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By Chri Rule

"This paper tells the story of the rapid commercial application of stirred milling technology at Anglo American Platinum’s many Concentrators. The first stirred mill – a 10 000 litre IsaMillTM; the largest at the time, was commissioned in late 2003. The project development work was presented at SAG 2001. This operation was “proof of concept” and vindicated the decision to scale up the technology; allowing a rapid and extensive roll-out of mainstream regrind mills as well as several further flotation concentrate regrind mills, over the next six years.Currently 23 stirred mills are in operation with 64 MW of installed drive capacity – this paper describes the projects’ roll-out and the significant results achieved to date. Many operational problems have been solved along the way, some of these will be described. The introduction of the technology has seen a step change in metallurgical results and progressively decreasing operating costs."

Jan 1, 2012

By Rae Simpson

"This paper provides insight into the elements of computerized maintenance systems and identifies some of the factors which influence their effectiveness. The paper describes what to expect in terms of benefits and problems, the nature of effective computerized maintenance systems, some of the systems available and a process for selecting a system for your organization.The paper will be of interest to mining company executives and maintenance or computer personnel who are involved with, or contemplating, the introduction of computerized maintenance systems.IntroductionIn the drive to improve profits in an increasingly competitive world, mining companies are now using some of the most sophisticated equipment available. The introduction of large and complex equipment such as drag lines, haul trucks, and high-capacity milling equipment has resulted in order-of magnitude improvements in productivity. However, this productivity is now, more than ever, dependent on the continued operation of the equipment. A prolonged breakdown of a critical component can have a significant effect on companies' bottom-line results. As more technologically sophisticated equipment is introduced, maintenance costs become an increasingly important factor for mining companies.Fortunately, sound modern management principles are being used more often in maintenance departments. Progressive maintenance managers are turning to computers to help manage the myriad of details associated with running a maintenance organization.Some maintenance departments in larger mining operations would find it difficult, if not impossible, to operate at current productivity levels without their computer systems. Unfortunately, some other companies gain very little from their computerized systems and would probably be better off without them.How can you be sure that computerized maintenance will improve the maintenance picture for your company? What benefits can you expect to achieve? How do you go about selecting a maintenance system for your organization? These are some of the questions facing industry managers and executives today. In the following sections, we will provide some guidelines and insights to help address these challenges."

Jan 1, 1988

By R. S. Nichols

"During 1973 to 1978, Canadaka Mines Limited, a subsidiary of St. Joseph Explorations Ltd., undertook an extensive exploration and development program in the Cobalt area. This program resulted in the delineation of previously unknown stratigraphic units in the Archean volcanic sequence. During this time period, significant are controls related to area silver deposits were also identified.The Archean geology is comprised of a volcanic pile conformably overlain by sediments. The volcanics contain at least two felsic volcanic centres near the stratigraphic top of the pile. The bulk of the pile consists of mafic flows and interflow sediments. lnterflow sediments around silver are shoots contain mineralized halos of base metal sulphides. The halos exhibit lateral and vertical metal zoning with Cu, Pb and Zn mineralization decreasing away from an are shoot.Silver mineralization controls determined during the Canadaka program agree with the historically well established importance of Coleman sediments as well as Archean contacts for hosting silver deposits. The vertical extent of are shoots is typically 150to 250ft. A strong correlation was found to exist in the Cobalt area between Archean strike and the strike of are veins. Finally, al/ Cobalt area are deposits appear to be associated with a distinct volcanic pile at the top of a sequence of Archean flows."

Jan 1, 1988

By Sadan Kelebek, Gerhard W. Heinrich, Peter F. Wells, Peter J. Whittaker

"Based on plant mineralogical data & circuit modelling, a pilot plant campaign was conducted at Strathcona Mill to identify options for improving the performance and operating flexibility of the copper-nickel separation circuits. Emphasis was given to options for combined treatment of the two feed streams (primary nickel ore rougher concentrate and copper ore circuit concentrate) to obtain more flexibility in the use of existing column flotation capacities. The pilot test results demonstrated that circuits which incorporated preconcentration prior to column flotation gave the best metallurgical results. Maximum column carrying rates were also related to the preconcentration. Predictions that increased circulating loads from the column scavengers would improve copper-nickel separation performance were confirmed.IntroductionThe copper-nickel separation circuits at Falconbridge's Strathcona Mill produce a high grade (>30% Cu) copper concentrate most of which is treated at the Falconbridge Kidd Creek smelter near Timmins. The remaining nickel concentrate which still contains approximately 20% of the feed copper is combined with other lower grade nickel/copper concentrates and shipped to the Falconbridge nickel smelter. The separation is required because of the limited capacity for copper processing in and downstream from the nickel smelter. Since no nickel is recovered at present in the Kidd smelter, the challenge is to minimize the nickel content of the copper concentrate.At present there are two independent separation circuits treating the rougher concentrates from the copper and nickel circuits as shown in Figure I. The minerals treated are mainly chalcopyrite and pentlandite but there is up to 25% of the copper present as cubanite in the copper ore. The circuits were kept separate because the flotation rates and froth characteristics were very different, probably because of the presence of cubanite and the large difference in the concentrate grades feeding the circuits."

Jan 1, 1995

By J. M. Paxton, R. L. Roscoe, G. A. McCreary, W. W. Muir, T. J. Drown, D. A. Barr, T. W. Law

"This paper reviews the complete cycle of a small mining operation in a remote section of northern British Columbia, including discovery, exploration, development and production. The discovery of high-grade epithermal gold-silver mineralization occurred in 1969 following a regional geochemical reconnaissance program designed to search for porphyry copper mineralization in the Cassiar-Omineca Mountains. Exploration and development from 1971 to 1979 included geological, geochemical and geophysical surveys; trenching, almost 30 000 feet of surface and underground drilling in about 100 holes and cross-cutting, drifting and raising on the principal goldsilver- bearing vein. This led to the delineation of 100000 tons at an estimated grade of0.9 oz gold per ton and 18 oz silver per [on to an average depth of 120 feet below surface. of a 100-ton per day mining operation employing about 50 personnel with all supporting infrastructure transported to the site by a Hercules aircraft. The operation was subsequently supported by its own Twin Otter aircraft with periodic Hercules campaigns supplying major items including fuel.The mining operation included both open-pit and cut-and-fill methods. The milling operation employed conventional cyanide leach process with cyanide destruction initially by alkali chlorination and subsequently by the Inco SOl /Air process.The fly-in operation, initially structured on a 21-day-in and 7-day-out basis was modified to al-t-day-in and Z-day-out basis with no loss in efficiency and with a significant increase in employee satisfaction. The operation, which earned the B.C. Small Mines Safety A ward in two consecutive years in its Ll-month operating history, emphasized safety and process hazard awareness. Wildlife studies in the environmentally sensitive mine area also showed that industry and wildlife can coexist in harmony.Most importantly, the paper compares the feasibility assumptions with actual operating experience."

Jan 1, 1986

By A. G. Matyas, B. Wasmund, R. C. Francki, K. M. Donaldson

"The construction of large. high-power electric furnaces has been an important factor in the growth of electric smelting technology . New developments in the design and operation of electric furnaces have been spurred by the escalating cost of electric power and increasingly stringent environmental constraints. Key areasofprogress include the application of high voltage to enhance furnace productivity; the installation of novel furnace cooling elements and robust binding systems to extend furnace life; development of process schemes to reduce power consumption by preheating and prereduction of the charge; and environmental control improvements for handling fine dusty feedstocks, and for furnace sealing.This paper reviews these developments and outlines a systematic approach for their application in the custom design of new or retrofit electric furnace facilities.IntroductionThe use of electric smelting furnaces has continued to progress during the last decade. Electric furnaces offer high throughput capacity and productivity. In addition, they produce minimum environmental impact, as the furnaces can be readily sealed, and only a small quantity of off-gas is generated. Electric furnaces present the most favourable choice of smelting technology where high process temperatures in excess of about l400°C are required.Their application is burdened by the escalating cost of electric power, hence it is important to seek new opportunities through further technological development. This paper reviews recent developments in the design and operation of high-power electric smelting furnaces, in the following areas:"

Jan 1, 1993

By H. W. King

"Cryogenic engineering is concerned with components and machines which operate for long periods of time at temperatures within a few degrees of absolute zero. The absence of a ductile-brittle transition is thus the prime component of the specification for a suitable low-temperature alloy. The word "" cryo"" means ""frost-forming"" , and this leads to the second component of the alloy specification, which is resistance to corrosion in humid atmospheres. Further, although most early applications of low-temperature alloys were limited to the storage or transportation of liquified gases, an increasing proportion of alternative energy storage and conversion technologies are being based on the availability of high-field superconducting solenoids. The third basic component of the specification for a low-temperature alloy is thus the absence of a low-temperature ferromagnetic transition.Although the firs t two of these components of the specification can be met by using austenitic stainless steels, many of these supposedly "" non-magnetic"" alloys have been found to undergo martensitic transformations to ferromagnetic phases at very low temperatures. In addition, steels which remain structurally stable may still exhibit other magnetic transitions, e.g. to antiferromagnetic or superparamagnetic states. The successful application of these alloys in cryogenic engineering has thus required an initial basic study of the types of magnetic transition that can occur in such concentrated solid solutions, followed by a more applied study directed at an alloy formulation which will induce beneficial magnetic states at low temperatures."

Jan 1, 1981

By R. H. Schonewille

One of the many challenges in developing new metallurgical processes is choosing the best option for validating process design parameters and establishing the process operating window. Historically this has been achieved by constructing pilot or demonstration plants of considerable size and complexity, to enable integrated operation of all key process units for a significant duration. While this would appear to be the best option for minimizing technical risk, it is often impractical from a perspective of cost, schedule, resources or bulk sample acquisition. Such an undertaking can even provide a false sense of security, as the optics of running a complete scaled-down version of a commercial plant suggest a high level of process understanding, regardless of the challenges encountered during operation. Xstrata Nickel has undertaken numerous process development and improvement projects over the past 15 years to support green field project development and continuous improvement in existing operations. The approaches used have included; computer simulation, cold flow modeling, construction of pilot test units in third party facilities, commercial plant referencing and the more conventional construction of integrated test plants. Regardless of the strategy employed, the keys to success have included; managing stakeholder expectations, involving the commercial plant design engineers in the planning stage, anticipating subsequent data and sample requirements and most importantly, constructing and operating complex demonstration plants only as a last resort. This paper provides examples of various process development approaches used by Xstrata Nickel and discusses the rationale specific to each project.

Jan 1, 2011

By Roger M. Nendick

"IntroductionThe stages of development for bringing a mill into production demand that a flowsheet for the process be developed at an early stage. Detailed engineering of the mill may then proceed without duplication of engineering effort on alternative processes. In the case of gold and silver mills, several process alternatives exist which must be evaluated before the flowsheet is finally fixed. The recently developed Carbon-in-Pulp process has added to this choice.Clearly, the major factor in determining the most suitable process is the amenability of the particular ore to a given treatment. Other factors that will also influence the choice are location, climate, power and water supplies, and available capital.Gold and silver milling processes can be divided into three main types:Gravity Concentration;Flotation;Cyanidation.Combinations of the three are frequently used; i.e. flotation followed by cyanidation of the concentrate, or gravity concentration in the grinding circuit with cyanidation of the classifier overflow. The following are the salient advantages and disadvantages of the three main alternatives.Gravity ConcentrationGravity concentration is suitable for free-milling gold ores, i.e. ores in which the gold is relatively coarse and free from sulphides. It should be noted that just because an ore is high grade, it is not necessarily free milling.Gravity concentration methods include jigs, shaking tables, spirals and more recently Reichert cone concentrators. All methods exploit the density difference between gold, which has a specific gravity greater than 15, depending on how it is alloyed, and the gangue, which usually has a specific gravity range of 2.7 to 3.5.A concentrate grade of several hundred ounces per ton might be produced, but recoveries by gravity alone are generally low in comparison to other methods. For this reason, gravity circuits are usually used in combination with flotation or cyanidation circuits."

Jan 1, 1983

By Alexandre Desbarats, Michel David

"All optimum pit design studies start from the geological are reserves inventory, the estimated grades of all blocks of potential are within the interpreted limits of the deposit. The actual optimization procedure is then carried out on block valuations based on these estimated grades. Thus, the relevance of any pit design can be seen to depend directly on the ore reserve estimation . To insure a proper pit design, a first step would be to use a geostatistical reserve estimation technique such as kriging, however, this is not enough. A frequently neglected fact is that the blocks of ore estimated during the planning stage of the mine are usually considerably larger than those on which the ore-waste selection will be made at the time of mining. Experience in the exploitation of large low-grade deposits has shown that large blocks, estimated to be are, when mined selectively in smaller blocks, often yield significant amounts of waste material. This phenomenon, known as internal waste, is a function of the variability of the grades, the size of mining unit and the amount of sampling information on which ore-waste decisions are made.In this study, it was proposed to consider the effect of internal waste caused by selective mining, on. pit design, using geostatistical methods to predict the tonnage and grade of recoverable reserves within large blocks.Optimum pits obtained using a block valuation formula taking into account the recoverable reserves within large blocks were compared with optimum pits obtained using a conventional block valuation formula. It was found that the optimum pits obtained by the proposed method had the highest total valuations and thus were, in fact, ""more optimum”. These pits were characterized by greater are tonnages at a lower average grade, the additional ore more than compensating for the drop in grade. It was also found that the consideration of internal waste in pit design could considerably alter pit limits in marginal areas of the deposit.It was concluded that selective mining had a significant, potentially critical, impact on the design of optimum pits especially in the case of large low-grade deposits."

Jan 1, 1984

By Ken Musgrave

"A program is described that helps managers and supervisors control maintenance more effectively. Work- order generation, preventive maintenance, repair parts inventory, planning and scheduling, reporting, analyzing costs, printing purchase orders and other functions are covered. Flexibility often permits integration with other programs such as payroll, cost accounting and materials management.The Role of MaintenanceMaintenance provides a service to allow the rest of the operation to do its job effectively. Its success should not be measured by maintenance cost alone, but also by its effectiveness in reducing downtime and maximizing production. It can make sense to spend more maintenance dollars if this results in an even greater contribution from increased production.The Cost of MaintenanceIn mining companies, maintenance costs can be as much as half of operating costs. Maintenance has generally not been given the management attention that an expenditure of this magnitude deserves."

Jan 1, 1986

By L. H. Rajala, K. H. Singh

"This paper presents the results of a detailed feasibility study carried out to investigate whether a low-grade deep underground mine of Falconbridge Nickel Mines Ltd., closed since 1975, could be made more productive and profitable by the introduction of new mining technology. For this purpose, recent advances in mine design and development concepts, larger and better designed machines, such as hydraulic drills, high-pressure down-the-hole machines, LHDs, new blasting concepts, more efficient and improved stoping methods, and ground control technology were considered. Technical and economic analyses incorporated the latest computer-based techniques. The mine was reopened in 1979 and the paper concludes with an assessment of actual progress and performance compared with that planned and forecast.IntroductionThe East Mine orebody, located between the Falconbridge Mine and Inco's Cryderman Mine in the Sudbury District of Ontario, has been in production since 1956. From 1956 to 1978, about 5.6 million tons of ore had been mined from this ore zone. The ore body is low grade and was developed as a cut-and-fill operation. Due to high operating costs, the mine has been shut down several times during economic downturns. The latest closure was in 1975 due to a lower demand for metal.In 1978, investigations were initiated to assess the economic and technical feasibility of mining this ore using new developments in mining technology. In this study, consideration was given to the application of bulk mining methods with a potential for higher productivity, trackless development utilizing efficient LHD machines and hydraulic drills, new blasting and fragmentation concepts, and new ground control technology. Advanced computer techniques, such as finite element, for mine design and rate of return with discounted cash flow analyses for the economic comparison- of various mining options were utilized for a rapid and comprehensive assessment during the feasibility stage."

Jan 1, 1981

By T. A. Wheat

"The presently increasing world-wide interest in advanced ceramic materials is generally focussed on their exploitation in both structural and functional applications. With the opportunity to engineer microstructures and thereby closely control and tailor the final properties, there are many new applications being made for these materials in both areas.The scope and some of the applications for functional ceramics are reviewed and examples of the present Canadian activity in this field are discussed.BackgroundThere has been progressively increasing international interest in the development and exploitation of ceramic materials in the last five years. The stimulus for this interest arises from several quarters, each of which are independent of the other.• There is a growing awareness of the strategic nature and vulnerability of supply of the raw materials used to produce high performance metal alloys.• The metal alloys are reaching the upper temperature limit for their performance as structural components in engines.• The dramatic increase in oil prices during the late 1970s focussed attention on the need for reduced consumption in many sectors, i.e., there is a need for more efficient engines that operate at higher temperatures - above those tolerated by the present superalloys.• A number of ceramics, especially the structural materials such as SiC, A120 3, AI20rSi02, Si3N4 and the Sialons are produced using non-strategic raw materials and they can exhibit startling performance-auto turbo-rotors are in production mad e of Si3N4 that operate up to 190000 rpm at 600°C, 150000 rpm at 900°C.• Ceramic s are generally of lower density - significant in the weight-reduction of automobiles such as the replacement of a 20-kg five-segment steel leaf spring with a single segment carbon-fibre reinforced unit of 3 kg. • Ceramics also offer major ad vantages in generating, monitoring or controlling the electromagnetic spectrum whether in bulk or thin-film devices that exploit optical, magnetic, pyroelectric, piezoelectric, electronic and I or ionic conductivity characteristics.The opportunity to combine several of these char acteristics in a single material by composition, processing and microstructural design has resulted in an advanced ceramics industry that had world-wide sales in 1980of $4.2 billion (U.S.)(I) and is predicted to grow to sales in the range $7 to $10 billion by 1990 and $16 to $24 billion by the year 2000(2). However, at present, advanced ceramics account for less than 20010 of the total ceramic market."

Jan 1, 1987

By J. F. Vynne

ABSTRACT This paper examines several of the systems and processes that have been developed over the past few years and are now being utilized by major mining companies on draglines in North America, Australia and South Africa. These technologies include production monitors and reporting systems, GPS navigation systems, structural integrity monitoring systems, structural analysis studies to increase the dragline rated suspended loads (RSLs) and inspection and response strategies. The use of these technologies provides significant increases in dragline production and reduces maintenance costs, downtime and the chance of a catastrophic failure.

Jan 1, 2010

By G. Mucsi, J. Faitli, K. Bohács

"The authors developed an online tube rheometer to supplement a Netzsch MiniCer (Netzsch GmbH, Germany) stirred media mill in order to monitor online the rheological characteristics of the suspension and therefore the result of grinding during the process. Previously it was demonstrated that the above measuring system was working appropriately based on the preliminary tests. The product related stress model was applied for the evaluation of the grinding results. It was found that the suspension concentration and the change of the material properties during grinding, consequently the rheology strongly affects the grinding result, i.e. specific surface area, median particle size as well as specific grinding energy. The tested model limestone – water suspensions behaved Newtonian initially, then after a given grinding time their properties had changed and they become Bingham plastic. INTRODUCTIONStirred media milling now is a common practice to produce fine and ultrafine granular materials for different purposes. With an increasing demand of ultrafine powders for industries (Kwade, 1999), wet and dry ultrafine grinding has been increasingly used in various fields, such as minerals (Mucsi, Rácz, & Mádai, 2013)(Rácz, 2014), ceramic materials (Becker & Schwedes, 1999), pigments (Ohenoja, Illikainen, & Niinimäki, 2013), chemical products (Baláž et al., 2013), microorganisms (Kwade & Schwedes, 2002) and pharmaceutics (Afolabi, Akinlabi, & Bilgili, 2014). It is well known that suspension rheology affects the wet comminution of materials (He, Wang, & Forssberg, 2006a). The rheological behaviour of the suspension containing the ground particles might indicate the level of interparticle interaction or aggregation and therefore it is an important variable factor of the process control (Muster & Prestidge, 1995). The influence of the rheological behaviour of mineral suspensions on their grindability has attracted more and more interests and attention, especially on ultrafine grinding performance (He, Wang, & Forssberg, 2006b) (Bernhardt et al., 1999). However, there are still many issues concerning the machine and the process for the different applications. When grinding is effective and the particle size range decreases significantly, the circulating suspension is becoming typically non-Newtonian. The changed rheological behaviour and the increasing rheological material parameters can negatively affect the grinding efficiency; therefore it is an important issue. Ultrafine stirred media milling as well as solid-liquid two phase flow have been studied for a long time at the Institute of Raw Materials Preparation and Environmental Processing of the University of Miskolc. Regarding ultrafine grinding the research is focusing on the description of materials’ grindability (energetic aspects) both in wet and dry circumstances (Mucsi et al., 2013; Rácz, 2014). Concerning rheology, the three measuring pipes tube rheometer was developed decades ago (Faitli & Gombköto, 2015). So far many different solid materials from all over the world had been tested in this rheometer (Faitli & Gombköto, 2015). Main aim of these tests was to gain basic data for large scale hydraulic transport applications. Among the many stirred media mills there is a Netzsch MiniCer mill at the Institute. It was reasonable to combine the two fields together, and the goal of the research presented in this paper is to develop an online tube rheometer for the Netzsch mill and to carry out grinding and rheological testing simultaneously."

Jan 1, 2016

By Gerald H. Luttrell, Lance Christodoulou, Jaisen N. Kohmuench, Michael J. Mankosa

The efficiency of the froth flotation process has long been known to be strongly dependent on particle size. For sulfide minerals, good recoveries are typically achieved in industrial flotation circuits for particles in the 30 to 200 µm size range. Particles outside this critical size are typically lost in industrial operations and rejected to tailings streams due to inherent constraints associated with the physical interactions that occur in the pulp and froth phases of conventional flotation equipment. In response to these limitations, a series of experimental studies were conducted to determine whether particles previously lost as tailings could be economically recovered using a suite of novel flotation technologies developed for upgrading ultra-coarse and ultra-fine particles in the industrial minerals industry. For the case of ultracoarse particles, a fluidized-bed flotation system called the HydroFloatTM separator was tested. The data obtained using this novel flotation device in both laboratory- and pilot-scale trials showed that good recovery of previously lost sulfide values up to 850 µm diameter could be achieved. Similarly, for ultrafine particles, a high-intensity cavitation-based column cell was tested. This technology, which utilizes highshear contacting of slurry and gas, was capable of recovering valuable ultra-fine sulfide that were previously lost due to the low capture efficiency of conventional flotation processes. The objectives of this article are (i) to describe the unique operating principles of these two advanced flotation technologies and associated ancillary classification equipment, (ii) to present laboratory- and pilot-scale experimental test data showing the metallurgical benefits of the proposed novel flowsheet for sulfide tailings processing, and (iii) to provide a generic cost-benefit analysis of the proposed system for recovering lost values in existing sulfide tailing streams.

Jan 1, 2016

By Gabriel Zarate

"Los Bronces had two ROM dump leach operations designated Leach I and Leach II. Leach I was commissioned in 1998 and stopped in 2014 due to the mine requirements. Leach II plant, commissioned in early 2002, was built to treat around 700 million tons of marginal ROM ore averaging 0.45 % total copper. The mineralogy of this material was estimated to be 70% chalcopyrite, 20% chalcocite/covellite and the balance oxides.The original electrowinning plant design capacity for copper production was nominal 19,500 tonnes per year at a current density of 276 A/m2 and a current efficiency of 92%. Presently, Los Bronces San Francisco plant typically operates at current densities between 390 and 440 A/m2, much higher than the average in the industry, with current efficiencies around 93% and a maximum copper cathodes production of 37,200 tonnes per year.In order to accomplish these achievements, a number of modifications in the process conditions, in the cell hardware and in the operational procedures have been implemented. In the first case, the specific flowrate, copper concentration and temperature of the electrolyte were modified to accommodate the operational requirements facilitating the increased current density. Associated with the cell hardware, a six cells expansion was added, upgraded equipotential inner cell busbars were installed and the cross section of the cathode hanger bars was enlarged for increased current carrying capacity. Documented operational procedures like short circuit detection and cathode weight control were improved.The modifications implemented and the results obtained are discussed in this paper.INTRODUCTIONLos Bronces Division of Anglo American Chile is located up in the Andes Mountains, northeast of Santiago. It had two cathode plants, Los Bronces at an altitude of 3500 meters above sea level (m.a.s.l.) commissioned in 1998 and closed in 2014 and San Francisco at an altitude of 2800 m.a.s.l. and in operation since 2002.The process is leaching run off mine (ROM) low grade copper sulphide ore in dumps. The mineralogy of this material was estimated to be 70% chalcopyrite, 20% chalcocite/covellite and the balance oxides. The average grade is 0.45% total copper (Cut).At Los Bronces dump, Leach I plant, the pregnant leach solution (PLS) was collected and stored in an underground reservoir. From there, it was fed to a solvent extraction plant with a series-parallel configuration in two extraction stages and one stripping stage. The electrolyte produced was fed to the electrowinning plant having 30 cells and 60 cathodes per cell. Maximum capacity of this plant was 12,000 tonnes per year (tpy)."

Jan 1, 2016

By H. Sakurai, M. Kato, F. Tanaka

The Mitsubishi Continuous Copper Smelting/Converting Process employs an electric furnace (CL- furnace) for settling the slag/matte mixture formed in the smelting furnace. The conditions in the CL- furnace change its settling efficiency, resulting in high variability of copper losses in slag. Modifications of the operation and maintenance procedures for the CL-furnace have significantly and sustainably reduced the copper losses in Gresik smelter to below 0.7%. A series of flow patterns evaluation in the CL-furnace demonstrated how the chemical reactions and settling conditions of the CL-furnace has been improved by the new operating procedures. Settling mechanisms for the matte droplets in the CL-furnace is also discussed using image analysis of solidified slag. INTRODUCTION The Mitsubishi Continuous Copper Smelting/Converting Process employs an electric furnace (CL- furnace) for settling the slag/matte mixture formed in the smelting furnace. Since the top-blowing in the S- furnace agitates the molten bath strongly, matte droplets are dispersed over the slag phase when melts flow out of the S-furnace. Thus, the CL-furnace has an important role to settle and recover matte droplets efficiently. Since many papers have ascribed major part of copper losses to matte droplets suspended in slag (Tanaka 2007; Genevski et al., 2008; Starodub et al., 2016), flow patterns of slag in the CL-furnace can affect greatly on the profitability of smelters which have adopted the Mitsubishi process. PROCESS DESCRIPTION Figure 1 illustrates the Mitsubishi process schematically. The Mitsubishi process is the only system for continuous production of blister copper from copper concentrates and consists of 3 furnaces connected by enclosed launders those ensure the minimum emission of fugitives. In a smelting furnace (S-furnace) copper concentrates are fed with flux, oxygen-enriched air to form a mixture of slag and matte which cascades down to a slag-cleaning furnace (CL-furnace). The CL-furnace settle matte droplets in the mixture on the crucible from which matte is siphoned to a converting furnace (C-furnace), while discharging the cleaned slag (CL-slag). The C-furnace converts matte to blister copper by the top-blowing of oxygen- enriched air.

Jan 1, 2019

By J. A. Meech, C. A. Harris

"The application of control theory in mineral processing is more difficult than in other industries because of the complex nature of the unit processes involved and because of problems with accurate on stream measurement of process variables. Conventional control is based on proportional, integral and derivative functions of a continuously measured error term. Computer control can enhance these actions by incorporating logical routines to switch from one relationship to another. The success of this logical approach depends on our understanding of the process dynamics and the stability of the process and model under all conditions. Typically the model does not apply at all times in mineral processing because of frequent and unmeasurable changes in the ore parameters.Recent advances in the theory of fuzzy sets have led to the application of this science to process control. Fuzzy Logic can be used to develop heuristic or rule-of-thumb controllers with the strategy based on the actual operating practice of experienced plant operators. Control action has increased flexibility through the adaptation of human reasoning. Acceptance of the control system by operating personnel is significantly higher because of their participation in its formulation. The requirement of an exact model is not essential.A heuristic controller has been designed and tested with a computer simulation model of a secondary crushing plant. The results of this study are discussed and future applications of this control technique to other mineral processes are suggested. IntroductionThe application of control theory in mineral processing is more difficult than in other industries because of the complex nature of the unit processes involved. Mineral processes typically are characterized by non-linear relationships between input and output variables. Many of these variables cannot be monitored accurately on-stream and so long time lags on the measurement loop are features of the system. The processes, themselves, often have long time-varying responses while the process loads fluctuate significantly on a short-term basis.Attempts to control these processes have led to the formulation of mathematical models to describe each unit activity. Adaptive techniques have also been tried to compensate and account for process changes and vageries. These approaches are mathematically rigorous so that their complexity and precision limit their usefulness when applied to ""vague"" processes."

Jan 1, 1987

By D. Doyle, T. Cienski

"This paper presents and discusses the results of a detailed study conducted on the subject of energy consumption in the comminution of industrial minerals. The study was based on pilot circuit testing, plant operating data collection, detailed equipment data and literature research. The areas covered by investigations include: high efficiency classification; air classifiers for cement grinding circuits; grinding aids in dry grinding; and dry grinding circuit control based on particle size measurement. Results obtained indicate a large potential for the reduction of energy consumption, in particular in the cement clinker grinding circuits. Better classification techniques and correct application of grinding additives can significantly reduce power used per tonne of product and also substantially increase grinding circuit output."

Jan 1, 1992