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By S. Rash Ahmadi

Thin brittle coatings are deposited or developed on component surfaces for different reasons. In many practical applications the coatings are stressed by externally applied loads. Under such conditions, coating failure can occur. In this paper the probability of the extension of surface crack in coated materials due to cylindrical sliding indentation is analyzed. Contact loading problems typically result in multi-axle and strongly inhomogeneous stress fields near the contact surface. This property which strongly affects the stress intensity factors is taken into account in the failure analysis. Edge cracks were selected to model the actually accruing surface flaws. A suitable method is described for calculating the contact stress fields in coating and substrate. The coating is idealized as a brittle-elastic layer of uniform thickness, which is bonded to the surface of a half space. Method of linear elastic fracture mechanics are then used to calculate the load required to cause fracture in the coating.

Oct 1, 2011

By B. Caldwell

"The CompanyCardinal River Coals is jointly owned by Luscar Ltd. and the Consolidated Coal Company of Canada (Consol). The Luscar mine is operated by Luscar Ltd. and is located 40 km south of Hinton near Cadomin, Alberta (Fig. 1). The plant sits on the old townsite of Luscar, Alberta, which was founded in order to develop the coal in 1912 (Fig. 2). Initially, the coal was mined by Luscar Ltd. for heating and steam generation and used quite heavily by the railways for their steam locomotives. In 1955, the mine was decommissioned as the demand for coal for tl1ese purposes had dropped off. In 1969, the mine was re-established by Cardinal River to provide metallurgical coking coal for its customers in Japan. The coal is mined from the 13m thick Jewel Seam by open pit methods at a 10 to 1 stripping ratio. The run-of-mine coal is then cleaned to meet customer demands.The PlantThe clean coal preparation facilities at Cardinal River were extended in 1980 in order to increase the feed rate from 450 t/h to 800 t/h. The extension is a separate plant which can be operated on its own or in parallel with the old plant. In addition, modifications have been made to the fine coal circuit (hydrocyclones added), the coarse refuse circuit, (refuse bucks replaced by a refuse conveyor which backfills a pit), and the fine refuse circuit (solid bowl refuse centrifuges, refuse classifying cyclones, and hydra-rake thickener no longer utilized) since the plant was built in 1969. The plant production of 3 M t per year with a yield of 78% is achieved by first screening and breaking the run-of-mine material to a top size of 1 ½ in. The feed is then slurried, sized, and processed in three different washing circuits. The washed coal is mechanically dewatered, thermally dried, and then stored in a 14 500 t capacity silo or on a 300 000 t stockpile. The fine refuse is thickened and pumped to the same pit to which the coarse refuse is being conveyed"

Jan 1, 2000

By A. Khan, C. Ciriello

The purpose of this paper is to demonstrate the value of constraint modelling in optimization of mineral processing systems. This will be achieved by first understanding the overall concept of variation and constraints present in any system. Next, the value of using a Constraint Model in optimization is demonstrated through comparison of business cases. The benefit of understanding the severity of constraints and movement of the bottleneck within a mineral processing system will be understood through the use of a case study. Paper will conclude with a summary of all optimization benefits that utilization of a constraint model can bring.

Jan 1, 2015

"Previous studies on the effect of polytetrafluoroethylene addition during chalcopyrite leaching under conditions similar to those of the CESL process have reportedly resulted in complete leaching of the copper without the need for grinding of the flotation concentrate. However, these studies employed a pulp density of only 1% and finely sized PTFE particle that required the use of high impeller rotation rates that are not sustainable at an industrial scale. This paper explores the performance of 1/8” diameter balls of PTFE, that readily sink in the leach solution, on leaching performance at impeller rotation rates and ore pulp densities more typical of industrial practice. Possible routes for separation of the PTFE from the leach residues and their regeneration for recycling back to the leaching stage are also discussed.INTRODUCTIONChalcopyrite, CuFeS2, is the most important primary sulfide source of copper. While pyrometallurgical smelting of chalcopyrite remains the only widely accepted route for treating chalcopyrite concentrates, several medium temperature pressure oxidation processes are claimed to be economically feasible (Muir & McDonald, 2007). Among these, the CESL process has been extensively piloted and demonstrated at the prototype scale. The overall process chemistry of the CESL process may be summarized as follows (Marsden & Wilmot, 2007):4CuFeS2 + 5O2 + 4H2SO4 ? 4Cu2+ + 4SO4 2- + 2Fe2O3 + 8S0 + 4H2O (1)4CuFeS2 + 17O2 + 2H2SO4 ? 4Cu2+ + 10SO4 2- + 4Fe3+ + 2H2O (2)Though copper extractions of over 95 % are achieved, the CESL process requires extra grinding of the concentrate (Muir & McDonald, 2007). This is because leaching is conducted at temperatures around 150 °C, where the elemental sulfur produced is molten and grows thicker on the mineral’s surfaces as oxidation progresses, creating an increasingly large barrier for mass transport. In addition, the sulfur is sticky and tends to cause the mineral particles to agglomerate, effectively halting further oxidation of the particles that end up embedded within the agglomerates. Consumable surfactants, such as ligin sulfonate, have been shown to be effective at avoiding agglomeration, but they are not effective at removing sulfur from the minerals. Hence, their use does not obviate the need for fine grinding."

Jan 1, 2012

By E. Henderson, L. K. Daneshmend

Drawpoint control is critical in determining the cutoff point for load-haul-dump mucking operations to minimize dilution. It is also necessary to ensure even mucking distribution and to prevent possible hang-up of material within a stope. A prototype production monitoring and reporting system has been developed for load-haul-dump operations in under-ground mines. The system generates accurate and timely information regarding mucked tonnages and drawpoint and ore/waste pass utilization. The monitoring system integrates a PLC-based load weighing system with a radio frequency identification (RFID) system for locating the vehicle. The system records the identification and time of entry and exit of each draw-point and ore/waste pass visited during a shift, as well as the weight of each bucket load. A trial of the system was conducted at the CAN-MET Experimental Mine near Val d’Or, Quebec. The monitoring and reporting system functioned as designed, with the exception that the maximum read range of the RFID tags under dynamic conditions was found to be a limitation. RFID systems with greater range capabilities have been identified for a second generation system. The system is the first of its type in North America to demonstrate that RFID tagscan be successfully applied to locate trackless underground equipment. Because of their ability to locate equipment and personnel within underground mines, RFID systems should be considered a key technology for future mine information and process control systems.

Jan 1, 1996

By L. B. Tsymbulov, N. A. Fedorova

The equilibrium of exchange reaction (Cu20)+[Ni]=(Ni0)+2[Cu] taking place in the course of interaction of metallic nickel-containing copper melts with different oxide melts (Cu20-NiO, Cu20-NiO-Si02, Cu20-NiO-FeO(Fe203)) in the area of their homogeneity has been studied. The studies, based on the known value of equilibrium constants and defined copper and nickel activity indices in metallic melts and equilibrium concentrations of Cu, Ni, Cu20 and NiO, determined the YNio/ycu2o ratios in the oxide melts of the above systems. For the equilibrium between nickel-containing copper and binary oxide melt Cu20-NiO, values of YNiO and Ycu2o were determined both by calculation and experimentally. Based of the data conclusions regarding oxide melts construction are presented.

Jan 1, 2007

By K. Hanumantha Rao, A. Javadi

Our recent studies revealed that the sulfide minerals in contact with water during grinding produced hydrogen peroxide (H2O2) where the amount of H2O2 production by the minerals found to be in the order of pyrite > chalcopyrite > sphalerite > galena. The H2O2 effect on the oxidation of pulp components and its influence on the concentrate grade and recovery in flotation have been studied and the results have been presented and discussed in this paper. Studies have also been carried out to build correlation between percentage of pyrite in the concentrate, grinding conditions and concentration of OH•/H2O2 in the pulp and as well of controlling the formation of these species through known chemical means for depressing the generation of the oxidant. Flotation tests using a complex sulfide ore with the same reagent scheme that is being used at Boliden concentrator in Sweden but with the addition of i) collector and depressant, ii) Na2S reductant and iii) inorganic (EDTA) and organic (TETA) surface modifiers, during grinding stage have been performed to judge the beneficial or detrimental role of H2O2 on the selective flotation of sulfides. The results demonstrate that the selectivity of metal sulfides against pyrite increases with increasing generation of H2O2 in the pulp liquid. H2O2 is also found to be a better oxidant in chalcopyrite-galena flotation separation than the commonly used K2Cr2O7.

Jan 1, 2016

By M. Zanini, D. Wong

ABSTRACT: Metals market improvements in 2005 drove the desire to increase nickel throughput and the production of nickel oxide sinter at the Vale Ltd. Copper Cliff smelter. Significant difficulties were encountered due to the unreliable quality of Bessemer matte being produced. Concentrate feed changes and the loss of technical and operational expertise during the previous market downturn contributed to the challenge of making the required improvements. Significant progress has been made in the converter aisle by focusing on employee engagement and standardizing best operating practices for a new generation of skimmers. This paper documents these initiatives and seeks to balance the art and science of converting.

Jan 1, 2012

By Harry Wilton-Clark

Introduction Coal cleaning may be taken as meaning the separation of coal-as-mined into two or more fractions. Coal cleaning includes coal washing, together with any other means used in the ultimate preparation of coal prior to shipment (as coal) . The method of coal cleaning devised for any given mine must be one which is based entirely on the economic results obtainable. The installation of a high-cost and complex washing plant, designed to produce a low-ash dean coal, at the highest possible recovery, may be unsound practice. A crude 'roughing' washer may be the best result of sound engineering and operating consideration, and in some cases coal cleaning should be confined entirely to preparation at the face. Consideration of complete costs, to the point where the coal is actually sold, may show that certain seams are workable or not workable. Of the seams found workable, extraction of the whole or parts of the seam may be decided on. The portion to be extracted may contain rock or bone partings, which must be removed. It may be good practice to mine the extra portion and remove the objectionable materials by surface washing; or it may be that such materials should be removed underground, even at an increased mining cost. For instance, in some of the steeply pitching seams of the Alberta Crow's Nest Pass district, the removal of bone and rock at the face may be almost impossible under the usual 'up the pitch' or 'angle' mining methods, but possible by mining across the pitch so that the material to be rejected can be removed and gobbed. Again, if a complete seam is being extracted, investigation may show marked differences between top coal and bench coal, and if sufficient mine cars are being loaded from a chute at one time, the fact that such a place is working top or bench coal at the time may be reflected by peaks in ash content or size proportions at the ripple. It may be very effective coal preparation to smooth out such peaks.

Jan 1, 1934

By K. D. Peaslee

Slag splashing is an important development that has dramatically improved BOF vessel campaign life and reduced operating costs. This paper highlights research from physical modeling work using a 1/8-scale room temperature model BOF and slag characterization studies from several plants in North America and China. In the model studies, gas flow rate during blow and viscosity of the liquid were found to be two of the most important factors to changing the overall rate of liquid splashed onto the vessel sidewalls. When the flow rate was increased or viscosity decreased, the lower regions of the walls were splashed at a much greater rate. It was also shown that by changing the lance height, more liquid was deposited in the upper regions of the vessel at the expense of lower regions. Reducing the number of nozzles was found to be the most effective method of selectively coating a particular vertical section of the wall. Studies of BOF's using slag splashing in North America and China showed a difference in the melting characteristics of the final slag. Generally, slag splashing is successful when the melting point of the slag is 220-270°C below the tap temperature to maintain a balance between fluidity and refractoriness.

Jan 1, 2004

Roasting of molybdenite concentrate is an important stage in the production of commercial molybdenum trioxide. The oxidation kinetic and mechanism of molybdenum sulfide concentrates from two plants were investigated at temperatures from 444 °C to 640°C. The rate of reaction was determined for thin layer samples in a muffle furnace at controlled temperatures, oxygen excess and removal of sulfur dioxide. For both concentrates the rate of reaction is fairly slow at temperatures below 500°C and remains fairly constant from 540 to 600 °C. It was observed that the concentrate from the first plant presents a tendency for sintering or glazing at temperatures above 620°C, whereas the same phenomena was observed at 20 or 30 °C higher temperature for the second concentrate. A kinetic model of two reactions, involving the formation of Mo02 as intermediate oxide for the production of Mo03 is proposed and activation energies of 23.0 and 20.8 kJ/mol for the first and second reaction were calculated for temperatures between 520 °C to 600 °C. These low values of activation energies indicate that the overall rate of oxidation is controlled by mass transfer, particularly in a porous layer of oxides. Therefore, the renewal of the surface by mixing and motion of the concentrate layer is of great importance. Sublimation of Mo03 becomes significant for temperatures above 650 °C.

Jan 1, 2007

By C. H. Stockwell

THE Eastern Townships of Quebec have been the chief Canadian source of chromite. Production, however, has never been large and, except for a period of steady but small output between 1894 and 1909, mining has been active only in war time. The known deposits are too small or too low grade to compete with overseas sources in normal times. During the last war, shipping difficulties and a greatly increased demand in the United States resulted in high prices and a ready market for low-.grade material. The Quebec chromite industry flourished and played an important part in relieving the wartime shortage. Shipments in 1918 .amounted to 15,600 tons of crude ore and 6,400 tons of concentrates. At the outbreak of the present war it was natural to turn again to the Quebec field as a possible source of this strategic mineral. Some of the old properties have since been opened by private and government money and some new deposits have been found. Total mill capacity is 750 tons per day, as compared with 200 to 300 tons in 1918. During 1940, 1941, and 1942, about 85 chromite deposits were examined by the Geological Survey in a belt 100 miles long and up to 7 miles wide. A part of this belt, about 35 miles long, in which the geological features ?were not well known, was mapped on a scale of 1/2; mile to an inch.? Small ..areas around some of the deposits were mapped in detail, on scales of 20 to 200 feet to an inch. Some geophysical work was done but did not result in the discovery of ore. Prospecting by stripping and trenching was then undertaken and chromite ore was uncovered at several localities. The above work was done by the writer and by J. W. Ambrose, who has kindly contributed his results for incorporation in this paper. Y. O. Fortier actd as assistant in the geological work and, in 1942, was in charge of a sub-party engaged in geological mapping. The author is indebted to H. C. Cooke and J. W. Ambrose for reading the original manuscript and for offering many helpful suggestions for its improvement.

Jan 1, 1944

By G. Deschênes

"In 2013, as the prices of precious metals dropped, investors moved their positions to equity markets for higher returns. As a result, the price of gold dropped further to below US$1200 per ounce, prompting additional substantial outflows from gold investments. In response to lagging gold prices, major gold producers initiated large asset write-downs and cost-cutting programmes. In 2015, this trend continues and gold mining stocks are close to lows not seen since the global financial crisis (GFC) of 2008. In the current economic climate many projects have marginal economics, and the number of projects that have competitive development and production costs is declining. A competitive edge is particularly important with the decreasing grades of orebodies, increasing complexity of the mineralogy, and increasingly demanding environmental constraints. In addition, higher cost producers seek to optimize their process t o reduce operating costs.This paper presents some highlights of three case studies on optimization of gold leaching strategies that improved the economics of brownfield projects. Processing of sulphide-bearing ores was optimized by using the synergy between cyanide, lead nitrate, and oxygen. The outcomes were significant reduction of retention times while maintaining or increasing gold extraction and reducing cyanide addition and effluent treatment costs. A stirred tank reactor experimental programme led to direct implementation of reliable leaching strategies from laboratory scale to production. This approach resulted in savings of $2.2 million to $15.2 million on the three brownfield projects discussed in this paper."

Jan 1, 2016

By W. Zheng

Pipelines can develop stress corrosion cracks in either intergranular or transgranular form. Since the mid-1980s, numerous colonies of transgranular cracks have been found across Canada and many other countries in the world. While the intergranular form of cracking has been well studied in the past 40 years, the mechanisms governing SCC in near-neutral pH environment, i.e., the transgranular form of the cracking, are yet to be understood in greater depth. Over the past ten years or so, a large number of research publications have been available on this subject and this paper summarize our latest progress in understanding the mechanistic aspect of the problem. Better understanding of the role of mill scale surface and the steel metallurgy in crack initiation has been indicated in the recent literature. However, the initiation of SCC in the lab research still relies on loading conditions that are far more aggressive than those encountered in the field. Most crack growth studies in the past are also performed under very aggressive mechanical conditions, which could have prevented the observation of environment effects. However, more recent research at lower K or Delta K ranges seems to suggest a strong role of the environment. Naturally, modeling of growth should reflect the effect of the environment, steel metallurgy, and the changing mechanical properties of the pipe steel with time. For a specific steel in a given environment, the crack growth rates tended to increase with the strain rate, indicated either by the nominal applied loading frequency or by the calculated crack tip opening rate. Future research needs to address the issue of concurrent growth of multiple interacting cracks. More attention should also be given to concurrent initiation of multiple cracks in a colony, as failure is usually caused by a coalesced crack not by an individual crack. The effect of soil environment should not be limited to the chemistry of soil solution; other factors such as cathodic processes, the variation of environment with time and physical conditions of coatings should also be considered as part of the study.

Jan 1, 2005

By Bennett McLaughlin

AGNICO-EAGLE started sinking the Penna Shaft in 1995 with a hoisting plant capable of hoisting 1,800 tonnes per day from a 2,240 metre deep shaft. Exploration success lead to the installation of a hoisting plant capable of extracting 4,500 tonnes of ore and 1,800 tonnes of waste per day from a depth of 2,210 metres. The introduction of a new rope selection factor, permitting a safety factor of 4.0, represented the breakthrough required for a cost-effective project. This paper describes the process taken to introduce the new rope selection factor and its impact on the original plant.

May 1, 2001

By Christine Hansen

?Kiss my Asteroid? Unofficial Title Human life is tied to minerals It?s worth noting that: The living human body consumes minerals. The minerals we take in multivitamins show the close linkage between human beings and mineral resources. Unlike tourism or specialized manufacturing, a human being could not live without mineral consumption. Minerals and their consumption is a tangible part of human life.

May 1, 2013

By K. C. Corin, Z. G. Song, J. G. Wiese

In the present investigation flotation was used as a diagnostic to understand the effects of changes to the media during the grinding stage. The observations from flotation for different media are discussed in terms of particle size distribution, water recovery, solid recovery and valuable mineral recovery. The chemical parameters; pH, redox potential (Eh) and dissolved oxygen (DO) levels were measured. A Base Metal Sulphide (BMS) ore was ground under media of different shapes and compositions to determine the effect of different rod/ball material on the flotation performance of the ore. For a given grind (D80 = 75 µm), media shape had no effect on flotation performance of a BMS ore. Different grinding media had significant effect on slurry chemical properties and flotation performance. Mild steel rods (RMMS) produced the highest solids recovery, nickel and pyrrhotite (Po) recovery, with the highest ethylenediaminetetraacetic acid (EDTA) extractable iron and the lowest DO level. Chrome steel balls and stainless steel rods produced the lowest metal recovery, EDTA extractable iron and the highest DO level. A complementary study was conducted to investigate the effect of using different grinding media compositions, viz, ceramic, forged steel, 15% chrome steel, stainless steel and a mixture of stainless steel and 15% chrome steel (50:50) balls were investigated using a Platinum Group Mineral (PGM), UG2 ore. Grinding products of five different media produced the same solids and water recovery, but the grades and recoveries of Platinum Group Elements (PGE) and chromite were different. Grinding products of ceramic media showed the best flotation performance, with the highest PGE recovery and the lowest Cr2O3 recovery. While grinding products of stainless steel balls (SS) produced the lowest PGE recovery and highest Cr2O3 grade and recovery in the concentrates.

Jan 1, 2016

By F. Habashi

Lead is an ancient metal, has been produced to-date from its ores exclusively by pyrometallurgical route. The process suffers from high operating cost and excessive pollution problems. Extensive research has been going on since the beginning of the twentieth century to find a non-polluting process for its production and a solution for its complex refining scheme. It has been assumed correctly that the hydrometallurgical route should be the most promising. Pilot plants have been constructed and operated for a reasonable periods, but no process has proved to be satisfactory. As a result, a number of smelters and refineries have been shut down. The present review analyses the situation and suggests that the best route to treat lead sulfide concentrates is by leaching with fluoroboric acid, HBF4, containing ferric fluoroborate, Fe(BF4)3, and electrolyzing the solution in a diaphragm cell - - a process recently invented by Italian metallurgists. In this process, any silver present in the concentrate remains in the residue together with elemental sulfur and can be recovered by known methods.

Jan 1, 2008

By H. J. McQueen

Aluminum was hot worked at 400 - 500°C and strain rates (e ) of 0.004 -0.1s-1, under reversing strains (c) of 0.5 to 0.2 or 0.5 to 0 and also advancing from 0.5 to 1 or 0.5 to 5. Under similar test conditions for different parts of the strain paths, the average measured flow stresses are found to agree with each other. In the forward and backward strain path tests, the almost identical steady state plateaus affirm the occurrence of dynamic recovery (DRV). On reversal of strain direction at constant e , there was generally negligible Bauschinger effect. In specimens annealed at 400°C, static recrystallisation (SRX) was followed microstructurally. mainly by disappearance of elongated grains with serrated boundaries because the new grains were only little a finer than the old due to low strain energy. The only influence of reversing strain path observed was the effect of change of grain boundary area as grains elongated or returned towards equiaxed. In optical microscopy, elongated grains with serrations and deformation bands confirmed DRV in forward path specimens. In reverse path specimens, equiaxed grains were gradually restored with retention of serrations and bands. In low magnification polarized optical microscopy, grain alignment increased with strain for forward path specimens; whereas it decreased in reverse path ones, supporting DRV. Orientation imaging microscopy (OIM/SEM) revealed that elongated grains are broken up as deformation bands rotate during the forward path and that grains return to equiaxed appearance on backward straining. Comparative studies using optical microscopy in polarized light (POM), OIM/SEM and transmission electron microscopy (TEM) revealed that while subgrains remain equiaxed and constant in size and character during the forward and backward paths, the fraction of low angle facets decreased while that of high angle grain facets increased with increasing strain; these are coupled with a fairly low fraction of medium angle boundaries. The results contribute to the understanding that dynamic recovery in aluminum maintains sub-boundaries with low misorientation but as grains elongate and more subgrain become adjacent to grain boundaries the fraction of high angle boundaries rises (with backward straining it was vice versa).

Jan 1, 2007

By G. Guzman

In the framework of the optimization of Teniente Converter operation the new system of automatic flux feeding through gar-gun was implemented in the Potrerillos Smelter, Codelco Chile, Salvador Division. The control algoritm based on simple iron and silica balance adjusted by empirical coefficients was incorporated in the logical programmer. The programmer works in real time gathering information from the plant instrumentation events and introduced chemical assays of concentrate, slag and flux. Through the auto-tuning of the automatic operation the criterions of optimal flux dosage were determined. Four month of operation of the automatic flux feeding system demonstrated the stabilization of magnetite content in the slag in the narrow range from 18 to 20% and the decrease of flux consumption, corresponding to annual savings US$ 340,000. Additionally, the automatic system helps operators in the control room in fast determination of optimal fluxing and avoid the errors in flux dosage affecting the slag quality and its impact on refractory wear.

Jan 1, 2007