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By M. Fafard, D. Picard, J. -F. Bilodeau, G. Soucy

To simulate adequately the behaviour of a Hall-Heroult electrolysis cell, a finite element model must take into account the properties of each material. However, it has some lacking knowledge on the mechanical behaviour of materials, like the long-term visco-elastic (creep/relaxation) behaviour of cathode. A three-dimensional model is then proposed in this paper and will be ready to be implemented in the finite element code FESh++. The model was developed using the three-dimensional model based on thermodynamic of irreversible processes where the choice of the internal variables is based on a phenomenological approach. All parameters of the model are represented by constant constitutive tensors and the temperature and chemical dependencies are taking into account through scalar functions multiplying the constant constitutive tensor. The goal of the first part of this project was to determine the parameters of the threedimensional visco-elastic model at the reference state (virgin material at ambient temperature) of three different cathode materials. This paper presents the theoretical model and the results of creep tests at ambient temperature for the semi-graphitic carbon cathode.

Jan 1, 2006

By K. Adham

Iron chloride pyrohydrolysis (ICP) is used as an efficient way to fix iron as an oxide, for sale as a by-product or for safe disposal. Iron chloride is reacted with water at elevated temperatures to yield iron oxide and hydrogen chloride. Both the steel industry and synthetic rutile producers make extensive use of ICP. Two technologies are available for ICP: fluidized bed (FB) and spray roaster (SR). Both technologies are energy intensive. Here, fluid beds and spray roasters are compared with respect to their fuel and electrical energy consumptions. Roaster size and oxide product characteristics are also considered. Process models are prepared, using the METSIM® software, and specific energy consumptions are compared. The results will help the industry decide which technology best suits its goals and at what energy cost.

Jan 1, 2006

By C. M. Acuna, M. Sherrington

In high temperature processes thermodynamic equilibrium is assumed and therefore chemical potential of elements, among the condensed phases, have to be the same. In such situation impurities distribute accordingly and their fractional distributions are affected by the masses of the coexisting phases. It has been claimed Teniente Converters perform quite well for smelting high impurity concentrates, especially in respect to volatilization and/or slagging. Production of high matte grade near white metal composition, requiring moderate oxygen enrichment in the process air, results in a huge mass of gas and therefore a high fraction of impurities report to it. Similarly, by recycling different sources of slag, flue dust or other materials, the mass of the final slag is increased and so do the masses of impurities reporting to the slag. Nevertheless, above a certain level the recycling of smelter byproducts is no longer feasible and the cycle has to be halted, unless higher impurity mattes are accepted. Although the process might be continued during converting and refining, lengthy and expensive measures have to be taken if suitable anode copper for electrolytic refining is to be achieved. In the present study samples of high arsenic matte grade and slag were obtained on a pilot scale. The matte samples, on the order 75%Cu, were equilibrated with slag at varying ratios in magnesia crucibles under CO/C02 atmospheres at 1523 K. After 24 hours equilibrium matte and slag were rapidly solidified and analyzed by copper, sulfur, iron and arsenic. Furthermore, industrial samples of matte and slag, in the order 75%Cu at 1523 K, were obtained via a special quenching sampling device to determine the association of copper and suspension of matte and copper in slag. Based on the results, the distribution coefficient of arsenic between slag and matte was evaluated along with copper species in slag and the fractional distribution of arsenic, in the coexisting phases, was determined as a function of the ratio mass of slag to mass of matte.

Jan 1, 2007

By S. Southall, F. McCaffrey, F. Stober, M. Darini

Electrode Columns are commonly used in electric furnaces to deliver current and regulate furnace power to the smelting or melting process. Hatch has developed an innovative patent-pending system for lowering ("slipping") and/or raising ("back-slipping") the electrodes through an electrode column, without requiring the release of any clamping devices. All clamping forces are applied by springs. Unlike systems employing hydraulically applied clamping forces, (e.g., water bladders) the spring system is failsafe. Its inherent simplicity virtually eliminates the need for maintenance. The Hatch system is particularly applicable to Soderberg electrodes, and comprises two axially movable slipping clamps and a stationary power clamp, each of which apply a distributed, radial clamping force to the electrode. The magnitudes of the slipping sleeves' clamping forces and sequencing of their axial movements are selected such that the slipping clamps, in conjunction with the weight of the electrode, provide slipping or back slipping without release of any clamping force.

Jan 1, 2005

By K. Nikkhah, N. Dhadli, G. Freeman

Ammoniacal pressure leaching operations have been in commercial use at the Fort Saskatchewan refinery of Sherritt International Corporation since 1954. Recent improvements have significantly increased the capacity of this circuit. The computer modeling of this process has proved to be a valuable tool in facilitating the evaluation of different operating scenarios in an effective manner. Reagent response in the ammonia leach of nickel and cobalt sulphides is examined using the dynamic process simulation capabilities of IDEAS(TM) software. The dynamic simulation enables accurate measurement of the sensitivity of the process to variables such as temperature, feed rate and ammonia concentration as well as compartmental analysis of metals concentration, pulp density, vent gas composition, and the formation of specific complexes. The complexity of the ammonia leach process makes it a logical choice for evaluation by computational analysis. The methodology for dynamic modeling of a pressure leach process is presented.

Jan 1, 2005

By M. Imamura

Sumitomo Metal Mining Co., Ltd. has developed a novel hydrometallurgical process for producing not only copper metal but also iron metal from copper concentrates. Because copper concentrates generally contains the same amount of iron as copper, cost-effective rejection of the iron is a key issue for the development of the process. Conventional hydrometallurgical processes produce a large volume of goethite or hematite for disposal and the residues are not environmentally friendly. In the novel Sumitomo hydrometallurgical process, copper is leached effectively from chalcopyrite concentrates using chlorine gas, followed by purification through solvent extraction and electrowinning for copper and iron recovery. This process has many advantages such as the minimization of the volume of solid waste by the recovery of metallic iron and the production of high purity copper. Iron metal with a purity of more than 98% can be recovered from the purified raffinate. This paper presents the results of the batch and continuous tests of the process flowsheet.

Jan 1, 2006

By Zhibao Li, Lanmu Zeng

The behavior of dicalcium silicate in NaOH-NaAl(OH)4-Na2CO3 solution is of significance for controlling the silica level in the production of alumina via the sintering process. Dicalcium silicate samples were obtained through a twostep approach: coprecipitation of calcium and silicate from CaCl2-Na2SiO3-NaOH solutions; and calcination of the hydrated precursor at 1200°C for 4 hours. The optimization of the synthesis parameters including temperature, solution concentrations and aging time was also investigated. Xray diffraction (XRD) and chemical analysis show that the calcined solids include dicalcium silicate with trace amounts of wollastonite. The solubility of the synthesized dicalcium silicate in HCl, NaOH, mixed NaOH-NaAl(OH)4 and NaOH-NaAl(OH)4-Na2CO3 solutions was determined. It was found that the solubility increases with increasing HCl and NaOH concentration. The effect of temperature on the solubility in HCl solutions is limited, but the solubility decreases with increasing temperature in NaOH solutions. The solubility of dicalcium silicate in NaOH-NaAl(OH)4 and NaOH-NaAl(OH)4-Na2CO3 solutions was shown to increase with increased temperature, Al(OH)3 and Na2CO3 concentration. The BromleyZemaitis model for the aqueous electrolyte system was selected to predict the solubility of dicalcium silicate. The model’s predictions yielded certain success compared with experimental solubility data.

Jan 1, 2014

By A. Cadieux, J. -B. Pineault, C. Allaire

The temperature measurement of the molten metal in the aluminum transformation process is of prime importance. This is particularly the case for aluminum treatment furnaces, such as holding and melting furnaces. Such reverberatory type of furnaces involve a thermal gradient across the metal line which limits the life of conventional thermocouple protective ceramic shields, due to the action of locally induced thermal stresses. This paper presents a novel thermocouple assembly using a composite refractory protective shield allowing long term resistance to such above conditions. Example of results obtained from various tests in aluminum holding furnaces are presented. The results confirm the superiority of the novel thermocouple assembly, as compared to conventional thermocouple units.

Jan 1, 2004

Mining Association of Canada ! Represent base and precious metal, diamond and oil sands producers as well as nonferrous metal smelting and refining ! Member companies account for the vast majority of Canada?s mineral and metal production ! Mining is a major economic sector in Canada ! 13% of total exports ($47 billion) ! Employment near 400,000 ! 4% of GDP The Kyoto Protocol ! November 18, 2004 -- Russia deposited its instrument of ratification with the United Nations ! The Kyoto Protocol entered into force on February 16, 2005 ! The Kyoto Protocol is now an international and legally binding agreement to reduce GHG emissions world wide ! Canadian GHG target = 6 percent below 1990 ! First Commitment period 2008-2012

Apr 1, 2005

By T. Cutard, H. Marzagui, E. Ouedraogo, M. Roosefid, M. Prompt, C. Deteuf

The present work is achieved in the framework of a French national program on modeling and experimental characterization of the thermo-mechanical properties of refractory materials (PROMETHEREF). This research program is aimed to establish fair models and experimental database and to make it available to industrial partners for numerical simulation of industrial structures made of these materials. The present paper focuses on two silica-alumina refractory castables, an andalusite based one and a bauxite based one. We will present the first rheological characterization results achieved at room on normal and preheated samples of these two refractory castables. Refractory castables are characterized with the help of four points bending tests, compression tests and tensile tests.

Jan 1, 2004

By Geoffrey C. Streeton

A continual objective of mine operations is to reduce ground control costs without compromising the overall safety or performance of the installed ground support. Any change in the ground support regime must not result in a less secure or safe workplace. The due diligence required to implement a change in rockbolting practice is extensive, particularly when the new bolting system has not been used at any other mining operation. Factors such as yield, shear strength and embedment strength must all be investigated to gain an understanding of how the rockbolt can be expected to perform. This paper also discusses the substantial cost reductions and efficiency gains which can be achieved through the introduction of the Jumbolt rockbolt.

May 1, 2001

By D. A. Beattie

Talc is a commonly encountered gangue mineral in metal sulfide flotation. Talc is naturally hydrophobic, resulting in high recoveries if polymeric depressants are not used to specifically reject this MgO containing mineral. We have studied the adsorption of a selection of polymers onto talc using a variety of techniques. Adsorption isotherms have been determined using ex situ depletion techniques and in situ ATR-FTIR spectroscopy has been used to determine adsorption kinetics. Adsorbed layer thicknesses have been determined for the polymers on cleaved talc surfaces using the AFM. The effect of the adsorbed polymer layer on the properties of the talc surface has been quantified through contact angle measurements and single mineral flotation tests. Distinct correlations are observed between the adsorbed layer properties and the flotation performance of the polymers. These observations are discussed with reference to the bubble-particle attachment process and the molecular structure of the polymers.

Jan 1, 2006

By K. E. Waters, C. Marion, T. Grammatikopoulos, A. Jordens

"The Nechalacho deposit, located in the Northwest Territories, Canada, is a heavy rare earth element (REE) deposit. The main REE-bearing minerals in the deposit are zircon, allanite, bastnäsite, synchysite, columbite (Fe) and fergusonite. Previous work investigated the use of gravity and magnetic separation in the processing of this ore and showed that coarse particles following grinding were enriched in zircon, suggesting the potential for selective comminution. The current work investigates the possibility to selectively comminute gangue minerals and concentrate REE-bearing zircon into coarser size fractions. The ore was ground wet in a laboratory rod mill for various lengths of time (0, 10, 20, 30, and 40 min). The resultant products were analyzed using ICP-MS, to determine the distribution of zirconium and REEs in the different size fractions produced after grinding, and QEMSCAN, to identify mineral phases, mineral liberation and the distribution of minerals. Optimum grind sizes for the upgrading of zircon due to selective comminution were then proposed, and dense medium separation was investigated as a means to further concentrate zircon.It is important to note that this process is not representative of the currently selected process design or recovery for the Nechalacho deposit. Any application of this process to this deposit would require optimization in order to ensure appropriate grade and recovery targets are met.INTRODUCTIONThe rare earth elements (REEs) are the fifteen elements in the lanthanide series of the Periodic Table, as well as yttrium (scandium is excluded in this work). Traditionally, REEs are categorized into two groups: the cerium sub-group of “light” rare earth elements (LREEs); and the yttrium sub-group of “heavy” rare earth elements (HREEs) (Golev et al., 2014). The LREEs comprise the first six lanthanides (lanthanum through samarium) and the HREEs comprise the remaining nine lanthanide elements (europium through lutetium) coupled with yttrium (Golev et al., 2014). HREEs are much less abundant in the earth’s crust and on average are more expensive than LREEs (Seredin, 2010). Of the fifteen REEs, the production of neodymium, europium, terbium, dysprosium and yttrium has been determined to be most critical due to their scarcity, high demand and criticality in many high-technology and clean energy applications, such as in illuminated screens for electronic devices and permanent magnets in wind turbines (Seredin, 2010; U.S. Department of Energy, 2011). These five elements are classified as critical rare earth elements (CREEs) (U.S. Department of Energy, 2011)."

Jan 1, 2016

By Jose Alberto Gonzalez, Said Sharif Mahboob, Jeffrey L. Shepherd

"During the industrial electrowinning of zinc, uneven growth can cause short-circuits and make the deposits more sensitive to the presence of impurities that can significantly impact current efficiency. To produce levelled zinc deposits, additives such as glue, licorice and sodium silicate are often added to the electrolyte. Even in the presence of additives, uneven zinc growth still takes place because of the combination of hydrodynamic and electrolysis conditions in the cell house. Recent advancements in imaging spectroscopy and scaling analysis have opened an avenue to further study the effects of additives on zinc growth morphology. In this study, Atomic Force Microscopy (AFM) and scaling analysis have been used to monitor zinc growth characteristics including roughness, periodicity, aspect ratios and growth mechanisms as a function of electrolyte composition as well as deposition time. Zinc was electrodeposited from an industrial electrolyte containing a host of additives onto an aluminum cathode with a platinum wire serving as the anode. AFM images of the samples were collected to obtain 3D topographical information on which scaling analysis was performed to extract details on root-mean-squared (rms) roughness, periodicity (grain size), aspect ratio of surface features and growth mechanism. This analysis provided information on the mechanism by which the previously mentioned variables can impact short term growth and also provided a prediction of expected growth at long deposition times.INTRODUCTIONElectrowinning is one of the final stages in the industrial production of zinc metal. It is during this process where dissolved zinc ions undergo electro-reduction from an acidic electrolyte onto an aluminum cathode and are later recovered by stripping the zinc metal from the substrate. However, due to the nature of zinc growth as well as the various operating conditions, zinc deposition may occur unevenly, sometimes causing short-circuits that can cause electrode damage and reduced zinc production."

Jan 1, 2016

By V. Schwinn, P. Fluess, N. Cauderlier, J. Bauer

From a strategic and economic point of view, the development of fine grain high strength steels for long distance pipelines is intensified world wide to satisfy the demand for natural gas in the future.The project related property profiles based on strength, toughness, crack arrest and sometimes resistance against HIC at defined design temperatures require an effective structural refinement using advanced steelmaking and processing in the rolling mill. The microstructure of modern line pipe steels ranges from ferritic pearlitic to ferritic-bainitic and structures where bainite is the dominant component, possibly upgraded by secondary phases. This paper illustrates microstructures and properties of recent orders on line pipe steels both for onshore and offshore application using different processing routes in the plate mill. Examples will be given for SAWL 485 offshore grades, X65 HIC and X70 HIC onshore grades, respectively. Finally, production results of a recent X80 order will be presented.

Jan 1, 2005

By J. Álvarez, J. Mesías, C. O. Gómez

"Operations routinely run flotation tests in laboratory mechanical cells to determine adjustments to plant operation based on feed flotation response or the effect of new reagents and dosages. The metallurgical results of these tests are certainly affected by changes in bubble size, which simultaneously impact the recoveries of the collection and froth zones. It is known that bubble size depends on the characteristics and operation of the machine in use, particularly on the gas flow rate delivered to the unit and the selected frother type and dosage. Although flotation rate constants have been related to bubble size, bubble surface area flux seems to be a more fitting variable to correlate flotation kinetics and cell performance, as it integrates bubble size and superficial gas velocity effects. However, although some evidence has been provided, a categorical relationship between cell recovery and bubble surface area flux has not been established. Our interest is to demonstrate this relationship to use it as a basis for developing soft sensors to track on-line collection zone recovery in cells. Flotation tests were designed to produce Cu concentrates for a range of bubble surface area flux values, obtained through changes in frother concentration at a constant gas flow rate, and by increasing gas flow rate at the same frother concentration. The tests were run on samples prepared from an ore batch supplied by a local operation, following strict grinding and flotation procedures, with a shallow froth to approximate cell recovery to that in the collection zone. Bubble sizes were determined using the sampling-for-imaging technique developed at McGill. The results unequivocally showed a consistent positive correlation between cell recovery and bubble surface area flux, and significant variations in performance when frother addition and gas flow rate were changed.INTRODUCTIONMineral flotation is a separation process to produce concentrates of valuable minerals by selective attachment of particles to the surface of bubbles. The process is carried out in machines where air is injected through a mineral pulp to form bubbles, and operated to create two zones: a bottom one (collection zone) where bubbles are continuously generated under conditions adequate to form bubble-particle aggregates by collision of the rising bubbles with suspended particles; and a top one (froth zone) where bubbles and bubble-particle aggregates continue to rise while concentrating and forming a froth layer for water and entrained particles to drain back to the collection zone, before overflowing as a concentrate stream. The phenomena occurring in these zones are complex and, in many cases, interactive, as they simultaneously affect stages of the particle separation sequence occurring in both zones. Although there have been significant advances in instrumentation to characterize particle and bubble populations, these have not resulted in knowledge to explain or models to describe phenomena from fundamental principles. Measurements continue to be limited to the development of empirical models for predicting the effect of operating variables on performance."

Jan 1, 2016

By D. Nie, M. Ren, T. Mo

This paper studied the phenomenon of room temperature creep deformation at crack tip and its effect on fatigue crack growth rate of a X-70 pipeline steel using compact-tension (CT) specimen on a MTS 810 testing machine. Time-dependent deformation at the crack tip under constant load was observed in this steel at room temperature and the amount of deformation produced was seen to depend on loading rate and the magnitude of stress intensity factor. It is found that there exists a critical stress intensity factor below which the deformation decreases with time when the applied load remains constant. It is also found that the occurrence of room temperature creep obviously affects the subsequent fatigue crack growth rate. The observed behavior was explained based on dislocation theory.

Jan 1, 2005

By Wayne F. Luinstra, Frédérique Vincent, André R. Laplante

"A test to determine the amount of gravity recoverable gold (GRG) in an ore is described. Typical GRG results are given; possible uses are discussed. A case study of how the technology was used at Hemlo Gold Mines is presented.IntroductionUsing gravity to supplement either flotation or cyanidation is a well established practice in the gold industry. It differs from most recovery circuits in that most of the gold recovered by gravity would be recovered in any case by the circuit downstream, be it flotation or cyanidation. The economic justification of gravity is therefore based on small margins (for example. a net smelter return of gravity gold of 99%, as opposed to 94% by flotation). It was easily demonstrated when either flotation or cyanidation were relatively inefficient processes, and labour costs low (as gravity can be labour intensive). Over the past thirty years, the advent of better flotation machines (flash, column, high capacity), more effective collectors, and better control systems has increased flotation's metallurgical performance, thereby decreasing the incentive for gravity recovery. Cyanidation technology has undergone similar changes, with the advent of activated carbon, oxygen and lead nitrate addition, and improved impeller design.Today, gravity could remain an attractive option only inasmuch as it can be implemented with very low capital and operating costs. This has resulted in a relative shift away from gold gravity recovery (except for alluvial deposits), in the seventies and eighties. For example, as of the early nineties, gold gravity recovery has disappeared from the typical South African flow sheet. The advent of the Knelson Concentrator, at the beginning of the eighties, foreshadowed a resurgence of gravity recovery, as gold's grinding and classification behaviour (Banisi, Laplante and Marois, 1991) makes it possible to achieve adequate gold recoveries with very simple, Knelson based, gravity circuits (Laplante et al., 1994).Consider for example the Hemlo recovery circuit, made of a single 61 cm x 122 cm (2' x 4') screen, an automated 76 cm (30"") Knelson feeding a Gemeni table, to produce a 70-80% Au concentrate which accounts for approximately one fourth of the gold production (about 3 million grams per year). The low capital and operating costs make it possible to justify the gravity circuit on the basis of savings in other operating costs (e.g. fewer carbon stripping and reactivation cycles). Any improvements in recovery, which would at Hemlo be difficult to measure, would be additional benefits. Such a circuit is rapidly becoming a standard in Canadian and Australian operations.The justification for installing a gravity circuit must be first based on an estimate of how much gold it will recover (irrespective of what the potential benefits are). This is a function of the nature of the gravity circuit to be installed; however, Knelson circuits, by their very simplicity and efficiency, limit the options. This leaves the amenability of the ore to gravity recovery as the single most important parameter. Various approaches can be used to characterize this response (Woodcock, 1993). The present work sought a route which would fulfil the following criteria:"

Jan 1, 1996

By J. Drelich

We report structural forces measured for 10 nm silica particles deposited on alumina substrate and 5-80 nm alumina particles on mica using atomic force microscopy technique. For nanoparticles forming clusters, oscillation of structural forces was recorded with a periodicity that is close to the size of the nanoparticles used. Additionally, selected force-separation results indicate that the forces involved between the AFM probe and individual nanoparticles can be studied using the nanoparticle-coated substrates.

Jan 1, 2006

By Free. Michael L.

Crushing ore prior to heap leaching enhances mineral liberation and creates fine particles that may require agglomeration to avoid permeability problems during leaching. Conventional modeling is relatively successful in describing general fluid flow and extraction in heaps. However, most models do not adequately account for the effects of mineral liberation and exposure or the effects of agglomeration, curing, and loading on heap leach performance. This paper will discuss methods to account for mineral liberation and exposure as a function of comminution. It will also discuss methods for incorporating liberation, exposure, and mineral locking as well as curing and fluid flow in heap leach modeling. It will also provide information regarding agglomeration and the effect of loading in heap leach modeling.

Jan 1, 2014