Search Documents

By Chris Ryan

Operational excellence along with the need for a capital management strategy demanded an educated budgetary retirement age for haulage fleets, with uniform applicability. Given fleet size and volume of data for the Komatsu 830E fleet within Teck, this unit type was selected for development of a retirement age model suitable for all operations. The model is designed to act as a capital planning and fleet management tool aimed at minimizing costs. Life cycle parameters were examined to facilitate a visual and numerical representation of a fleet over a period of time. Physical availability and operating cost models were developed to obtain an understanding of the life cycle. These models became the drivers behind the fleet-wide retirement model. A wide analysis range of the equipment life cycle was used as it assured that the optimum retirement regime would be accurately captured. Average annual spend, including cost of operating and ownership was measured against the corresponding retirement age. Targeting the minimum within this range yielded the optimal retirement age.

May 1, 2010

By R. von Gal

Hazelett Strip-Casting Corporation has been producing the Hazelett® twin-belt casting machines for copper casting since the mid-1960s. The first commercial casters were developed for copper alloy strip and anode plate. In 1968, development work was started to adapt the twin-belt caster for copper bar casting to be rolled in-line into wire rod. Since then, 36 casters have been sold as part of the CONTIROD® system for the production of a substantial portion of the world's copper rod supply. A unique feature of the twin-belt caster is the mold's ability to comply with the size and shape of the cast bar as it shrinks during solidification. Maintaining contact between the mold and the bar provides a high rate of heat transfer as well as other benefits, including the prevention of surface imperfections caused by remelting in the mold. This paper will give an overview of the continuous evolution of the twin-belt caster technology with an emphasis on recent developments in compliant mold technology for copper casting.

Jan 1, 2007

By James R. Yeager, Eric L. Hoffman, John R. Clark

"Abstract -This paper describes fire assaying and ‘high tech’ alternatives for gold analysis, including advantages and disadvantages of each method. These ‘high tech’ methods include INAA (instrumental neutron activation), aqua regia digestion/AA (atomic absorption), GFAA (graphite furnaceatomic absorption) or ICP/MS (inductively coupled plasma emission mass spectrometry) and a combination of cyanidation with AA, GFAA or ICP/MS methods.Fire assay remains the stalwart among analytical methods for gold but, even with its multiple analytical finishes, is not fool-proof for recovering 100% of the gold present. Consumers of assays should not blindly trust the assay results without consideration of quality control data. Laboratories can and do make mistakes. Some of these can be easily discovered if you do your own due diligence. All these measures should ensure that gold analysis values from successive campaigns and from different laboratories meet acceptable levels of accuracy and precision, and can be correlated together, particularly when they occur in neighboring holes. This is essential just as much for prospect evaluation as for project feasibility."

Jan 1, 1998

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 C. Gravel, A. Fathi, P. Rivard, G. Ballivy, Z. Moradian, M. Quirion

Numerous schemes have been proposed in the past to evaluate the shear strength of rock discontinuities based on in situ and laboratory testing. Due to scale effects, in situ testing is the most reliable way to assess the shear strength parameters. However, practical reasons often impede this kind of testing. This is unfortunate because advances in theoretical rock mechanics are still dependant on qualitative experimental works. This paper presents a mobile high capacity shear apparatus developed for in situ direct shear testing of discontinuities along with testing methodology. The apparatus has the advantage of being simple, although of high capacity, and can be moved to different site locations for other tests. The in situ test was performed on a natural rock outcrop of schist with subvertical schistosity. A concrete block 50 x 50 cm with a base layer of high strength mortar was cast on the rock surface. Prior to the test, the concrete block was lifted and repositioned to have an unbonded joint but with interlocking asperities. The shear load was applied perpendicularly to the schistosity direction. The test was conducted in a constant normal load (CNL) condition. Both normal and shear loads were applied manually. The instrumentation consisted of two load cells for shear and normal loading, eight displacement laser extensometers for shear, normal, and lateral displacements and fourteen acoustic emission sensors for monitoring evolution of asperities’ degradation during the test. The friction angle obtained is 72° for the peak and 58° for the residual. The high values of friction angle indicates that first-order roughness and good interlocking of the joint surfaces can result in high shear strength parameter values in a rock generally regarded to have low values.

Jan 1, 2015

By Liangtian Liu, Tie Ou, Guangqiang Li, Chenghuan Yu

For stabilizing the production of containing nitrogen steels, a study on nitrogen absorption behavior of killed molten steel has been carried out by means of the RH vacuum device in which nitrogen was used as a driving gas. The results showed that there was an increase of nitrogen content in molten steel under vacuum processing but the rate of nitrogen absorption was slowed down by the surface active elements. Therefore, a kinetic equation for nitrogen absorption of molten steel with apparent first order reaction was derived by constructing a modified model in which the adsorption of closed surface site was taken into account. The experimental results confiimed that the calculated values agreed with the observed ones. This model is suitable for the prediction of nitrogen adsorption operation for containing nitrogen steels.

Jan 1, 2004

By K. J. Brouwer, J. P. Haile

"Construction of the first stage of the tailings disposal facility for the Montana Tunnels Project was completed in October 1986. The project is located 37 km south of Helena, Montana, and involves mining of42 million tons of weathered diatreme are at a rate or 13 500 tpd to produce a gold/silver dore, as well as lead and zinc concentrates. The tailings disposal facility for the project includes a fully drained tailings impoundment for storage of the tailings solids, and a process waterpond for storage of all decanted water prior to recyling to the mill. The over-all facility is designed to achieve the basic objectives ofminimizing seepage to the environment in the short- and longterm, and achieving a fully drained stable tailings mass suitable for immediate reclamation on completion of mining. Specific features of the design include a soil bentonite seal and drainage system within the tailings basin, a free draining embankment with a design flow-through capacity of 4000 US gpm and an ultimate height of 230 ft (70 m), and a soil bentonite lined make-up water pond with a capacity of 420 acre-feet (530 000 m'). The tailings will be discharged in a rotational sequence through multiple spigot offtakes to achieve a thin-layer low energy laminar flow. This 'sub-aerial' deposition results in higher stored densities and maximizes liquid-solid separation on the tailings beaches. The over-all design played a major role in the successful permitting of the project, and was significantly cheaper than a conventional wet disposal system, with overall unit costs for tailings disposal of less than US$0.36 per ton.This paper outlines the site characteristics and the tailings material properties and their influence on the design. Extensive use was made of naturally occurring free draining materials as well as bentonite modified soil liners within the tailings basin, embankment and retention ponds. General construction procedures for the various components are described, as well as on-going construction requirements utilizing materials from the open pit. Finally, the over-all costs and unit costs for tailings disposal are presented."

Jan 1, 1988

By M. Sheedy

This paper discusses the short bed ion exchange technique for the removal of metal contaminants from copper electrolyte bleed streams. Processes for the selective removal of sulfuric acid, arsenic, antimony, bismuth, and iron will be discussed. A case study outlining the performance history of a short bed system for sulfuric acid removal followed by a two stage selective precipitation system producing a nickel carbonate by¬product at the Phelps Dodge Mining Company El Paso operation will be presented.

Jan 1, 2007

By Kathy Pomeroy

Sharing?? l Maybe not the first image that comes to mind when we think about the historical corporate mind set and track record of many corporations ? ! A Fundamental Change in Relationships l From a worldview of independence to one of recognized interdependence l Collaborative action with communities for long range mutual goals l Acceptance of greater accountability for the whole l Community and government relationships based on trust, mutuality, respect for human rights, equity, sustainable agreements

May 1, 2002

By L. J. Surges, C. Bazin, D. Hodouin

"A kinetic model was developed for the conditioning and flotation processes of an industrial lead concentrate dezincing circuit. The models were incorporated into a flowsheet simulator. Simulation results demonstrate the advantages of split conditioning of coarse and fine particles and the potential of this approach for the production of the heuristics required for the development of intelligent control strategies.The conditioning model relates the proportions of activated and hydrophobic surfaces and residual reagent concentrations to activator and collector reagent flowrates. The model accounts for the solids and water flowrates, and for the solids grade and size distribution. The flotation model uses the predicted proportion of hydrophobic mineral surface, the aeration rate and the froth depth to estimate cell, bank and circuit performances. IntroductionFlotation has been the object of modelling and simulation studies for more than two decades. The process is usually modelled as a kinetic one in which the particle flotation rate constants are key parameters. Rate constants are related to the operating variables (pH, reagent flowrates, aeration rate, etc), however these relationships are seldom established in the literature.In spite of the large amount of literature on flotation modelling and simulation, few papers deal with the interaction between flotation rate constants and operating variables. This important gap, which was identified in the early seventies by Woodburn (l970), still exists. One of the first attempts to include operating conditions in a flotation simulator was made by King (l973), who explicitly introduced the aeration rate into an air bubble loading model. Lynch et al. (1981) used an empirical model to relate the proportion of slow floating particles to the ratio of collector per ton of ore. Such empirical relationships are difficult to calibrate and cumbersome to use when an activator and a collector are added to slurries in which particle size distribution and surface characteristics are changing. Eascur and Herbst (l982) relate in a fundamental way the mineral flotation rate constants to the aeration rate, froth depth, agitation and frother concentration, however the model does not account for reagent flowrates. Niemi et al. (1982) have proposed a model for the conditioning of minerals and included it into a conventional flotation simulator."

Jan 1, 1988

By F. R. Archibald

IN a recent paper on Roasting of Beattie Concentrate (1), the importance of controlling the temperature, and the sulphur dioxide concentration was pointed out. It is the purpose of the present paper to present further information by which the most satisfactory conditions for roasting are more specifically defined. Incidentally, a method of illustration is developed for representing roasting curves on a three-dimensional diagram. The primary purpose of this investigation, as in the case of the earlier work, was the search for information that would be of practical value in improving plant operation and gold recovery. For this reason, emphasis is laid on the regulation of essential variables and on definition of their optimum values and limits for maximum gold recovery in the subsequent cyanidation process. Good roasting is considered at least as much an art as it is a science, and, in this light, theoretical consideration of the nature and sequence of the chemical reactions involved is of secondary importance. The presentation which follows includes a series of graphical illustrations, an interpretation of the graphs, some theoretical considerations, and a description of laboratory technique.

Jan 1, 1940

By T. Krumins, L. Zunti, R. Frischmuth

Titanium and titanium alloys are commonly selected for pressure oxidation autoclave vent piping and pressure control valve components, as well as autoclave internals, in high-temperature operations. In a vent application, titanium ignition risk is reduced by limiting oxygen concentration, and preventing high gas velocity gas impingement on surfaces. Oxygen concentration is dependent on the autoclave pressure and temperature conditions and therefore titanium ignition risk is dependent on standard operating procedures, and process control interlocks and permissive conditions. It is not uncommon for standard controls to be deficient during atypical operating conditions, or for operations to deviate from the operating procedures, increasing the potential for titanium ignition incident. Titanium ignition risk caused by elevated oxygen concentration in autoclave vent systems can be reduced with the introduction of an online autoclave overpressure calculation and the configuration of associated interlocks and permissive conditions.

Jan 1, 2014

By G. P. Cooper

A comprehensive computational heap leach model was used to evaluate options for operating a chalcocite-ore heap leach process. The stockpile leach model is based on the computational fluid dynamic software framework PHYSICA+ and incorporates various physical and chemical phenomena to simulate fluid transport, mineral reaction kinetics, bacterial effects, and heat, energy and acid balances for the overall leach process. The leach model is calibrated against small-scale column leach tests, and simulation results are validated against closely controlled column pilot-scale tests. For a given set of ore conditions, the effects of raffinate irrigation rate are examined. Several options for pulse leaching were investigated, and the effects on copper recovery and pregnant leach solution (PLS) grade are described. Model simulations indicated that pulse leaching could be used to control copper grade of the PLS. Finally, an analysis of inventory issues is presented for various lift heights including multi-lift simulations to examine potential operating options. U sing irrigation rate, raffinate copper grade, and lift height as variables in a factorial design of experiments, the simulations showed that raffinate copper grade is the main factor that affects the soluble copper inventory grade.

Jan 1, 2007

By J. Shibata, K. Manabe, A. Fuji, N. Matsunaga, D. Murakami, Yamaguchi University, T. Suzuki

"Spent hydrodesulphurization (HDS) catalyst contains rare metals such as cobalt, nickel (Ni), molybdenum (Mo), and vanadium (V). The overall objective of this project is to develop a hydrometallurgical process that provides a degree of high recovery and selectivity of these rare metals from spent HDS catalyst. As a part of this project, this study focused on (i) development of a solvent extraction-precipitation stripping process for separation of Mo and V from solutions and (ii) optimization of grinding conditions of alkaline leaching residue for selective Ni sulfuric acid leaching against aluminum (Al). Experimental results showed that effective separation between Mo and V can be achieved by the two-stage process; solvent extraction of Mo and V with TOA (tri-n-octylamine) and precipitation stripping of V with ammonium salt at pH above 8.0. Regarding grinding conditions of alkaline leaching residue for selective Ni leaching against Al, it was found that Ni leaching efficiencies increased by providing higher grinding intensity, while the Al leaching efficiency increased and then decreased with increasing grinding intensity.INTRODUCTIONHydrodesulphurisation (HDS) catalysts account for about one third of the total worldwide catalyst consumption and are extensively used for sulphur removal in petroleum refineries (Zeng & Cheng, 2009). Fresh HDS catalysts generally contain molybdenum (Mo) and nickel (Ni) on an alumina carrier, but various elements included in the crude oil such as sulphur, carbon, silica, arsenic, cobalt, and vanadium (V) deactivates HDS catalysts during HDS reactions. As a result, spent HDS catalysts contain high concentration of rare metals. For example, regarding to Mo and V, it has been reported in the literature that the concentrations of Mo and V in the general spend HDS catalysts are generally 10-30% and 1-12%, respectively (Zeng & Cheng, 2009), which makes it economically viable to recover these rare metals (Biswas et al., 1986).Among a number of processes proposed for the recycling of rare metals from spent HDS catalysts, alkaline leaching is often used for selective Mo and V leaching (Zeng & Cheng, 2009). However, the process which provides a high degree of separation between Mo and V from a leaching solution had not been developed. Therefore, the first objective of this study was set to develop a solvent extraction-precipitation stripping process for the separation of Mo and V from solutions. More specifically, using artificial aqueous solutions of Mo and V, a series of experiments was performed to optimize the extraction pH, stripping agent, and the stripping pH."

Jan 1, 2016

By Andrew Kerr

Abstract - The base-metal and PGE contents of samples from magmatic sulfide mineralization are commonly correlated with their sulfide contents, indicating that the metal contents of bulk sulfides remain approximately constant within a given prospect or part thereof. Calculated sulfide metal contents provide valuable information in mineral exploration and research, but there are few formal descriptions and analyses of the procedures. Sulfide metal contents are best calculated using an assumed value (35.7% S) for a typical pyrrhotite-chalcopyrite-pentlandite mixture, and there appears to be little advantage in accounting for sulfide species separately. Regression of metal data against sulfur is probably the most rigorous approach, but is not always practical. Above 10% S, calculations are very robust, but lower sulfide contents generally demand at least some correction for non-sulfidehosted metals. Such corrections can become significant below 5% S, and/or in olivine-rich samples. They are best accomplished by mass-balance calculations, using concentration data from unmineralized host rocks. Significant uncertainties are introduced by analytical errors for sulfur, base-metals, and PGE, which are commonly measured from separate sample aliquots. These combined errors in sulfide metal contents generally exceed ±10%, but expand further at low S contents. In general, treatment of data from samples containing <2.5% S must be approached with caution, especially for PGE, for which the exact host minerals may not be known. Application of the method in simple grade-potential assessment is straightforward, but research studies involving sulfide-poor samples are inherently more complex. Under-correction or over-correction of data for non-sulfide-hosted metals can lead to false negative or positive correlations between sulfide metal contents and sulfide content. As the latter may itself be linked to geological parameters, such as depth within an intrusive body, undue significance could be ascribed to such trends. There are also valid geological reasons for such correlations, and such data require careful assessment to separate true and artificial variations. Propagated analytical uncertainties increase significantly in sulfide-poor samples, and must also be borne in mind whenever data from different localities or units are compared and contrasted.

Jan 1, 2001

By H. Polkowska-Motrenko

Analytical methods for the determination of uranium and other precious elements in ores, industrial wastes and by-products have been developed. The analytical techniques employed are NAA and ICP-MS. Two procedures of digestion were applied: microwave acid digestion and alkali fusion. Accuracy was checked by using CRMs. Results of analysis of the same samples by the elaborated methods have been presented and compared. The methods will be used for estimating the capacity of uranium production for the Polish nuclear power programme.

Aug 1, 2010

By A. F. Gregory

"AbstractA resumé of aerial radiation survey studies performed by and for Eldorado Mining and Refining, Limited, since 1943 is presented. Flight tests were initiated in 1947 and were followed .by intensified use and study of Geiger counters and other radiation detectors. Development of an aerial scintillation counter began in 1948, but •a sensitive large crystal unit was not available for exploration purposes until 1950. Modifications of this unit have been used in all subsequent surveys.For the Eldorado detector, several limiting conditions were established for successful radioactivity detection, the most important being that natural vein exposures can only be assuredly detected .at distances less than 150 feet. Sedimentary and pegmatitic radioactive occurrences can be detected at much greater distances. A helicopter investigation technique appears to •have •a useful prospecting potential.IntroductionAerial radiation surveys were first proposed in the early 1940's. However, it was not until 1949 that airborne detectors were extensively used in the search for radioactive minerals. Eldorado has flown about 50,000 miles of exploration flights, exclusive of tests, using a variety of •detectors and aircraft. Considerable data have •been gathered for .the evaluation of the several techniques employed. Much of the early work was performed with the co-operation of the National Research Council of Canada ( 1). More recent work was done in conjunction with the Commercial Products Division of Atomic Energy of Canada, Limited. The Development Department of this latter corporation designed and built the scintillation counter used in recent Eldorado surveys."

Jan 1, 1955

By M. M. Papic, J. C. Whitehead

"A sample of Hat Creek coal has been extracted using supercritical aromatic solvents in a laboratory-scale extraction unit. Extract yields in the range 21 to 27 per cent of dry-ash-free coal were obtained.These yields are significantly lower than yields available from high-volatile bituminous coal and some lignites. Thus in a combined extraction/hydrocracking scheme for the production of liquid fuels from Hat Creek coal the char product would exceed that required to supply the energy and hydrogen requirements of the process. Excess char could be used for the production of power or gas for sale.IntroductionThe Supercritical Gas Extraction (SGE) process developed by the U.K. National Coal Board operates in two stages: an extraction stage in which a coal extract is separated from mineral matter and undissolved coal and a subsequent hydrogenation stage.The SGE process is based on the ability of a compressed supercritical fluid to dissolve relatively high molecular weight substrates. It is operated under conditions where a hydrogenrich portion of the coal is selectively extracted in a short residence time extraction stage leaving a hydrogen-deficient char. The process schematic shown in Figure I illustrates that the extract produced is separated from the solvent and passed to a conventional hydroprocessing stage while the char product is utilized in the production of heat, power and hydrogen for the process. An extract yield in the order of 50 per cent dry-ash- free coal represents a ""balanced"" case for such a process in which there is just sufficient char for the provision of these commodities."

Jan 1, 1985

By J. H. Reiss, D. F. Bruhn, Idaho National Laboratory, Y. Jiao, D. W. Reed, Y. Fujita, D. L. Daubaras

"Bioleaching offers a potential approach for recovery of rare earth elements (REE) from recyclable materials, such as fluorescent lamp phosphors or degraded industrial catalysts. Microorganisms were enriched from REE-containing ores and recyclable materials with the goal of identifying strains capable of extracting REE from solid materials. Over 100 heterotrophic microorganisms were isolated and screened for their ability to produce organic acids capable of leaching REE. The ten most promising isolates were most closely related to Pseudomonas, Acinetobacter and Talaromyces. Of the acids produced, gluconic acid appeared to be the most effective at leaching REE (yttrium, lanthanum, cerium, europium, and terbium) from retorted phosphor powders (RPP), fluidized cracking catalyst (FCC), and europium-doped yttrium oxide (YOEu). The Acinetobacter isolate, BH1, was the most capable strain and able to leach 33% of the total REE content from the FCC material. These results support the continuing evaluation of gluconic acid-producing microbes for large-scale REE recovery from recyclable materials.INTRODUCTIONAn enhanced recovery, substitute, reuse or recycle paradigm is important for balancing the supply and demand of critical materials (DOE, 2011). The recovery of rare earth elements (REE) from recyclable materials is an important component in this model. REE are used in a variety of modern products. For example, neodymium, europium, terbium, dysprosium, and yttrium are important for applications such as permanent magnets, lamp phosphors, rechargeable batteries, etc. (Binnemans, Jones, Blanpain, Van Gerven, Yang, Walton, & Buchert, 2013; DOE, 2011; Graedel, Harper, Nassar, & Reck, 2013). Cerium and lanthanum are used in glass polishers and additives in fluidized cracking catalysts (FCC)."

Jan 1, 2016

"High Pressure Grinding Roll (“HPGR”) technology is applied in a broadening range of minerals processing applications for relatively wet or moist materials. HPGR grinding of dry material or involving drying and air classification is more common, for example in cement manufacturing. A number of minerals processing plants are also operating with dry material, either due to process reasons, such as considerations of preceding or subsequent process stages, or as dictated by local conditions of arid areas and scarcity of water. The present world-wide expectation of decreasing availability of water supply urges us to look for alternatives that minimize water consumption.Recently established and envisaged future HPGR applications with dry ores have indicated that the technology of dry crushing and classification as practiced in cement and limestone grinding can be applied in minerals processing. Moreover, dry technology could very well be applied for generating a final fine product at sizes near or below 100 microns, as may be required for beneficiation by, for instance, flotation, magnetic separation or tank leaching.Dry HPGR grinding requires special attention in maintaining suitable process economics, when considering power input in grinding, drying and classification. In some cases, HPGR capacity and roll surface wear life may be negatively affected by a lack of moisture in the feed.This publication summarizes some of the features of, and experiences in dry HPGR applications. This includes design aspects of the classification system and discussion of the wear protection of the roll surfaces. The paper also includes examples of operational experiences of dry practices in minerals processing and cement plants."

Jan 1, 2012