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By A. Rahimi

The smelting plant at Sarcheshmeh Copper complex commenced working with two reverbatory furnaces, four pierce smith converters, two anode furnace and one holding furnace having a known capacity of 420 metric tons of anodic copper according to the initial design in 1982 (1361 Iranian calendar). During the period from the commencement date up until now, the smelting plant has undergone changes for improvement and enhanced production by substituting holding furnace with another anode furnace, installing the fifth converter and utilizing oxyfuel burners on the ceiling of the reverberatory furnaces. According to the different operational processes in reverberatory, converter and anode furnaces different types of corrosion mechanisms and degradation can be observed in the refractories of copper smelting furnaces. In the case of reverberatory furnaces, the corrosion and degradation of refractories may be factors such as hot corrosion by melt, corrosion attack by the constituents of burning fuel, degradation of sidewalk exposed to mechanical stresses of the feed charge and the hydrostatic pressure exerted by the melt inside the furnace, all of which are due to the unique operational condition governing the reverberatory furnaces environment, i.e. burning fuel atmosphere, charge concentration and combination, furnace temperature, calm melt condition, etc. In the case of converter furnaces, the most likely corrosion and degradation of refractories may be due to the chemical reaction between the melt and degradation of tuyere zones due to sever movement of the melt and mechanical strikes of the punch rod. Also the most essential corrosion reaction occurs around the mouth of the converter because of the mechanical strikes by the cleaning device and thermal heat shock. Other parts inside the furnace are corroded due to the reactions between the fayalite slag and the furnace refractory. In anode furnaces the degradation mechanism is mostly related to the gaseous corrosion (penetration of natural gas or liquid gas inside the refractory structure due to the long period of reduction processes and refining stages. Finally another important factor responsible for destruction of refractories in these furnaces is the copper oxide slag together with the fume constituents of burning fuels.

Jan 1, 2004

By J. L. Rodrigues Bravo

The aim of this paper is to show the results of the study that relate the variations of the bismuth content in the Caraíba Metais' electrolytic copper with the main electrolysis' process variables as electrolyte flow rate and temperature, anode's impurities content, electrolyte composition, current density, etc and their combinations and factors like cathode washing, blend of materials entering rod plant's furnace, analytical methods, shot-circuit inspection, etc. Also, the methodology considered arsenic, bismuth and antimony mass balance in the electrolysis and their electrolyte's molar ratio relations as well as bibliographic references of refineries that operate in similar conditions. The results showed the circumstances with the major probability of causing bismuth content increasing in the electrolytic copper and the main operating conditions that have to be fixed for having less bismuth variation and lower content in the electrolytic copper.

Jan 1, 2007

By S. K. Sadrnezhaad, B. Hashemi, Z. A. Nemati, Z. Moghimi

Based on the kinetics relationships of a solid - gas model, a software was developed for the prediction of oxidation. Preliminary prediction of oxidation by the software and experimental results of MgO-C refractories were studied and compared. By using the obtained data from this approach, the effective diffusion coefficient, intermolecular diffusion coefficient and diffusion activation energy in the MgO-C refractories, containing various amount of graphite were obtained at different temperatures. First of all, the prediction by the software was very compatible with experimental results, for different oxidation mechanisms in the MgO-C refractories. The results showed that pore diffusion is the predominant oxidation mechanism in this system. The results indicated that when graphite content was above 10wt%, the intermolecular diffusion coefficient was independent from graphite content, and it was closed to a constant value at each temperature.

Jan 1, 2004

By T. H. Etsell, P. C. Holloway

The fly ash produced by oil sands operations in northern Alberta represents a large, high-grade, potential resource for vanadium production in Canada. After extensive batch testing at the University of Alberta, a conceptual process flowsheet for the recovery of vanadium from oil sands fly ash has been developed. The various unit operations for this process, including decarbonization, roasting, leaching, desilication, precipitation, salt recovery and byproduct recovery, are described. Processes for the recovery of molybdenum and ammonium chloride from waste streams from this process, are proposed, as are potential uses for the ash residue; these byproducts represent significant potential sources of secondary revenue while reducing the environmental impact from the process. A preliminary economic analysis for vanadium recovery from oil sands fly ash using this process is also included and several major economic factors influencing its commercialization are discussed.

Jan 1, 2004

By M. Reza Bateni, M. Zandrahimi, J. A. Szpunar

Titanium aluminides and nickel aluminides offer the potentials, as coating materials, for high temperature and aerospace applications. In this research, attempt has been made to develop Al-Ti and Ni-Al intermetallic compound coatings on the surface of Inconel 738. The coatings applied through pack cementation and simultaneous diffusion annealing processes. Scanning-electron microscopy (SEM), energy-dispersive X-ray spectrometry (EDAX) and grazing angle X-ray diffraction were used for evaluating of coating structure. It was demonstrated that the pack cementation technique could be used to develop TiAl3 and AlNi intermetallic compounds coating on Inconel 738 substrate. When pack cementation technique is based on a halide-activated pack with aluminum and titanium powders, the coating consists of TiAl3 intermetallic compound phase. Whereas, by pack aluminization of Inconel 738, the coating consists of AlNi intermetallic compound phase.

Jan 1, 2004

By Z. Mubarok

An overview of the problems encountered the electrorefining of copper anodes containing high levels of nickel and antimony is presented. Our investigations have been focusing on the passivation behaviour of the anodes with high contents of Ni, Sb, Sn, and Pb, the formations of kupferglimmer and floating slimes. The results of linear voltammetry, chronopotentiometry and electrolysis test revealed a noticeable lower resistance of the anodes to passivation in comparison to those with lower contents of Ni, Sb, Sn, and Pb. Anode containing kupferglimmer exhibited oxygen gas evolution during the passivation state. Scanning electron microscopy (SEM) and energy dispersive X-ray (EDX) indicated that tin can replace and/or join antimony in the kupferglimmer structure. Under specified experimental conditions, floating slimes precipitations took place with high Ni, Sb, Sn, and Pb anodes prior to the end of one anode period.

Jan 1, 2007

By F. Golestani-Fard, A. A. Nourbakhsh

In this paper microstructural development of nitride-Bonded SIC refractories is reported in presence of Al203, Mg() and Urea additives .The samples were prepared by mixing, shaping and firing at 1400-1500°c in a controlled atmosphere furnace. Phase analysis, microscopic observation and mechanical evaluation were taken for microstructural investigations. The strength of samples doped with Al203 was first increased and then decreased at higher amount of Al2O3 additions. The addition of MgO decreased the strength while the urea showed an improving effect on strength. These phenomena could be attributed to microstructural evolution and mainly to liquid phase formation and grain morphology. It was found that the additives such as Al203, MO and urea could modify the microstructure in terms of phase formation and texture modification, which in terms influences the mechanical behavior.

Jan 1, 2004

By G. Ladouceur

"LOCATIONThe mine and mill are located in Lemoine township which is 20 miles directly south-east of the town of Chibougamau Quebec. Personnel live in Chibougamau and commute to the property over 33 miles of paved and gravel roads. Concentrates are trucked 13 miles to a railway siding on the line connecting Chibougamau and Quebec city.HISTORY Several companies explored the property before acquisition by Patino Mines (Quebec) Limited in 1973. Further exploration led to the discovery of a high grade copper-zinc orebody and the property was brought into production by the above company in 1976.ORE The ore contains 85% - 95% sulphides consisting of chalcopyrite, sphalerite, pyrite, pyrrhotite and minor gold and silver. Argenti tetrahedrite, antimonial silver, native bismuth and galena are also pre sent in very minor quantities. Associated gangue minerals are quartz, carbonates and occasionally chlorite."

Jan 1, 1979

By Lee W. T. Weitzel

This paper reviews the Falconbridge- SMRQ?s Raglan project in northern Quebec and the process that was used in developing its current long-term mine plan. Challenges were many and not only limited to the longevity of the project, numerous ore deposits (both underground and open pit), and a 40km property strike length. As a result of its remote northern location other factors such as progressive reclamation, leachable mine waste, water treatment, and waste management were also part of the plan. A combination of modern planning tools were used to formulate the plan including DataMine, Mine 2-4D, AutoMod Simulation, and an Excel based financial spreadsheet to bring the total plan together. The focus of this paper is to show the complexity of modern mine planning and associated economic modeling of mine processes.

May 1, 2002

By Dale Coffin

Definition Of A Crisis Crisis \kri-ses:\ An unstable or crucial time or state of affairs whose outcome will make a decisive difference for better or worse (Webster's New Collegiate dictionary) An event or set of circumstances that could significantly affect a company?s ability to carry out its business, damage a company?s reputation and/or threatens the health, safety and well-being of employees, the community or the public at large You?re Having A Crisis When... . The emergency poses a significant threat to the public or employees . The emergency situation provokes government scrutiny . The company no longer has full control of the situation . The situation has created significant regional, national or international media interest . The corporation?s reputation may be damaged or there is a threat to the bottom line or share value

May 1, 2004

By Y. Vermeulen, J. Simoes, P. Guillo, A. Di Donate

New design techniques have been developed to optimize continuous casting (CC) refractory components. The overall objective is to increase CC productivity as well as steel quality by using optimized refractory from tundish-to-mold. These techniques allow the prediction of steel and refractory chemical interactions and, thus, steel chemistry evolution as well as build up and corrosion occurrence. Specific fluido-dynamic models (CFD) have also been developed to better take into account the physical parameters at the steel/refractory interface and to optimize steel flow control. The CFD model can be coupled with refractory chemical interactions to simulate steel chemical evolution. These two different approaches result in shape and material modifications. They are completed by dedicated thermal stress analysis in order to improve thermal shock resistance. The mechanical FEA evaluations take into account specific mechanical behavior of refractory components as well as high temperature evolution of their properties.

Jan 1, 2004

By F. King, R. Sutherby, J. Been

With thousands of kilometers of buried oil and gas pipelines throughout the country, carrying flammable, high-energy hydrocarbons, the integrity and safety of this transportation and distribution network are paramount. The pipeline industry has the primary responsibility for pipeline safety and has in many ways taken the lead in dealing with safety issues. Over recent years, regulatory demands have increased, requiring operators to comprehensively evaluate their pipelines through indirect and direct inspections and to manage risk through integrity programs. Mechanistic and correlative models have been developed that assist in the prediction of pipeline integrity and the determination of reassessment intervals. These lifetime prediction models are based on decades of laboratory research as well as pipeline operating data, material data, and field monitoring data pertaining to soil conditions and CP. An overview is presented of an integrated approach towards the development of such models for the evaluation of external cracking and corrosion of transmission lines.

Jan 1, 2005

By G. Kordosky

Leaching aids that result in an increase in leaching rates and overall copper recovery have the potential to be beneficial to copper leach/solvent extraction/electrowinning operations. It is generally accepted that effective leaching aids facilitate the penetration of leach solution into ore by lowering the surface tension of the leach solution. Surfactants are designed to do this, and a leaching aid containing the widely used surfactant class, alkyl phenol ethoxylates, has been suggested. Alkyl phenol ethoxylates were tested to determine how they may affect phase separation, entrainment and degradation in a copper solvent extraction plant. The test results suggest the use of leaching aids at a regular rate, or even for a short time period, may have a long term impact on copper solvent extraction. Several scenarios are evaluated regarding existing operations and future solvent extraction projects and cautionary suggestions related to the use of surfactants as leaching aids are given.

Jan 1, 2007

By R. A. L. Drew, J. P. Immarigeon, F. Jalilian, M. Jahazi

In the present work TLP bonding of Inconel 617 is investigated. The influence of the main processing parameters i.e. time and thickness of the interlayer were studied with optical and scanning electron microscopy. Boron containing interlayers with two different thicknesses were used and the influence of various holding times from 5 min to 24 hours on the microstructure of the bond region was investigated. The results indicated that, for the testing temperature of 1065°C and holding times above 2 hours with an interlayer of 25.4 microns thick no liquid phase was observed. The same phenomenon occurred only after 6 hours for a 76.2 microns thick interlayer. Precipitate growth started at grain boundaries and continued inside the grains. The composition, size and morphology of the precipitates were studied using electron microprobe analysis. No noticeable changes were observed in the grain size of the base metal with increasing holding times.

Jan 1, 2004

By R. Ramirez

Atlantic Copper Refinery (Huelva, Spain) has operated the ISA permanent cathode technology since 1995. The current production rates are 260,000 t/y cathodes and 730 t/y anode slimes. These slimes undergo an atmospheric leaching in which their copper content is reduced from an average value of 24 % to 16 %. In June 2005 an optimization study of the leaching conditions was carried out aimed at lowering the copper content in the slimes to less than 8%. At the same time, a new mixer (Outukumpu Technology GLS-mixer) was installed in one of the three leaching reactors. As a result of the improvement of the leaching performance and to prevent the return of tellurium to the tankhouse, a cementation plant was commissioned in July 2005 to ensure a Te content below 50 ppm in the Cu-rich leachate. This paper describes the results of the improvement of the leaching conditions and the operation of the new tellurium removal plant.

Jan 1, 2007

By R. S. Rogers

Abstract - Forensic geology in a mineral exploration context is concerned with geology and related technical matters as they pertain to legal cases involving exploration and evaluation of mineral properties. Such cases involve the possibility of outright scams that include falsification of data and information, as well as inappropriate application of various technical procedures. Experience in forensic geology in such cases emphasizes the need for systematic quality control procedures during routine exploration/appraisal and indicates the need for more attention to ‘target hardening’ (improving security in the chain of custody of samples and assay results). A number of ‘early warning signs’ that might suggest some form of tampering or falsification of information are listed. These measures will support the work of the "Qualified Persons" (geologists and engineers) entrusted with the scientific and technical aspects of mineral exploration, and facilitate the increased attention to regulatory oversight and enforcement of securities laws recommended in the report "Setting New Standards."

Jan 1, 1998

By S. Afshar, C. Allaire

Several studied have recently shown that the use of non-wetting additives is not always a sufficient solution to improve the corrosion resistance of refractories against molten aluminum. Once in contact with liquid aluminum, the coarse aluminosilicate aggregates, which do not benefit from the protective effect of non-wetting additives in the matrix, may be corroded. In some cases, the corrosion of aggregates, especially those containing a significant amount of free silica and/or alkalis, promotes corrosion in the surrounding matrix. The present work explores the possibility to protect the poor corrosion resistant aggregates via a lining procedure. A slip casting method, using either alumina or celsian-like composition based slurries, has been applied for lining of a series of aggregates. The results from this study show that such linings may prevent efficiently the corrosion of aluminosilicate aggregates. This work also analyzes the effects of firing temperature and lining quality on the corrosion behavior of aggregates

Jan 1, 2004

By B. T. Lu, J. L. Luo, T. Yu, C. W. Chen

In this paper, the synergism in erosion-corrosion process occurring in oil sand wastewater transportation caused by the interaction of mechanical and electrochemical factors was experimentally investigated. The erosion-corrosion tests were conducted with A1045 steel in synthetic slurries comprising tap water and silica sand. The material loss due to corrosion-enhanced erosion was assessed with the chemo-mechanical model developed by the authors recently. The results indicate that the material loss produced by corrosion-enhanced erosion at the open circuit potential can be formulated as a linear function of logarithm of corrosion current density. The wastage caused by the erosion-enhanced corrosion was analyzed based on the concept of non-equilibrium thermodynamics. The material loss induced by the erosion-enhanced corrosion is approximately a linear function of overall erosion rate measured in synthetic slurries, indicating that erosion-enhanced corrosion could be reduced by adopting surface strengthening techniques to improve the resistance to the plastic deformation in surface layer.

Jan 1, 2004

By Steven Aiken

The East Boulder Mine located in Montana, U.S.A. utilizes snowmaking to assist with mine water treatment for nitrogen removal. Nitrogen species, including ammonia, are common contaminants in mine water from underground mining operations. Snowmaking provides secondary treatment of nitrogen during the winter due to the chemical and physical processes that occur during snowmaking, in the snow pack and in the snowmelt. The primary processes include atomization, evaporation, sublimation and volatilization. The snowmakers also provide secondary treatment for nitrogen removal when used as evaporators and/or land application units during the summer. In 2002, the snowmaking process was successful at reducing total nitrogen in the mine water by up to 87%. If additional losses due to soil and root zone processes are included, total nitrogen reduction would increase to between 87 and 97%. Snowmaking is an effective nitrogen reducing treatment method during the winter when other treatment methods such as land application cannot be used.

May 1, 2004

By D. D. Rodier

The mining and metals indusrty's approach to Sustainable Development has dramatically evolved in response to growing concerns for the future ability of the industry to continue as a vital contributor to the sustainability of society. This paper will review recent trends,including the overriding global issues impacting the sustainability of society and what the Global responses to these issues have been. This will be followed by the response of the mining and metals industry to better contribute to sustainable development, starting with the landmark independent study the MMSD Study and the creation of a global policy voice for the industry, the Intrenational Council for Mining and Metals (ICMM). The tenants of the ICMM's Sustainability Framework guide this organization's work with the overall themes of performance improvement, leadership and leverage through partnerships. The paper will then conclude with a brief description of an example of what, an individual company, a service provider to the industry, is doing to assist in the industry's efforts.

Jan 1, 2007