

At Creighton Mine, magnitude events are a regular occurrence due to depth and major seismically-active structures. Over the last ten years, major advances have been made in research and development to develop strategies for the management of these major events. Today, the number of rockbursts has been drastically reduced at the mine and damage due to seismic events, when they occur, is often minimal. This paper describes the evolution and implementation of appropriate geomechanics strategies, designs, and practical ground control measures undertaken for the management of seismicity at Vale Inco?s Creighton Mine. A description of the research and development approach, implementation, and ground control strategy is provided for placement of enhanced support systems to manage the consequences of magnitude events at Creighton

May 1, 2009

By John G. Henning

The Porcupine Joint Venture operates the Dome Mine in South Porcupine, Ontario. Dome underground began production in 1910. It is the longest continuous operating gold mine in Canada, producing in excess of 15 M ounces. More than 900 underground stopes have been mined and hundreds of miles of drifts, sublevels and raises developed. Underground mining methods included shrinkage, cut and fill and longhole. Not all stopes were backfilled upon completion, particularly the longhole stopes. The Dome open pit was designed above the underground mine workings such that, as the pit is excavated, it intersects underground drifts and stopes. Potential operational problems associated with the interactions between the stopes and the pit walls may occur, necessitating pit wall redesign, ground support installation and operational rescheduling. Each intersection of the pit with the underground mine workings is closely evaluated to maintain a safe working environment and wall stability. This paper discussed how risks to pit wall stability are assessed, mitigated and monitored.

May 1, 2004

By Turgut Yalcin

"In this study, potential benefits of focculant usage were explored in the processing of mill tailings by hydrocyclones. Tests conducted on copper-nickel mill tailings have demonstrated that, under suitable conditions, flocculation could significantly enhance solid-liquid separation in hydrocyclones. For example, at a feed pulp density of approximately 9%, focculant-assisted hydrocyclone produced an underflow with over 98% solids recovery, compared to a recovery of less than 53% with conventional hydrocyclone. However, feed pulp density was found to be a critical factor, and tailings with pulp densities of greater than about 15%required a two-stage hydrocyclone operation where the focculant-assisted hydrocyclone was employed at the second stage to process the overfow of a conventional hydrocyclone.The underflow and overflow products obtained from the focculant-assisted hydrocy-clone may be discharged into tailings dams in the same manner as those produced by gravity thickeners. The focculant-assisted hydrocy-clone would, however, provide a higher throughput."

Jan 1, 1996

By P. C. Holloway, A. Tshilombo, T. Xue, M. J. Collins, R. Lopetinsky, I. Mihaylov, I. M. Masters

The Voisey’s Bay deposit contains a trace amount of cadmium, which reports to solution during pressure leaching of the nickel concentrate at Vale’s Long Harbour Hydrometallurgy Plant, and must be removed to produce high quality nickel cathode. In 2006, Vale approached Sherritt Technologies to collaborate on the development of a process for removing cadmium to low levels (<1 mg/L) in the nickel raffinate. Following successful bench scale and pilot plant testing at Sherritt’s laboratories, the cadmium removal process was then moved through engineering and construction, culminating in the successful commissioning and startup of a cadmium removal circuit at the Long Harbour Hydrometallurgy Plant in 2017. This paper presents the results of this collaboration and the challenges that were encountered through each stage of development, as well as current results from operation of the commercial cadmium removal circuit. INTRODUCTION Vale’s Long Harbour Processing Plant, with a nameplate capacity of 50,000 t/y nickel, began operation in 2014. In addition to electrolytic nickel rounds, the plant also produces electrolytic cobalt rounds and copper cathode. The Long Harbour Processing Plant uses a unique hydrometallurgical process developed by Vale Base Metals Technology Centre, as shown in Figure 1, to treat a nickel sulphide concentrate produced at the Voisey’s Bay mine and mill located in northern Labrador (VBN concentrate) (Stevens et al., 2009).

Jan 1, 2019

By L. M. Southwick

"The history of extractive metallurgy is replete with examples of commercializing new processing technologies. The successes are widely reported, but failures seldom are. This is unfortunate, for usually we can learn more specifics on how to succeed in technology development by studying and thoroughly understanding their failures. Frequently one encounters a red herring that caused the whole effort to fail. A thorough and objective due diligence up front would have identified those red herrings and prevented the pursuit of a bad idea and the resulting destruction of capital. Due diligent analyzes performed before construction of three such bad ideas will be discussed. One is an EAF dust process, which pursued the red herrings of a poor understanding of the business, a naïve view of past experience, and false confidence in the technology. Another will examine the effort to commercialize a new pressure copper leach process that followed the red herrings of inadequate testing of the raw material, application of processing conditions that were inherently unsafe, and an improper assessment of the inherent advantages of past developments. The last is an alternative iron-making process, where the red herrings were incomplete and superficial assessment of prior pilot plant and demonstration plant tests, an assumption that the commercialization model of “build it and we will make it run” was viable, and a technology whose technical fatal flaws had already been identified. Unfortunately, capital destruction often also closes the window to more intelligent pursuit of technology development. TECHNOLOGY COMMERCIALIZATIONThe development and commercialization of new technology is a vital part of keeping industry profitable, able to deal with new sorts of feed stocks and current with economic, product, operational and environmental requirements. This is a difficult task in the best of times, and can be compounded when the developers become enamored of a particularly favorable characteristic of the project or of the product. These “red herrings” divert project focus away from the arduous path to success and, in the end, result in project failure."

Jan 1, 2012

By J. Armitage, J. Erskine

Feed level and thickness measurements are essential in the optimization of an electric arc furnace. A precise measurement of the feed thickness and level gives operators the ability to increase the smelter efficiency and reduce the maintenance cost. Hatch has developed a radar system which is an affordable, low maintenance, and accurate level measurement system. The radar units can be installed across the furnace to measure the feed level and the feed thickness can be calculated with one slag level sounding. The present paper describes the development of radar systems as a process optimizing tool by furnace controls. The authors will discuss the challenges involved in installing eight radar units on the roof of a six-in-line electric furnace.

Jan 1, 2015

By K. Hawboldt, J. E. Halfyard, C. Bottaro, I. A. Harrison

"The removal of elemental sulfur from leach residues derived from massive sulfide concentrates via hydrometallurgical routes has been demonstrated in a laboratory setting by converting water-insoluble sulfur to water-soluble polysulfides. The approach was applied to leach residue from Vale's nickel hydromet demonstration plant in Argentia, Newfoundland, which contained significant amounts of elemental sulfur. This technique offers an alternative treatment protocol for residues with a sulfur component not amenable to standard flotation/hot filtration processes. The practical considerations of a proposed flow sheet will be discussed including the impact of other sulfur species (e.g. thiosulfate and sulfides) and key process variables. INTRODUCTIONPresently, large scale elemental sulfur extraction from hydrometallurgical leach residue is performed by Teck Resources using a process of sulfur flotation followed by hot filtration (Chalkley et al., 1993). As mentioned, the technique proves viable for residues derived from specific concentrations - in this case zinc - whose residues constituency is primarily elemental sulfur itself. However, problems arise when this constituency is altered as happens when, for example, a mine containing one particular concentrate is mixed or replaced with a differing concentrate from a second mine. Such cases can often strain the effectiveness of current sulfur removal processes (D'Odorico, 2004). If hydrometallurgical residue containing elemental sulfur cannot be effectively treatment by flotation, the residue is stored subaqueously as is the case in some 'grass roots' hydrometallurgical plants (those not coupled with smelting operations). Hydrometallurgical processing of concentrates involving pressure leaching is becoming increasingly common throughout the mining world, the genesis of which can be found in research performed by Sherritt in Fort Saskatchewan since the 1950’s (Ozberk et al., 1995).The investigation of elemental sulfur removal by means other than flotation includes the uses of sulfide salts (NH3S or Na2S) effecting the conversion of hydrophobic elemental sulfur to hydrophilic polysulfides. The work of Kunda et al. (1974) and Olper et al. (2007) shows that elemental sulfur can be quantitatively removed from hydrometallurgical leach residue via the formation of a mixture of polysulfides."

Jan 1, 2012

By E. M. Watkin

"Land directly disturbed by hard rock mining activities in Ontario and Quebec was surveyed in 1974 as part of a country-wide assessment, (Murray 1977). Some 15, 000 hectares, or 5 7 square miles, are listed as having been disturbed by overburden removal, waste rock and tailings deposition (Table 1) in the region. That area represents sixty-eight per cent of the total area which ha1; been disturbed by mining in central and Atlantic Canada. Assessment of disturbed areas was undertaken using LANDSAT-1 and LANDSAT-2 satellite imagery. Certain limitations of the technique were recognized but the data obtained were considered a relatively acceptable assessment of the extent of disturbed areas larger than ten hectares.Approximately ten per cent of the land disturbed by mining in the two provinces has been reclaimed to varying degrees. Indeed, this proportion is correct for the country as a whole. As pointed out by Ripley, Redmann and Maxwell (1978), some of the land was disturbed long before environmental concern 01· reclamation were ever considered. In numerous instances reclamation will remain impossible until presently active operations are closed. Nevertheless, these authors feel such figures make it clear that reclamation has not been a high priority in Canada in the past. Canada is a vast country, and there has been little pressure toward efficient use of all land space. Most mining operations occur in areas distant from the country's population centres. Under these circumstances, therefore, the pressure to reduce the environmental impact of mining is much less than in the more densely populated areas of Europe and the eastern United States, where such activity can occur in or adjacent to large metropolitan areas."

Jan 1, 1980

By T. Bhambhani, Mukund Vasudevan, Partha Patra, D. R. Nagaraj, P. Somasundaram

Selective Ni separation from ultramafic ores rich in serpentines has been a huge challenge in the mineral processing industry, and therefore highly inefficient. Analysis of the root causes of the challenges and consequent development of robust processing solutions were the main goals of the Cytec-Columbia. University-Vale Joint Development Program. In this context, the subject of this paper is limited to one of the key findings of this research program which is the influence of fibrous serpentines on grade-recovery characteristics. Specifically, the poor flotation behavior is characterized by an atypical reverse C-shaped grade-recovery curve.

Jan 1, 2011

By A. A. de Gast, R. B. James

"The metal content of ore blocks can be calculated by the use of many different methods. These methods range in sophistication from manual calculation to computer. oriented techniques. In this case a cubic polynomial regression model is developed to depict the grade distribution of an orebody. Mine production, in stope dimensions, is then simulated on a computer to predict the output of metal content. The volume, grade and variance of the grade are estimated by triple integration and matrix algebra. A case study shows reasonable agreement between the results from the mathematical model and the mine geologists' estimate of production and ore reserve grade and tonnage."

Jan 1, 1972

In the last five years, new iron ore pellet plants have been built with significantly reduced air pollution levels compared to the older generation of plants. European and American pollution controls are more stringent that in China and Brazil. The recent American plants have successfully employed circulating fluidized beds for sulfur control, baghouses for particulate control, activated carbon injection for mercury and a new design of specialized low-NOx burners.

Jan 1, 2015

By E. M. Watkin

"Although Canada has achieved one of the highest living standards in the world, people and organizations have, over the past decade, begun to question the cost and means of this achievement. Concern has been expressed about the degree of environmental disturbance arising from industrial activities which have greatly contributed to our increased living standards. These industries include hardrock mining, pit and quarry operations, hydro-electric schemes, various agricultural enterprises and urban land developments.In the construction and operation of the above industries many environmental problems arise because the natural vegetative land cover is destroyed or drastically disturbed. Disturbance may occur to such a degree that revegetation is di ffi cult, often it appears impossible. Portions of the environment around such industries remain aesthetically unacceptable and appear to offer little or no potential for future resource use in wildlife, recreation or agriculture.The general public cannot dissociate itself from the activities of the aforementioned industries. It has, over many years, accepted the benefits and conveniences arising from those activities. Despite this, the increasing level of public concern imposes upon industry a need to alleviate or repair past, present and future environmental disturbance. Therefore it is incumbent upon industry to modify present technology or develop new techniques which would allow the disturbed environment to be easily and rapidly repaired."

Jan 1, 1975