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By Denis Landry

"RÉSUMÉAu cours de dix dernières années, la compagnie Maghemite a développé, expérimenté et breveté un nouveau precédé de concentration du minerai de fer à partir de la récupération d'hématite présente au bassin de sédimentation de la Compagnie Minière Québec Cartier.A partir de cette nouvelle technologie de concentration par induction, la compagnie Maghemite produit une poudre d'hématite qui est mélangée avec du strontium carbonate à un ratio de l à 6 en poids. Le mélange homogène est achemine sur un disque d'agglomération, et ensuite incorpore dans la fournaise de la Compagnie Minière Québec Cartier. Le temps de cuisson et la température (l200°C) correspondent exactement aux critères nécessaires pour la fabrication d'aimants de céramique, Grade 5, à partir de la poudre de ferrite.IntroductionMeghemite a débuté sa production de poudre de ferrite au printemps 1986et prévoit une production de 20 000 tonnes par année dans cette nouvelle usine. A très court terrne, une usine sera construite pour la production de cinq à dix millions de Iivres d'aimants permanents par annee et à long terme qu'une usine de fabrication par robotique de moteurs à aimants permanents, utilises dans I'industrie automobile. La poudre de ferrite à base de strontium est une compose ferro-magnétique forme d'une molécule d'oxide de strontium et de six molécules d'hernatite. Ce compose d'hexa fluorite de strontium a une force tres puissante et fournit la source d'énergie magnétique la moins dispendieuse comparée aux autres aimants permanents. L'utilisation des aimants de céramique formes d'hexa fluorite de strontium a connu un croissance phenornenale depuis 1970 pour atteindre un marché de 500 millions de livres par année en 1985.II n'y a aucune autre usine de production commerciale de poudre de ferrite à base de strontium au Canada. Le facteur determinant qui a favorise l'etabilissement a Port Cartier est base sur la réduction de 30% du cout des aimants de cerarnique provenant de notre poudre. Notre debouche majeur se situe aux États-Unis et vise la production des aimants de cerarnique pour les moteurs utilises dans les automobiles, les ordinateurs et les appareils ménagers, L'objectif de cette compagnie est de réduire le prix futur des aimants de cerarnique à environ 30% du prix actuel.L'usine commerciale de production de poudre de ferrite est maintenant opérationnelle. Le financement et la construction de cette usine sont Ie résultat de l'opération d'une usine pilote sur une période de 5 ans afin de récupérer l'hematite d'un haut niveau de pureté provenant de résidus de I'usine de bouletage de la Compagnie Minière Québec Cartier (CMQC) à Port Cartier. La fournaise de CMQC est utilisee pour chauffer les boulettes cornposees d'un mélange de carbonate de strontium et d'hematite d'un haut niveau de pureté en étalant environ 5 tonnes à l'heure de ces boulettes au-dessus du tablier de boulettes de fer dans une des fournaises fonctionnant à environ 450 tonnes à l'heure."

Jan 1, 1987

By Fabio Mielli

In these times of increasing costs and diminished returns, energy consumption is one source of savings that remains relatively untapped in the mining sector. Typically, 15% to 40% of operational costs can be attributed to energy in mining operations. This ?process variable? is a complex, multi-faceted variable that involves government regulations, societal pressures, cost and competitiveness. A mining company able to successfully embrace an energy efficiency program is more often than not a successful mining company. Production optimization programs, relatively common today, provide increased production, increased availability of assets and, in many cases, improved quality. They generally ignore the energy question altogether. Production Energy Optimization combines reductions in energy consumption with production improvements to reduce the cost per unit of production while improving emissions reporting. An energy strategy in mining and mineral processing operations is a critical component of Production Energy Optimization. This strategy must support the financial and operational integrity of the business. Developing a successful energy strategy requires a well structured approach such as following: ??Understanding where energy is being used and why, ??Recommending and implementing energy conservation measures, ??Driving visibility to targets and results, ??Re-evaluating continuously. The objective of this paper is to help you better understand the process, tools and technologies that enable mining organizations today to address energy and sustainability issues more tactically and proactively.

Aug 1, 2013

By S. G. Coultis

Turner Valley is in the foothills of the Rocky mountains, at an altitude of 4,000 feet, and is 42 miles south west of Calgary. The present producing area is 8 miles long by 1 1/2 miles wide, while drilling is being carried on over an area of 10 miles by 2 miles . There are 32 wells producing, 26 wells drilling, and 17 wells shut down, making a total of 75 wells, which range in depth from 2,160 feet to 5,900 feet, varying according toa the well location on the anticline centre wells being shallower than those located on the flank. The first indication of possible production in this field was a gas seepage on the banks of Sheep river, in what is now the Royalite plant yard (Figure 1). Geologically, this seepage proved to be located on an anticline running through the valley in a southwesterly direction. The Calgary Petroleum Products Company was formed in 1912, and under the direction of Mr. A. W. Dingman, President, and associates, the first well was drilled. Production was obtained in this well. Gas was found in several horizons from 884 feet to 3,960 feet, and oil at 1,557, 2,718 and 3,839 feet. In May, 1914, oil was struck at a depth of 3,839 feet, this being a light straw-coloured oil of 60 gravity, which was blown spraying from the well accompanied by three to four million feet of gas. The latter contained some 200 grains of hydrogen sulphide per 100 cu. ft., giving it the disagreeable odour so well known in Turner Valley gas. This strike caused considerable excitement and started the famous 1914 boom, when some 400 oil companies were formed. The well referred to produced from two to five barrels of 60 gravity oil per day, and 4,000,000 cu. ft. of gas. The oil was used in the crude form in cars and trucks.

Jan 1, 1929

By Claude Bazin

The Quebec province in Canada is a major producer of aluminium through electrolysis of alumina. The alumina that feeds the electrolysis cells is mainly imported from foreign countries, where it is extracted from bauxite. Other alumina sources, such as clays, have sometimes been considered as potential substitutes for bauxite. There is a large clay deposit in the area of Murdochville in Quebec, with sulfuric acid and electricity available nearby the orebody, as well as sea port facilities leading to the major aluminium plants in Quebec. These are favorable factors to assess the economics of an industrial plant to produce alumina from clays. This paper reviews some of the processes considered for the extraction of alumina from clays and presents results of the initial work carried out on the clay available from Murdochville.

May 1, 2001

By G. M. Mason

History Due to its strong affinity for oxygen, aluminium as an element was isolated only after many other rarer metals had been prepared and studied. It was just over one hundred years ago that two scientists, Hans Christian Oersted and Friedrich Wohler, produced the first few pellets of aluminium and determined its physical properties. These early investigators used metallic potassium as a reducing agent. Later, St. Claire Deville, by using sodium instead of potassium, improved the yield in the reduction and produced some pounds of aluminium. From a figure of about $110 per pound in 1855, the price had fallen to about $4 per pound by 1886. In that year, a very important discovery was made independently by Charles Martin Hall in Oberlin , Ohio, and Paul . Heroult in France. Stated in its simplest terms, the discovery of Hall and Heroult was that aluminium could be produced by electrolyzing a solution of the oxide in molten cryolite. The application of the Hall-Heroult process made the metal immediately available in commercial quantities and, by 1900, the price had fallen to 23 cents per pound. The growth of the industry in the past fifty years is well known, and is outside the scope of this paper. It is, perhaps, not generally known that aluminium was first produced in Canada at Shawinigan Falls in 1901. Since that time, production has been continuous at one or more smelters in the Province of Quebec. The largest of these smelters, which is also the largest aluminium smelter in the world, is at Arvida, Quebec, on the Saguenay river. A large power potential and access to ocean shipping were the two principal reasons for the establishment of aluminium production facilities in the Saguenay district. It is interesting to note that the aluminium industry, as a large user of power, took an active part in the early industrial development at Niagara Falls and Shawinigan Falls, and is now repeating the process in the Saguenay valley.

Jan 1, 1949

By A. W. JR. Whitaker

Introduction Within the last quarter of a century the Lake St. John-Saguenay valley has been converted from a quiet agricultural district to one of the important industrial centres in the Dominion. First there was the expansion -of the pulp and paper industry, and then, starting a little over ten years, ago, the development, in large .blocks, of the enormous hydro-electric power resources of the Saguenay river. Coincident with this power development, the world aluminum industry was rapidly expanding and looking for a new source of cheap power. This was found in the Saguenay valley-and so, in 1925, Arvida was established by the Aluminum Company of Canada as a location for one of the largest aluminum plants in the world. Arvida, an incorporated city comprising an area of some ten square miles, is ideally located on a more or less level plateau about 350 feet above the Saguenay river. Seldom has industry stepped boldly forth and carved out of Nature a community with full city status. The process usually goes through the steps of camp, village, town, and city, involving improper planning or lack of planning; all of which has been avoided at Arvida by starting out in the right way. While this community has only a population of approximately 2,000 at the present time, it is carefully planned for a population many times this figure. Streets, city parks, business and residential sections, have been definitely planned, and, with a City government, proper ordinances were passed at the beginning to ensure the building and maintenance of a model industrial community. As the crow flies, Arvida is about 35 miles due east of lake St. John, and 0 miles west of the St. Lawrence river at Tadoussac. From a shipping standpoint, it is well served by the Canadian National railways, with direct lines to Quebec and Montreal, and by ocean shipping facilities at Port Alfred, which is about 15 miles to the east on the Saguenay river and is served by the Roberval & Saguenay railway. The latter has interchange connections with the Canadian National at Arivda, and also operates a branch line into the city of Chicoutimi.

Jan 1, 1933

By I Wilkomirsky

The neutralization of S02 from copper smelter gases to produce calcium sulphate (anhydrite) is considered an attractive alternative to sulphuric acid production. To develop the required technology for the process, a three-stages fluidized bed reactor prototype was designed and operated using both high and low grade limestone and gases with 2, 8 and 12 vol -% S02. The results obtained shows that at 800°C and up to 8 vol-% S02 in the gases, the capture of S02 reaches near 99% with limestone conversion to anhydrite of 45 to 48%. A larger pilot plant is presently being built at the Codelco El Teniente-Caletones Smelter to demostrate the technology and to evaluate the economics of the process. Cu2007

Jan 1, 2007

By B. S. Ignasiak, Dennis Carson

"Laboratory study of the behaviour• of binary coal blends shows that coke strength is more closely dependent on the distribution of ""reactive"" oxygen in the parent coals than on their proximate, elemental or petrographic compositions, and it also appears possible to qualitatively predict coke strength from information about reactive oxygen. Proceeding from this recognition, experiments were carried out to test the possibility of preparing metallurgical cokes from binary blends in which non-caking hvb coal was substantially freed of reactive oxygen by prior heat t1•eatment under controlled conditions. The results indicate that such blends can yield surprisingly strong cokes and that coke strength may be amenable to further improvements by modifying the size distribution of the pre-heated component and the rate at which it is charred."

Jan 1, 1976

By K. N. Subramanian

Previously reported work on total oxidative leaching of chalcopyrite concentrates ha s shown that high copper extractions are obtained at 210°C and 0.4 MPa oxygen pressure. A simple integrated flow sheet using pressure leaching, solution treatment involving precipitation with a calcium base, and electrowinning to produce wire-bar-quality copper is described. Reagent and energy requirements developed from this work indicate that the process could be attractive for small operations where a smelting-refining complex cannot be justified.

Jan 1, 1978

By S Romanchuk, V N. Macvkiw, D. J. I. Evans

The paper describes the processes developed and piloted by Sherritt Gordon Mines Limited for recovering copper, in the form of specification copper powders, from Lynn Lake sulphidic copper concentrates and Fort Saskatchewan Refinery by-product copper sulphides. The process includes ammonia pressure leaching and hydrogen reduction from solution. Nickel and cobalt present in the con-centrates dissolve in the leach solution and a method was developed for separating these metals from the cop-per. Methods are described for con-trolling the physical properties of the copper powder produced in the reduction vessel. The chemistry of the process is briefly discussed and the effects of some of the more important process variables are described. SHERRITT Gordon Mines Limited have developed and proven on a pilot plant scale, a process (I) for the production of copper powder

Jan 1, 1961

By A. G. Lylie

Introduction At the Britannia Mining and Smelting Company's mill, the equivalent of 2,500 to 2,800 pounds of copper sulphate crystals per day is made from copper which is precipitated from the mine-water. This copper sulphate is used in the mill for the recovery of sphalerite by2 flotation. From 1932 until 1936 it was produced by exposing the precipitate to air for thirty days and then dissolving the oxidized copper with dilute sulphuric acid. In 1936, the flotation of sphalerite was discontinued and, when it was resumed in 1947, steps were taken to try to improve the former method. The present paper outlines the way in which this was done, and describes the plant and procedure by which copper sulphate is now being made, and by means of which an appreciable saving is being effected. Aboratory Tests The previous work had established that the precipitate, which consists mainly of metallic copper, must be oxidized before the copper would dissolve in dilute sulphuric acid. Various methods for oxidizing it were tried but in the early laboratory work the only suitable one found was to heat the precipitate to 600°C. and hold it at this temperature for two hours. When this was done, approximately 90 per cent of the copper became soluble in .acid. This percentage was considered satisfactory for practical purposes, but the cost of roasting was prohibitive because only a small amount of roasted precipitate was required each day.

Jan 1, 1951

By G E. Craig, W. M. Williams

A simple, easily constructed apparatus suitable for the zone refining of iron and other reactive materials is described. After eight passes at one inch per hour, the iron produced showed a marked drop in hardness to 49 Brinell. In addition, an arbitrarily -defined recrystallization temperature was lowered by about 35°C and the rate of grain growth greatly increased. CERTAIN materials, of which iron is one, are so reactive that they cannot be zone refined in any known container without becoming contaminated. For such substances, the floating zone method ( 1) may be used. In this method, the specimen is supported vertically in an inert atmosphere and the molten zone supports itself by its own sur-face tension. The method was first applied to silicon (2) and has since been used for other reactive metals such as zirconium and titanium. Smith and Rutherford (3) have previously reported on the floating zone refining of iron; the efficiency of the method for reducing the car-bon content was demonstrated on

Jan 1, 1962

By J. Kempken, R. Hagmann, C. -P. Reip, W. Hennig

The CSP technology symbolizes a highly productive process for the cost-effective production of steel grades with a range of sophisticated properties comprising both the inner quality of hot strip, its surface formation as well as the relating technological characteristics. Thanks to extensive development work undertaken during the last 15 years, the range of steel grades that can be produced was continuously expanded and the process technology optimized. The present paper describes the ongoing development work concerning the production of higher-strength, microalloyed pipe steels. The resulting hot strip, due to the associated thickness and the potential pipe diameters, is particularly suited for being processed to HFI-welded pipes. Based both on ferrite-pearlite as well as very fine-grained, ferrite-bainite hot-strip microstructures, strength levels of up to grade API X80 can be realized. It can be demonstrated that hot strip produced in a CSP plant has very good toughness values at temperatures down to -60°C and can even make application with required sour-gas resistance possible.

Jan 1, 2005

By A. S. Gendron

A brief description of Inco's ORC copper refinery tankhouse and the electrowinning tankhouse is followed by a comparison of the requirements for the production of the high-quality copper in both systems. The description will focus on both tankhouses, with emphasis on experience to date in the electrowinning tankhouse. Particular attention will be paid to sensitivities of each tankhouse to process upsets which can. significantly afject the quality of the product cathodes.

Jan 1, 1977

By Hammenm R., J. Hammen, C. Hammen

"The production of salable Rare Earth Element (REE) products necessitates a sequence of chemical separation steps between the mine and market commodities. The effectiveness of the chemical separations that purify REE salts is critical to the success of the producer, as the purity of REE salt products affects their market price. This is due to the fact that impurities in REE salts, even at low levels, can be deleterious to the function and usability of the end product. The purification of REE by removal of low levels of contaminant has been referred to as "product polishing". The technologies commonly in use for product polishing, solvent extraction (SX) and ion exchange (IEX) are challenged by the availability of separation chemistries to separate the contaminant from the desired REE salt. In simple terms, if a product specification is 99.9% purity, the SX or IEX separation reagents need to have at least a 999:1 selectivity ratio. Significant testing has been carried out on the use of solid phase extraction (SPE) columns to extract low-level impurities such as aluminum or zinc from REE product streams. The SPE columns are nano-composite materials that have rapid equilibration kinetics with the solutes being processed by the columns. The SPE matrices have been modified with chelating ion exchange ligands that bind the contaminating ion with great selectivity in residence times of a few seconds. Thus, REE streams with 1 to 2% of contaminating aluminum ions, have been polished to >99.99% purity. In this paper, results are presented on the removal of aluminum impurity from a didymium (neodymium+praseodymium) product stream using SPE technology. The selection of the SPE medium and the process steps to treat the feed solution for aluminum removal and ultimate stripping and recycle of the solid phase extractant are discussed."

Jan 1, 2014

By C. H. Tiernon

"This paper was' prepared to emphasize the part that coal washing tables can play in the development of many of the reserves of coking coals in Western Canada_ It covers a brief history of the development of the coal washing table through the present third-generation unit, which suspends from overhead steel beams and is driven by a counter-rotating gear mechanism. The design and operation of this unique table are covered in detail.An analysis of actual operating data is included, with explicit statistical breakdowns of the table products. The data used were actually produced by operating coal companies, and also produced by the United States Bureau of Mines while gathering data for a research investigation. Table feed capacity is discussed, as well as performance criteria and the parameters of relative table performance. Several typical table flowsheets are described, emphasizing the specific reasons for their use. The paper covers the past and present value of the table to the United States coal industry, and makes mention of the newest addition to the family of suspended, multiple-deck, counter-rotating, gear-driven, coal washing tables, the CONCENCO ""88"" Deister table."

Jan 1, 1973

By Saeid Akhavan

Accumulative roll bonding (ARB) is a severe plastic deformation process for achieving ultrafine grains in metallic sheets without changing the sample dimensions. In this study, ARB process was carried out on 5083 aluminum alloy sheets up to 6 cycles. In this process, the surfaces of the strips to be joined are roughened and cleaned and then stacked. After stacking, the specimen is roll-bonded by rolling using a 50% reduction. The rolled specimen is cut into two halves, and the above-mentioned procedure is repeated for several times. Microstructural characterizations were analyzed by transmition electron microscopy (TEM). Tension and Vickers hardness tests were performed on produced sheets for evaluating their mechanical properties. In order to clarify the failure mode, fracture surfaces after tensile tests were observed by scanning electron microscopy (SEM). The results indicated that at the early stages of ARB process, grains were subdivided by deformation induced boundaries. After several ARB cycles, lamellar structure elongated in the rolling direction contains lamellar boundaries was formed. With increasing the strain, mean spacing of lamellar boundaries decreased. Finally, continuous recrystallization resulted in a microstructure covered with small recrystallized grains with an average diameter below 100 nm at the end of four cycle. The tensile strength and hardness of the 6 cycle ARB processed 5083 aluminum alloy sheet increased about two and three times of the initial values, respectively. Results indicated conformity between mechanical evolutions and microstructural changes during ARB process. Fracture surfaces observations showed that failure mode in ARB processed aluminum is shear ductile rupture with elongated small dimples.

Oct 1, 2011

By G. C. Nowlan, A. Illis, H. J. Koehler

At its iron ore recovery plant at Copper Cliff, INCO produces about 17 million pounds per year of a pure, acid-soluble, dense nickel oxide from nickeliferous pyrrhotite. The process used is also applicable to a broad range of ammoniacal nickel-bearing streams. The product has been widely accepted by the chemical, ceramic and electronic industries.

Jan 1, 1970

By Gregg Hodges, Fred Schoenbrunn, Steve Slottee, Chad McCleary

"In December, 1999 Stillwater Mining Company (SMC) commissioned a new paste /cement backfill plant to supplement the existing sand backfill system for the cut and fill mining operation at it’s Nye, Montana mine. The new plant uses the Baker Process Deep Cone TM Paste Thickener to thicken the total concentrator tailings from 30% solids slurry to a 71% solids paste. This paper describes both general paste formation concepts and the evolution of the SMC paste plant operation from original design criteria, through problem solving and plant modifications, to the operation of the existing plant.Although the original process design was not effective for consistently producing and delivering acceptable paste to the stopes for backfill, SMC was able to make the mechanical and process modifications which allow the plant to now produce and deliver an acceptable product to the stopes. Ongoing test work is targeted at increasing the pumping range of the system, increasing the paste solids concentration from the Deep Cone Paste Thickener and reducing the operating and maintenance costs of the system.INTRODUCTIONThe authors would like to thank both Stillwater Mining Company (SMC) and Baker Process for their assistance in the preparation of this paper. Stillwater Mining Company chose not to participate directly in this paper due to time constraints, but was very helpful in answering questions concerning their approach to problem solving and specific details with regard to engineering criteria.This paper will begin with a general review of the technical and mechanical concepts in paste formation and then focus on the overall design, start-up and problem solving process for the paste backfill operation at SMC’s mine and concentrator near Nye, Montana."

Jan 1, 2001

By A F. Kravic

Carbonyl nickel powders of irregular particle shape and low a11parent density are used extensively in the production of porous nickel electrodes for nickel-cadmium storage batteries and hydrogen-oxygen fuel cells employing alkaline electrolytes. Such porous nickel matrices are at-tractive for these intended applications as they are relatively inexpensive, are corrosion resistant, have good electrical conductivity, can be welded to form electrical contacts, have a long life (as demonstrated in alkaline storage batteries), and are rugged and vibration and shock resistant. This paper describes a feasibility study concerning the production of porous multi-layer nickel electrodes by the pressing and sintering of stacked layers of green-powder rolled nickel sheet. Background H AUSNER (1) conveniently listed nine different powder compaction processes used for forming metal powders into useful shapes. These are shown in Table I. There are additional powder metallurgy processes; however, most of these are combinations of two or more processes listed in the Table. A study of the literature revealed that every powder compacting process, with the exception of isostatic pressing and explosive forming, has been evaluated or is being used for the manufacture of porous metal electrodes.

Jan 1, 1965