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By E. Talebi, P. Roghanchi

"This study aims to discuss personal and behavioral parameters contributing to heat-related accidents. To study the prevention approaches, it is essential to look at the various factors at the individual, management, and industrial levels. Qualitative risk analysis methods are used based on the public data in the USA to find the impact of the environmental and behavioral parameters on the heat stress and heat strain of mine workers. The effects of individual factors such as worker experience, age, fitness, lifestyle, acclimation, and more are illustrated. The significance of factors such as the roles of the mine management and regulatory agencies are addressed.INTRODUCTIONOccupational hazards in mining industry endanger the health and safety of the workers and productivity loss for mining companies. Among those hazards is the exposure to excessive heat that has adverse effects on the health of mine workers. The intensity of heat load is a significant factor in fatal and non-fatal heat-related accidents. Severe environmental conditions combined with a high level of activity in the mining industry increases the vulnerability of individuals to health and safety hazards (Ngwenya, Oosthuizen, Cross, Frimpong, & Chaibva, 2018). Lack of regulations and legislation addressing the heat issue in the mining industry (i.e., underground and open pit mines, processing plants) also raises widespread concerns.Along the climate change, various sources contribute to the overall heat load at a mine site (Hanna, Kjellstrom, Bennett, & Dear, 2011; Kjellstrom, Lemke, Hyatt, & Otto, 2014). In underground mines, the majority of heat comes from different sources such as geothermal gradient, equipment, auto compression, groundwater, and blasting (Maurya, Karena, Vardhan, Aruna, & Raj, 2015). On the surface, however, the majority of heat load can be sourced to solar energy. The exposure to excessive heat might result in heat-related illnesses, fatigue and fainting, loss of concentration, performance reduction, and production loss (Kocsis & Sunkpal, 2017; Roghanchi, 2017). The severity of the effects depends on duration and level of exposure and the response of an individual to heat stress. The response of an individual is influenced by different factors including age, gender, fitness, lifestyle, experiences, and past medical history."

Jan 1, 2019

By B. Krysa, A. Mitsui, T. L. Koehler

The presence of arsenic, even at trace levels, in copper processing leads to the risk of arsine gas where reducing conditions exist that can reduce any soluble arsenic present to its minus 3 valance state and generate hydrogen gas from the solutions. This risk is understood to be significant within the industry, particularly in the case of liberator cells where copper concentrations in solution are drawn down to remove the copper and impurities from the bleed stream. However, there are numerous other potential areas where the arsine gas risk exists including contact between active metal such as iron, zinc or aluminum and arsenic bearing solutions in pyrometallurgical dust treatment, refining and acid plant operations. In turn this breaks down to different mitigating strategies dependent on the risk scenarios considered; for example, how this risk interacts with Change Management, Confined Space Entry or Contractor Training. The ISO 45001 is an emerging standard meant to improve employee safety, reduce workplace risks and create safer working conditions all over the world. The paper shows a case study of how a framework consistent with the tenets of ISO 45001 has been used to provide a consistent assessment of this risk for a wide variety of copper operations and the expectations of how this may be used to effectively improve the effectiveness of barriers against future incidents. INTRODUCTION Arsine gas (AsH3), first identified in 1775, is a highly poisonous, colorless, non-irritating gas with a mild garlic odor that is heavier than air. Arsine gas is generated when reducing conditions are generated in the presence of hydrogen ions and arsenic compounds. Present permissible occupational exposure limit as defined by Occupational Safety and Health Administration (OSHA) as an 8-hour time-weighted average is ppm (0.2 mg/m3). Further increasing the risk, conventional respiratory protection utilizing half or full masks with gas filtering cartridges provide minimal protection against arsine. In copper processing plants, the risk of arsine generation is well understood in liberator cells, which are part of the electrolysis process. In this process, solutions containing copper are reduced in copper concentration removing not only the copper, but also arsenic, antimony and bismuth. The residual solution can be bled to control impurity build-up in the refinery. In this process, if the copper concentration is reduced to the point where As3- can form, arsine gas is generated via reaction with hydrogen ions generated during the plating process. The copper concentration at which arsine gas is generated depends on copper concentration at the cathode surface, the temperature and the acidity. As a result, there is always a risk of arsine gas generation in the liberator cell. Process measures to minimize or mitigate arsine evolution are tight control on final copper concentration, warm temperatures, fresh feed distribution and internal acid recirculation rates. Operator exposure protection measures are hooding, ventilation, arsine detection systems, restricted personnel access, automated shutdown controls and pre-defined evacuation plans.

Jan 1, 2019

By O. Mejia

"As study was undertaken to investigate the relationship between mill liner wear and grinding energy efficiency and to assess the opportunity to control mill speed to improve energy performance as mill liner wears. The study involved analysis of plant operating data and liner wear profiles over time. The operating work index was found to be an effective tool to identify the decrease of grinding efficiency along the liner service. The plant data show that the mill grinding efficiency as determined by monitoring the operating work index, and throughput decreases as liner wears. However, efficiency and throughput can be maintained by either changing the liner more frequently or by increasing the mill speed. Two scenarios for increasing mill throughput were analyzed. The first one involves changing the liner before the efficiency drops and the second one requires increasing the mill speed from 75% to 79%. Both scenarios show financial benefits that can be used in mill operations.INTRODUCTION The analysis of the mill power draw is used in this study as a key parameter for comparing mill liner profile and its effect on mill performance. Current technology and simulation software used in the mining industry do not factor in the impact of liner wear profiles in grinding efficiency and mill throughput (Toor, 2013). To address this gap, this study provides an analysis of key factors affecting mill throughput and grinding efficiency: mill speed, ball loading, and liner profiles. Several years of plant mill operating data, published research papers, and MillTraj® simulation results are used to demonstrate that face angles impact grinding efficiency and throughput and that mill speed can be used to overcome this problem. Moreover, the liner profile wear analyses clarify a mismatch between actual and estimated power draw calculations."

Jan 1, 2019

By L. Yuan, J. H. Rowland, R. A. Thomas, D. Bahrami, G. P. Cole

"The past several decades have seen a steady increase in the use of atmospheric monitoring systems (AMS) in underground mines as sensor technology has advanced and costs for this technology have decreased. The AMS is a reliable tool for early mine fire warning by detecting gaseous products of combustion in underground mines. During a mine fire emergency, mine decision makers rely heavily on the prompt and accurate knowledge of the ventilation and fire situation in the mine, such as fire location, fire size, and the spread of smoke to make effective and efficient decisions on firefighting strategies and miner evacuation. Meanwhile, a prediction of the potential for fire development at a later time, such as whether the currently designated mine escapeways will be contaminated by smoke and toxic gases with the progress of the fire, is critical for effective decision-making to save lives that are in danger. The AMS monitoring data, including carbon monoxide (CO) concentration, airflow rate, smoke, etc., can provide information as to whether the smoke has reached the locations where AMS sensors are installed and if a mine-wide smoke spread has occurred. The National Institute for Occupational Safety and Health (NIOSH) has undertaken a task to integrate real-time AMS monitoring data with the mine fire simulation program, MFIRE, to simulate and predict the spread of smoke and toxic gas in a ventilation network based on the real-time AMS data. This paper reports the developed real-time method for characterizing the size and location of an underground mine fire and for predicting the spread of contaminants throughout the mine ventilation network using sensor data from the AMS.INTRODUCTIONNIOSH conducts research to develop workplace solutions to improve detection of and reduce the risk of hazardous conditions in underground mines. The advancement of senor technology and the increasing demand for real-time mine parameters monitoring have led to extended applications of atmospheric monitoring systems (AMS) in underground mines worldwide. In the United States, AMS is primarily used for early mine fire warning by detecting carbon monoxide (CO) in fire hazard areas, such as belt entries. Mine fires can grow rapidly, and time is the critical element. Prompt detection, timely and accurate warnings to those miners potentially affected, and a proficient response by underground miners can have a tremendous impact on the social and economic consequence of a small underground mine fire (Conti et al., 2005). The early detection of a mine fire could gain time for the first responders to put out the fire before it develops into a disaster. An AMS system with CO sensors has especially played an important role in the early detection of mine fires. The continuous monitoring of an underground mine atmosphere with an AMS could generate a large amount of data in a mine fire event. However, the current application of AMS is mainly limited to sending out an alarm when monitored CO concentration exceeds a certain level. An opportunity arises as to whether these data can be further used in fire emergency response. In order to make effective decisions on firefighting strategies, mine workers’ seeking refuges, evacuation and escape, and the timing on when to send rescuers, decision makers need accurate and timely knowledge of the ventilation and fire situation in the mine. Information about the fire intensity, where in the mine the smoke and toxic gases have spread, and whether designated mine escapeways have been compromised by smoke and toxic gases from the fire would greatly increase the effectiveness of these decisions. However, the monitored AMS data only provides atmospheric conditions in the vicinity of sensor locations. What is concluded from the monitored AMS data highly depends on the decision makers’ capability and experience. Predictive insight into fire growth and smoke transport would greatly help decision makers during a fire emergency."

Jan 1, 2019

By A. Kishimoto, Yoshida Honmachi, T. Uda, Y. Taninouchi

Recycling of e-scrap is often performed by utilizing a pyrometallurgical Cu smelting process. Several valuable metals, including precious metals, can be efficiently recovered through the Cu smelting process. However, recovery of Sn is quite difficult because it is distributed in slag during the smelting process. Sn is used as solder and plating in electronic devices, and its recycling will be more important in the future. In light of this background, a pretreatment process that can extract Sn directly and selectively from e-scrap was developed in this study. The proposed Sn extraction process involves alkaline leaching using iodate ions, IO 3, as an oxidizing agent. We conducted leaching experiments for Sn, Sn-Ag-Cu alloy solder, and Cu, and the effective dissolution of Sn was confirmed. In principle, the electrodeposition of Sn from the leach solution and regeneration of IO3 are possible by a subsequent electrolysis process. The results obtained in this study suggest that the proposed leaching process can be an effective and useful pretreatment for Cu-smelting-based e-scrap recycling. INTRODUCTION Electronic scrap (e-scrap), including waste printed circuit boards (PCBs), is one of the fastest growing waste treatment streams in the global urban environment. E-scrap contains numerous valuable metallic elements, including Cu, Sn, and precious metals, in rich quantity. Furthermore, some metals and other materials contained in e- scrap are hazardous to human health and the environment when they are not properly managed. The recycling of e- scrap is therefore a major concern in terms of resource supply and waste treatment, and it has been performed by many companies using a variety of methods.

Jan 1, 2019

By L. Garycki, P. Poks, R. Urbaniak, T. Gabka

In 2016 at Głogów Copper Smelter KGHM Polska Miedź S.A., after shutting down the shaft furnaces new FSF was launched. Currently, it is the only smelter with two direct to blister flash smelting furnaces in operation. The main difference between the vessels are the dimensions and production capacity. The new furnace design output is about 30% higher compared to the old flash smelting furnace working for 40 years. The paper presents a comparison of both FSFs operation, differences in technology and the way to optimize the process to maximize efficiency. INTRODUCTION KGHM Polska Miedź S.A. is the only company in Poland (eastern part of Europe) that extracts and processes copper ores. It is located in the south west of Poland and this region is called the "Copper Basin”. KGHM PM S.A. consists of three underground mines: Lubin, Polkowice-Sieroszowice, Rudna, concentrator plants, a tailings pond plant, three copper plants: Legnica, Głogów and Cedynia wire rod plant in Orsk. The publication relates to the operation of the furnaces in Głogów (the plant in Głogów consists of Głogów 1 and Głogów 2 which form integrated smelting and refining facilities). In 2016, after closure of the shaft furnaces technologies in the Głogów 1, a new FSF commenced operation. The simplified process flow sheets are given in Figure 1 and 2. Technological schemes are similar, but due to the differences in them, they will be discussed separately. Głogów 1 Enriched ores are discharged and directed to the feed preparation plant. Delivered concentrates are built up on the three bedding aisles in appropriate proportions. The concentrates are distributed in even layers in one of the three aisles. Aisle emptying is done with a blending machine which cuts across the concentrate layers and collects thus blended material, sending it via belt conveyors to a storage bin. From the cross- blending machine and conveyor assembly, the mixture of concentrates is directed to drying in the steam dryer. Part of the charge is directed to the FSF and part to the roaster for carbon elimination. Known in the world roasters are used to eliminate sulfur compounds or arsenic. In the case of KGHM deposits, the aim of the process is to reduce the energy value of the feed by eliminating carbon and converting sulfur from sulfide to sulfate. Changing the nature of exothermic to endothermic material is crucial in the case of furnace operation with design performance. Roaster is a separate furnace with an innovative character.

Jan 1, 2019

By C. W. Chao, M. Melashvili, F. Hilário

The processing of a bulk concentrate containing copper as chalcocite, enargite, bornite and chalcopyrite along with pyrite and precious metals of silver and gold was studied. A leaching study was undertaken to examine the application of the atmospheric acid leaching process to a bulk copper concentrate for copper recovery followed by cyanidation or thiosulfate leaching for gold and silver recovery. The extraction of copper exceeded 90% under some conditions and the recovery of gold and silver reached a maximum of 44 and 45%, respectively. A sample of bulk concentrate was roasted in air to oxidize the sulfides with release of sulfur dioxide followed by acid leaching of the roaster calcine and cyanidation of the acid leach solution. The copper extraction reached over 92% and the gold extraction exceeded 88%. The sulfur dioxide may be captured for acid production. INTRODUCTION The processing of a large primary copper deposit in Indonesia is under investigation. One of the possible routes for processing involves flotation of a bulk copper-gold concentrate followed by treatment by an atmospheric leach/SX-EW process for copper recovery. The atmospheric leach residue would then be leached for recovery of gold and silver. A second route involves roasting of the concentrate followed by acid leaching and SX-EW for copper recovery. The leach residue from the roaster calcine would then be leached for recovery of gold and silver. The roaster off-gases could be used for sulfuric acid manufacture, enabling the production of a valuable by-product. The Cobre Las Cruces (CLC) process (Munoz, Garcia, & Delgado, 2017) was designed to treat a resource of copper discovered close to Seville, Spain. The process was developed by Outotec with MK Gold (original project owner). INMET Mining subsequently purchased the deposit from MK Gold and built the copper processing facility. The CLC process is similar to the Mt. Gordon Copper process; except that OKTOP reactors have been installed instead of a low temperature, low pressure autoclave process. The plant was designed to treat 1.3 mtpa of ore at a grade of 6.2% Cu to produce 72,000 tpa of cathode copper over a 15 year project life. The main gangue mineral at Cobre Las Cruces was pyrite. The Cobre Las Cruces ore is therefore similar to a rougher flotation concentrate containing copper minerals and pyrite. The roasting of a rougher flotation concentrate can be designed to produce hematite, basic copper oxides and sulfur dioxide off gas. The acid leaching of the basic copper oxides may produce soluble copper for SX-EW recovery of copper. The sulfur dioxide off-gas may be used to make sulfuric acid.

Jan 1, 2019

By Akira Miura, Katsuyuki Sato, Yuken Fukano

JX Nippon Mining and Metals Corporation has developed the JX Iodine Process, which is an innovative and patented copper-leaching process for low-grade primary sulfide ores. This process consists of the irrigation of ferric iron and a low concentration of iodide solutions. One-meter column leaching tests were conducted on ore samples from two different mines. At the end of experiments, the total copper recovery exceeded 70% for Sample A and 50% for Sample B with the iodine method, which was significantly higher than that with conventional ferric leaching of 14% for Sample A and 20% for Sample B. To elucidate the reason for the JX Iodine Process effectiveness, cross sections of leached residues were studied. Reaction products were confirmed around chalcopyrite even in the central area of particles in Sample A, however, reaction products were recognized at a depth of only 1 mm from the ore rim in Sample The resistance of Sample A to the leachate appeared to be lower than that of Sample B because Sample A had a high permeability and porosity, whereas Sample B had been affected strongly by a potassium alteration. No reaction products were visible on conventional leaching samples, even at the ore surfaces. INTRODUCTION Hydrometallurgical copper leaching (heap leaching or dump leaching) has been used extensively for copper recovery from oxide and secondary-sulfide ores, but not for primary copper sulfides, which contain mainly chalcopyrite as copper minerals. Although they are major resources of copper, primary copper sulfides are difficult to process because of their refractory nature. Extensive leaching studies have been carried out to leach primary copper sulfides (chalcopyrite), including biological and chemical, using a variety of oxidants and additives to enhance copper recovery. Watling (2013) reviewed acid-chloride-oxidizing agents with chalcopyrite. Abdollahi et al. (2015) tested silver as a catalyst for bioleaching with a chalcopyrite-bearing molybdenite concentrate. Hiroyoshi, Miki, Hirajima and Tsunekawa (2000) found a specific redox-potential zone for high-speed chalcopyrite leaching by controlling the ratio of ferric and ferrous iron. However, no ambient-temperature economic process has been developed for leaching primary copper sulfide, which usually has a low copper grade.

Jan 1, 2019

By R. Alarcón Sch., R. Abel F.

For many years, copper cathode quality has been a priority for end consumers, since it affects the variety of products that can be obtained from them. From the beginning, physical and chemical quality of the wire bars was controlled, as this product was used to obtain wire rod and other forms of copper by wire drawing. At that time, all the electro refined cathodes were melted and casted as wire bars. Subsequently, in the 80’s, with the introduction of continuous casting furnaces, it was possible to directly produce wire rod from cathodes. From then on, cathodes quality standards were consistently increased, by the introduction of uniform criteria, among which we can identify ASTM and British Standards as well. Also, producers began to use more demanding internal standards than the existing specifications, in order to differentiate their cathodes as high quality products among customers. Today the physical aspect of cathodes, including nodules, cracks, sulfates, or others, is the first element used by end customers to assess their quality. This paper aims to show a brief vision of the evolution of quality specifications for products used to manufacture copper wire. INTRODUCTION From the beginning of refined copper production for industrial purposes, mandatory minimum quality conditions were established. These quality conditions were used as the main element to determine prices and discounts of the respective sales contracts. Reviewing the copper development history, we can appreciate that its quality requirements had been constantly evolved, so that currently refined copper has an extremely high quality standard, that allows its direct use in the production of ultra-thin cables and other products applied in the industry. In each stage, refined copper production has fostered the development of technology used in their treatment. Similarly, cathode processing technology has been evolving to minimize treatment costs in order to generate a wire rod for several uses, ranging from power cables to super conductors. In this sense, to the already known type of fusion processes of the Southwire or Asarco type (capacities over 80 kt / year), wire rod production processes of the Upcast or Rautomead type (capacities between 20-50k t / year) have been added. They immediately deliver oxygen-free wire rods. In both cases, we can conclude that the clients' requirement had evolved from a chemical criteria focus, to considering more subjective aspects, such as visual control as the first stage of inspection.

Jan 1, 2019

By A. Karzhau, B. Aldamzharov, Y. Tussupbekov

"This case study produced for the metal mine operating in Kazakhstan, which has ventilation controlled manually and working continuously at maximum speed to keep air flowing through each part of the mine 24 hours a day. The mine auxiliary ventilation has been designed with the maximum length of ducting systems with extra air volumes to compensate for potential leakage. The mine provided auxiliary ventilation to all production stopes even to those, which for various operating reasons become temporarily inactive. However, mine safety has to consider risks associated with the deficit of fresh air for mine gases dilution and removal. The mine needs additional investments for re-designing ventilation network and therefore needs to estimate financial risks associated with it. The aim of this study is to conduct risk analysis for ventilation network optimisation processes at the operational metal mine in Kazakhstan. Mine ventilation surveys were undertaken for validation of the computerised ventilation model. The mine ventilation network modelling has been undertaken to be compliant with Kazakhstan mining regulations. Results of the mine ventilation optimisation processes were analysed in terms of financial risks for investments into reconstruction of the ventilation shafts, extension of the ventilation network, variable speed fans and automated regulators. Savings were resulted from improving ventilation system efficiency by reduce airflow in areas without mining activity and redistributing existing ventilation capacity. Based on savings derived from the optimised ventilation network an additional NPV has been received. Stochastic modelling use Monte Carlo simulation producing representation of possible outcomes for the additional NPV considering electricity pricing as a major variability. As result probability distribution for the optimised ventilation network demonstrates the additional NPV in a range of 1.6 - 2.2 million US$ in the corresponding defined value of 90%. Moreover, there is only 5% chance that the additional NPV to be less than 1.5 million US$. Conducted risk analysis for ventilation network optimisation processes gives considerations on volume of investments into the mine ventilation system.INTRODUCTIONCosts for mine ventilation are typically increasing when mines expand to deep levels. Some underground mines in Kazakhstan still use continuously operating fans at its maximum capacity. This is not helping to save energy and costs that are in many cases very significant. This case study produced for the metal mine operating in Kazakhstan, which has ventilation controlled manually and working continuously at maximum speed to keep air flowing through each part of a mine 24 hours a day. The mine auxiliary ventilation has been designed with maximum length of ducting systems and extra air volumes to compensate for potential leakage. The mine provided auxiliary ventilation to all production stopes even to those, which for various operating reasons become temporarily inactive. However, mine safety has to consider risks associated with the deficit of fresh air for mine gases dilution and removal from the mine workings (Sabanov, 2019). The mine needs additional investments for re-designing ventilation networks and therefore need to estimate financial risks associated with it. The aim of this study is to conduct risk analysis for ventilation networks optimisation processes at the operational mine in Kazakhstan. Mine ventilation surveys for validation of the computerised ventilation model have been undertaken"

Jan 1, 2019

By A. Hutwalker, T. Plett

"Blast fumes are one of the major sources for NOx in underground mines. In 2016, the Occupational Exposure Limits for NOx in Germany were reduced by 90%. The task is to keep re-entry times after blasting at the present level and thereby ensure an economic operation of the mine. Measurements show that using ventilation solely is not sufficient. A new approach to reduce NOx from blast fumes is described. Laboratory experiments were performed and a reduction of NOx was observed. Measurements were conducted at an explosive factory’s testing facility and in an underground mine at blasting operations. INTRODUCTION Whether for production of ore or for drift development, the processes in an underground mine are always the same: 1) fracturing the rock, 2) loading the pile, 3) support the resulting cavity. The fracturing of the rock can be done mechanically, by cutting, for example by using continuous miners or tunnel boring machines, or by drilling and blasting. Drilling and blasting is more flexible than mechanical driving, as it can be used independently of the rock strength. Furthermore, this driving method allows a more flexible reaction to changes in geological and/or operational conditions. Thus, underground mining and blasting are almost inextricably linked with each other, and regardless of the size and level of technology of the mine, blasting is hardly avoidable. Depending on the mining method chosen and the existing framework conditions, such as the mechanical properties of the rock or the availability of machinery, blasting is an integral part of daily operations. Even in mines where blasting is not part of regular operations, it cannot be completely avoided. The blast fumes generated by the explosions are, in addition to diesel engine emissions, one of the two main sources of emissions of nitrous gases underground. Up to now, state of the art for dealing with blast fumes is ventilation. The fumes are diluted with fresh air and ventilated out of the mine. This treatment of blast fumes is more than sufficient with the former German Occupational Exposure Limits (OEL). The adaption of the OEL in Germany to the recommendations of the Committee on Occupational Exposure Limits (SCOEL), a committee of the European Commission, leads to big challenges for the mining industry in reducing the concentrations of these gases at the workplaces underground. On its meeting on May 2nd and 3rd 2016, the Committee on Hazardous Substances (Ausschuss für Gefahrstoffe, AGS), an advisory body of the German Federal Ministry of Labour and Social Affairs (BMAS), advised the BMAS to copy the OEL, as recommended by the SCOEL, to the Technical Rules for Hazardous Substances (TRGS 900). BMAS followed this advice, consequently the new OEL where published on November 4th 2016 and became part of the TRGS 900. Table 1 shows the former and new OEL for Germany. These new OEL became law after publishing, but two exceptions were made: For tunneling operations, they became law on October 31st 2017, for mining operations they will become law on October 31st 2021 (BAuA, 2004, 2016, 2017)."

Jan 1, 2019

By Gary Walters, Thomas Gonzales, David George, William Davenport, Andreas Siegmund, Suping Yao, Shijie Wang

The previous survey of world copper smelters was in 2016 (Copper, 2016). The copper smelting industry has grown and improved considerably since then, including continuing growth in China and modernization in Japan (Extraction, 2018). Outotec flash smelting and Outotec flash smelting/Kennecott - Outotec flash converting continue to be adopted while newer processes continue to be adopted in China. In addition, some of the world's original flash furnaces have been completely rebuilt (Extraction, 2018). This paper provides recent industrial production data and discusses these new developments. INTRODUCTION A world copper survey was redone in 2016 after a thirteen year lag since 2003. Some of the notable changes were the significant increases in production particularly from China. Since then, several smelters have gone through modernization processes and decommissioning of older technologies. This paper will review the notable changes since the last publication at Cu2016. In the last paper, Copper Smelting: 2016 World Copper Smelter Data, the author gave an audible sigh after observing that copper smelter sites as well as new and notable smelters have been spreading like wildfire in China since 2003. Indeed, seeing is believing. Figure 1 shows the Ningde Copper Smelter (double flashing, 400,000 MT Cu/Year capacity) that started up producing copper in 2018; Figure 2 shows the Nanguo Copper Smelter that is under construction with 300,000 MT Cu/Year capacity (first phase, side blown smelting and continuous top blown converting). We should not only admire the Chinese copper industry’s significant technological developments, but also the copper price support that it has provided throughout this century.

Jan 1, 2019

"Load-haul-dump machines (LHDs) are typically used in underground metal mining operations. Delays or inappropriate use of LHDs can result in production loss. Optimized LHD use is especially crucial in larger mines because longer travel distances increase heat, dust, and gas emissions, which in turn increase ventilation costs. This study, conducted at an existing Swedish sublevel cave underground mine, used discrete event simulation and the AutoMod™ DES tool to determine the ventilation costs related to using too many diesel LHDs in a production area with reduced ore pass availability. When fewer ore passes are available, ventilation costs related to operating LHDs in the production area were found to increase by as much as 200, 224, and 306% for one, three, and six LHDs in operation, respectively. ¦ KEYWORDS Discrete event simulation (DES), Loading operations, Production rate, Ventilation costs RÉSUMÉ Dans les exploitations souterraines d’extraction des métaux, on utilise généralement des chargeurs-transporteurs (LHD, de l’anglais Load-haul-dump machines). Les retards ou l’utilisation abusive des LHD peuvent entraîner une perte de production. L’utilisation optimisée des LHD est particulièrement importante dans les grandes mines en raison des longues distances parcourues, lesquelles augmentent la chaleur, la poussière et les émissions de gaz qui, à leur tour, décuplent les coûts de l’aérage. Cette étude, menée en Suède dans une mine souterraine utilisant la méthode d’exploitation en sous étages avec foudroyage, s’est basée sur la simulation à événements discrets (SED) et l’outil de SED AutoMod™ pour déterminer les coûts de l’aérage liés à l’utilisation d’un nombre trop élevé de LHD alimentés au diesel dans la zone de production, avec une disponibilité réduite de la cheminée à minerai. Lorsque les mines disposent de moins de cheminées à minerai, l’étude montre que les coûts de l’aérage liés à l’exploitation des LHD dans la zone de production augmentent respectivement de 200, 224 et 306 % pour un, trois et six LHD en fonctionnement. ¦ MOTS CLÉS coûts de l’aérage, opérations de chargement, simulation à événements discrets (SED), taux de productionINTRODUCTION Transporting material from the mine face to the dumping location requires flexible loading and hauling equipment that is able to cope with sharp curves and a complex mining environment. Load-haul-dump machines (LHDs) are designed for such an environment. Models are available to suit specific features of the working environment such as small, large, or narrow open stopes (Atlas Copco Rock Drills AB, 2007). When carrying a full load, haulage speed is higher for LHDs than for front-end loaders with the same engine size. Also, payloads are approximately 50% higher for LHDs than for front-end loaders (Atlas Copco Rock Drills AB, 2007). LHDs are capable of climbing steep (Bloss, Harvey, Grant, & Routley, 2011). The haulage distance between stope and ore pass is usually between 50 m and 400 m. LHDs are efficient for tramming distances up to 200 m (Bloss et al., 2011), whereas when loading trucks, the LHDs work efficiently when the distance is less than 100 m (Atlas Copco Rock Drills AB, 2007). The largest diesel-powered LHDs, with drive motors of up to 350 kW, can handle a payload of 21 t (Wennmohs, 2014). Most mining equipment runs on diesel fuel, which provides flexibility, high durability, and high efficiency (Pronk, Coble, & Stewart, 2009); however, other alternatives such as electric, hybrid diesel/electric, or hydrogen fuel cell machines are increasingly being developed and used. This change is due to diesel-powered machines accounting for a significant portion of the ventilation costs in the mine (Chadwick, 2008; Paraszczak, Laflamme, & Fytas, 2013). Currently, as part of the European sustainable intelligent mining systems (SIMS) project, Epiroc AB is planning to demonstrate technology for a diesel-free underground mine at Agnico Eagle’s Kittlä mine in Finland using"

Jan 1, 2019

By Zhuo Chen, Jun Zhou, Jiemin Zhou

Samples of the reacting suspension particles were taken from the reaction shaft of a commercial flash furnace at different heights. The processes of matte and slag formation and morphology of the samples in the shaft were observed and analyzed. Variations of matte and slag composition in the shaft were investigated. By analyzing the samples taken from the settler at different locations, settler processes were studied such as slag formation, agglomeration and separation of matte-slag phases, Fe3O4 reduction, copper-in-slag reduction etc. In accordance with the characteristic of matte and slag formation the flash furnace can be divided into 6 functional regions, and a mechanism model called as “Micro bath process” is proposed for matte and slag formation in a commercial flash furnace. INTRODUCTION During flash smelting, concentrate particles scattered in the reaction shaft complete their oxidation reactions in suspension. The droplets produced fall into the settler beneath with a small amount of un-melted solid particles, agglomerate and separate into matte and slag layers which are tapped out from their tap holes separately. With respect to the extent of slagging reaction in the reaction shaft, there isn’t any commonly accepted understanding in literature (Kimura, Ojima, Mori & Ishii, 1986; Kemori & Kondo et al.,1988; Kemori, Denholm & Kurokawa, 1989; Fagerlund &Jalkanen, 2000). Some assume that the slagging reaction in the shaft can be ignored and some propose that all slag is produced in the shaft. With regards to the characteristics of the physical-chemical changes of concentrate particle in the reaction shaft, although there are some research results reported from pilot scale and commercial scale experiments (Kemori, Ojima & Kondo, 1988; Hagni, Vierrether & Sohn, 1988; Jorgensen, Taylor, Dickinson & Stevenson, 1992; Swinbourne, Simak & Yazawa, 2002; Kivinen & Tuominen, 2005), they are generally limited themselves to theoretical analysis and calculations. No studies are published concerned with the processes of matte and slag generation in the shaft, quantitative analysis of the processes, variations of matte and slag composition and morphologies of the melts along the axis of the shaft, etc.

Jan 1, 2019

By S. Hopkins, R. Preston, S. Gillis

"This paper examines typical visual inspections of operational soft rock mine shafts and discusses some of the challenges involved, many of which are associated with inconsistent inspection practices. The paper presents the development of a more standardized approach to periodic shaft inspections that supplement the more frequent inspections performed by shaft crews at the mine. This approach helps to keep an accurate record of changing conditions, compare conditions between multiple mine sites, as well as prioritize and plan potential remedial work. INTRODUCTION Shaft inspections, whether they are performed daily or weekly by members of the shaft crew at the mine, or periodically by consultants, traditionally involve a visual inspection undertaken with personnel traveling on an inspection deck on the conveyance, taking notes and photos. Inspections are typically required by mining regulations and carried out to identify and address hazards before a safety incident occurs that could cause harm to people or damage to property, as well as to help plan required maintenance work. Depending on the site, there can be many challenges associated with inspections in the shaft, especially compared to a typical inspection at surface. Some of these challenges are associated with the shaft environment itself, while others are related to the subjectivity of inspections and a lack of standardization, particularly between multiple sites within the same operating company. Recognizing these challenges, a more consistent and repeatable approach to shaft inspections in soft rock mines is evolving. This approach involves reviewing available historical data, comparing sites with similar conditions, establishing survey control, documenting observations and measurements with locations, and updating as-built or condition drawings. Part of this standardized approach is the implementation of an innovative 360-degree camera with a high-power lighting system that can be used either remotely or alongside personnel completing a traditional visual inspection. The system uses six cameras to take photos at a rate of 15 frames per second, with the image data subsequently processed and stitched, then joined into a high-resolution video. This tool improves time-efficiency, objectivity, and repeatability of inspections."

Jan 1, 2019

By J. Sammut, T. G. Joseph, R. Andreev, M. Curley

"Decisions regarding mining method and subsequent choice of excavator must take into account the quantitative factors of productivity, availability, and capital, operating, and maintenance costs. Dig performance was compared between a hydraulic excavator (HE) and electric rope shovel (RS) of similar size class (i.e., use the same amount of energy to excavate a unit quantity of the same material from a mining face), focusing on the quantitative factors above. Machine performance, normalized to bucket capacity, was assessed as a function of hours of service (60,000 hours per machine). Results showed higher production rates for the HE of similar capacity and age. In general, the RS exhibited lower service cost per volume capacity, though it had higher capital cost. The RS became more cost effective than the HE of similar capacity within approximately 30,000 hours of service. ¦ KEYWORDS Cost, Electric rope shovel (RS), Excavation, Hydraulic excavator (HE), Surface mining RÉSUMÉ Les décisions concernant la méthode minière à adopter et le choix ultérieur d’un engin d’ex¬cavation doivent tenir compte des facteurs quantitatifs de la productivité, de la disponibilité ainsi que des coûts d’investissement, d’exploitation et d’entretien. Cette étude compare les performances en termes d’excavation d’une excavatrice hydraulique et d’une pelle électrique à câbles de même taille (qui utili¬sent par exemple la même quantité d’énergie pour creuser une quantité unitaire du même matériau dans un front de taille), en se concentrant sur les facteurs quantitatifs susmentionnés. La performance de la machine, normalisée à la contenance du godet de volume unitaire, est évaluée en fonction des heures de service (60 000 heures d’activité par machine). Les résultats montrent des taux de production plus élevés pour l’excavatrice hydraulique d’une capacité et d’une ancienneté similaires. De manière générale, la pelle électrique à câbles affiche un coût d’entretien par capacité volumique inférieur, mais son coût d’in¬vestissement est plus élevé. La pelle électrique à câbles devient plus rentable que l’excavatrice hydrau¬lique d’une même capacité au bout d’environ 30 000 heures de fonctionnement. ¦ MOTS CLÉS coût, excavation, excavatrice hydraulique, exploitation à ciel ouvert, pelle électrique à cablesINTRODUCTION The most common excavating tools in surface mining operations are the hydraulic excavator (HE) and electric rope shovel (RS). In general, electric RSs are more reliable and cheaper to maintain (P&H Mining Equipment, 2007), but where complicated geological conditions exist, HEs are preferred because they are generally considered to be more mobile."

Jan 1, 2019

By K. Kim

"All milling operations would like to achieve the best possible recovery in combination with the highest achievable throughput. Unfortunately, many operations have problems with low recovery, low throughput or both. In the majority of these cases investigated by the author, the solutions to improve recovery and throughput were simple. The solutions did not include implementation of new technology or major capital, but rather a return to fundamentals. In most cases, problems occurred because the operation was not following their own operating procedures, because the design of the circuit was changed without adequate change management or understanding of the implications of changes, or because basic metallurgical measurements and control were not taken or ignored. In this paper, examples of these problems and their solutions derived from long and varied experience will be discussed. The objective of this presentation is to provide the milling operator with practical and readily implementable solutions to common milling issues to improve throughput and recovery.INTRODUCTION Mill operations can be evaluated by many operating parameters, but the two best indicators are recovery and throughput. These two parameters summarize the wellbeing of an operation. The grade to the mill is also a good indicator, but this is usually controlled by the mine. The best recovery and throughput are achieved through a team work involving operators, maintenance workers and metallurgical staff. The milling operations include many unit operations, such as crushing, grinding, flotation, leaching, carbon in leach, Merrill Crowe, roaster, autoclave and refinery. The tools available to the operations are plant design, process measurements, assays, metallurgical balance, and operating strategy. Twelve real life examples of improvements of recovery and throughput are presented in this paper. EXAMPLE 1: CRUSHING CIRCUIT WITHOUT FINE ORE BIN At this operation plant throughput could not be maintained at a high rate because feed to the mill became coarse during the day. The cone crusher was feeding the ball mill directly. As the day wore on, the gap on the cone crusher would slowly increase, which would cause the product size to increase. This would increase the re-circulating load on the ball mill. The throughput would decrease accordingly. Furthermore, the throughput would decrease more with high frequency of maintenance on the cone crusher."

Jan 1, 2019

By A. J. Rigby

The wear mechanisms of the tuyere lines of Peirce-Smith and Hoboken converters are a subject of endless debate and speculation. However, there has been an indication that one of the primary factors in the deterioration of tuyere lines is due to the batch operation of the converting process. The cooling of the brick in the tuyere line during out-of-stack times leads to shrinkage of the brick and resultant opening of the joints. Subsequently, on re-entry of the tuyere line into the bath, the joints become penetrated with matte and re- expansion of the brick is prevented. It is thought that this regular cycle of exiting the batch for slag skimming and replenishment of matte and re-entering for further blowing leads to a gradual “ratcheting” of the tuyere brick lining. If no expansion allowance is furnished between the endplate and the endwall of the lining, then the generation of damaging compressive stress is unavoidable. INTRODUCTION It is generally accepted industry-wide that the integrity of a refractory lined vessel is determined by an inextricable combination of refractory brick quality, the caliber of the lining design and installation, and the severity of the process inflicted upon the high wear areas of the vessel lining. Rigby has summarized the concentrated attempt, over the past several years, to optimize the microstructural, chemical, and fracture properties of the refractories used in non-ferrous pyrometallurgical vessels. Furthermore, lining design concepts involving larger and longer brick and the extent and positioning of expansion allowance in the joints have been extensively trialed. All these efforts have provided some, but not startling, improvements. The simple fact is that a vessel lining composed of bricks with an optimized microstructure and chemical inertness must installed with a well-conceived design to decompress the lining stresses that are generated by the batch operation of copper converters. REFRACTORY QUALITY Converting is conducted by injecting air into the molten matte and white metal for the very purpose of generating iron and copper oxide slags. These slags must be contained by a refractory which, by its mineralogical formulation, is optimized for chemical inertness.

Jan 1, 2019

By S. Konetschnik, Lux Degel, R. Degel, T. Haslinger

UrbanGold and its partners from Mettop and SMS group have developed a novel technology for the recovery of valuables from all non-ferrous metals’ fractions of WEEE (Waste Electrical and Electronic Equipment), with a special focus on low qualities which are commonly landfilled or incinerated. The technology is marketed under the brand name “UrbanGold Flex” to illustrate the high flexibility in respect of plant design and raw material portfolio, allowing also the processing of low grade material and materials with high caloric values. The process of the technology’s centrepiece, a modified and enhanced bath smelting furnace called “HENRI”, was investigated in numerous pyrometallurgical trials as basis for a scale-up towards a capacity of up to 100,000 tons of WEEE-concentrates per year. All relevant facility components have been evaluated in respect of references, fall-back options, as well as exit strategies (alternatives) to minimize risks when establishing a novel technology. A spin-off within the development is the “UrbanGold Compact” technology which can be seen as optimization of state-of-the-art smelters by using an optimized TBRC as primary processing unit. As an UrbanGold Compact plant will be the first industrial scale reference of UrbanGold’s technologies, it is also explained in the publication. As precious metals recovery is of major (economical) importance when recycling WEEE, major attention has been given to minimize the losses of these valuables. These measures, as well as a sophisticated way of utilizing waste heat as far as possible, result in interesting business cases with gross profits of up to 20% or even more. INTRODUCTION Over the past years, the demand of electrical and electronic equipment has increased dramatically with technological progress. Innovations on the technology of electronic devices led to a shorter usage and lifespan and thus boosted the generation of Waste Electrical and Electronic Equipment (WEEE). WEEE is one of the fastest growing waste streams, growing at 3 to 4% per year worldwide and is expected to reach more than 52 million tons per year by 2021. Currently, about 45 Mt of these wastes are estimated to arise worldwide, and the trend is rising (Baldé et al., 2017).

Jan 1, 2019

By Barry Hope, Javier Rico

"Goldcorp’s Hoyle Pond mine has recently completed several projects which have impacted the overall ventilation system. The project includes extending the Fresh Air Raise (FAR) to depth, development of a new Return Air Raise (RAR), and the installation of new sensors and ventilation controls throughout the mine. Two years after the completion of #2 Winze, the mine is ramping up its ore production to 1,300 tpd (up from 1,100). To ensure safe and profitable production, a reliance upon technology has been needed to provide the required ventilation to the work areas according to the mine plan. To systematically assess the mine’s ventilation in real-time, a significant increase in remote monitoring was required. This included installing additional flow, pressure, temperature and gas sensors. The first step in upgrading the existing monitoring was to purchase airflow and differential pressure monitors and install them in key areas of the mine. This paper presents the process of expanding the monitoring capability at Hoyle Pond mine, the selected equipment and the results of the implementation. The intended goal was to improve safety while minimizing capital and operation costs. The monitors were installed in strategic locations to provide immediate feedback on the impact of changes to the primary ventilation airflows. Comparing the available sensor technologies, installing them and systematically monitoring the ventilation served as a first step towards developing a mine wide Ventilation Control System. In addition, the initial state of the monitoring and control system, with final results and the chosen solution for the mine site, are presented. INTRODUCTION The Hoyle Pond mine is located in the City of Timmins, within the Porcupine mining district, Ontario, which has produced more than 70 million ounces of gold since 1910. Currently, approximately 60% of Porcupine Gold Mines gold production comes from the Hoyle Pond underground mine. Mechanized cut and fill and long-hole mining methods are used to extract the ore. The remainder of the ore comes from the Hollinger Open Pit mine. The Dome Underground mine ceased operations in 2017. Hoyle Pond is currently mining at 1820 meters below the surface and plans to go deeper. The average dry-bulb as wet-bulb temperature underground varies according to the depth and surface conditions which has extremes of –40°C in winter to +30°C in summer. The total airflow volume pushed down from surface is 240 m3/s to accommodate the diesel-powered equipment needed for normal operations. In order to improve the quality of air underground a program has been implemented to use diesel particulate filters, starting with the truck fleet and 6-yard scoops, followed by the intention to implement the rest of the functional diesel-powered equipment and eventually move to electric equipment."

Jan 1, 2019