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By M Reza Afshar

In this work a mathematical model was developed to study the effect of electromagnetic force on the magnesium melt containing nonmetallic inclusion in an electrical isolated channel. The electromagnetic force exerted on the inclusion induced by DC current field was calculated. A three dimensional turbulent flow equations were solved numerically to compute the velocity field within the channel. On the basis of computed velocity and magnetic fields, the trajectories of inclusions were calculated using the equations of motion for inclusions. Parametric studies were carried out to evaluate the effect of various parameters such as current density, channel diameter and particle density on the removal efficiency of inclusions from magnesium melts.

Jan 1, 2004

By J. Doucet, C. Price

In an industrial setting, operational changes are continually introduced, driven by new technologies or changing economics. Because of day-to-day variability, quantifying the impact of these changes based on metallurgical performance requires long trial periods to achieve statistically significant results. Tools and techniques developed by the mineral processing group at McGill University have allowed for direct measurement of process variables (e.g., bubble size, gas and solid holdup). Two case studies are described where direct measurement techniques were used to evaluate: a) a new rotor stator mechanism; and b ), the introduction of a new frother type. Application of these methods has accelerated the evaluation of process changes and improved confidence in results.

Jan 1, 2009

By Jonathan Peck, Jim Gray

"With the implementation of more advanced monitoring, control and locating systems in surface mines, there is an ever increasing need for their mine-wide integration toward achieving over-all optimization. AQUILA Mining Systems Ltd. is developing the basis for a comprehensive real-time monitoring, control and information system called the Total Mining System or TMS. This system is being designed to address both current and future needs of open pit mines toward improving productivity and minimizing costs, through better two-way information flow between each component in the operation. At a basic level, feedback from equipment and process monitoring will enable decision making to be based on quantitative, on-demand information, thus permitting proactive rather than reactive planning. Dynamic planning would be a valuable tool as market conditions fluctuate, equipment fleets age and variations in the grade, quality, geometry and hardness of the mined material all contribute to either changing production targets or levels of achievable performance. Such a capability could be implemented within the next two years.At a higher level, and within five years, autonomous operation and/or real-time supervisory control of mobile and stationary equipment in open pit mines will be achieved. A discussion is provided in regard to the development and implementation of an autonomous haultruck and blasthole drill, to demonstrate the need for such a system.This paper outlines a preliminary program for the design, development and implementation of this system, primarily in relation to high-level communications and its role in the future automation of open pit mobile equipment."

Jan 1, 1995

By J. H. H. Chamberlin

"In the Introduction the author briefly discusses the company history as it relates to the development of its contracts with the Japanese steel mills. The main part of the text describes how Coleman Collieries Limited approached the problem of mining coal profitably in thick, steeply inclined seams. For many years a basic room-andpillar system was worked by conventional methods. Main roadways were driven on strike across the mineable area. These roadways acted as haulage routes for coal, materials and men. Rooms were developed to the rise of the main haulage route by pairs of men using air-operated hand picks. As these rooms advanced the miners would lay and extend a sheetiron chute down which mined coal would gravitate to a controlled loading point, where it was loaded into trains of mine cars. Connecting roadways or ""OFFS"" were driven at predetermined intervals between adjacent rooms, forming pil1ars or blocks. Extraction of the blocks followed on a line conducive to good strata control some distance behind the developing rooms. A need for higher productivity, expansion of the operations and a scarcity of qualified miners resulted in the company deciding to mechanize its underground mines. Joy 6 CM continuous miners and 10 SC shuttle cars were selected as being machines that could reasonably negotiate the problems associated with the pitching seam. The equipment, nonetheless, has definite limitations and Coleman therefore developed a modified version of the room-and-pi11ar system such that the miners and cars could work on cross pitch. In the area described, main roadways were driven to the rise on an average gradient of 12 degrees. Panels, which consisted of two parallel roads with interconnecting cross-cuts, were then developed on strike to a boundary point. Blocks formed in the development of the panels were subsequently extracted on retreat. Problems associated with each phase of the operation are thoroughly discussed, together with roadway support methods and equipment used for the conveyance of coal and materials."

Jan 1, 1972

By C. A. Pickles

Nickeliferous limonitic laterite ores contain considerable free moisture. In this research, the application of microwave radiation for the drying of this ore was investigated. The effects of sample mass, initial moisture content and porosity on the microwave drying rate were studied and the results were compared to those obtained with conventional drying. Microwave drying rates of two to three times the conventional values were achieved. Further enhancement of the microwave drying rate was realized by increasing the flow rate of air over the sample or by operating at reduced pressure. The high microwave drying rates were attributed to the inverted temperature gradient which resulted in internal heating and boiling and this in turn promoted movement of the water, both as liquid and vapour, to the surface.

Jan 1, 2005

By S. Wood

"Plastic Filled Valley (PFV) wire rope represents a significant development over the design of conventional wire rope. A sealing thermoplastic is impregnated under controlled conditions of temperature and pressure into a conventional lubricated wire rope to produce a lattice of plastic which surrounds and separates the strands from each other and from the core. Metal-to-metal contact is thereby alleviated and the lubricant is sealed in. The wear resistance, rope breaking load, fatigue resistance and crushing resistance are all increased. The result is a rope which offers exceptional service life.Laboratory tests carried out in Canada and at the University of Stuttgart, in West Germany, confirm the increase in fatigue life. The field trials conducted so far have indicated that the results obtained in the laboratory can be duplicated in the field.IntroductionIn times of double -digit inflation, the consideration given to operating costs throughout industry commands considerable attention. The same can be said of the mining industry. A set of large-diameter wire ropes used on the huge draglines in strip mining can cost in excess of $100,000. Because a machine may use three sets of rope s each year, it is clear that the costs of wire rope can contribute a considerable percentage to any operating budget. As wire rope is a product which is used extensively throughout the mining industry, it would appear timely to turn our attention to any ""Method of Extending Wire Rope Service Life"" in order that wire rope life can be optimized and wire rope costs can be minimized."

Jan 1, 1982

By Jean-François Dorion

In an underground mine rock reinforcement elements and surface support units are often exposed to conditions that make them susceptible to corrosion. These unfavourable conditions include high relative humidity, the presence of dust and various other particles in the atmosphere, splashing of water and gases from blasting and diesel equipment. The corrosion of support systems is often associated with a loss in capacity that can be a major safety and economic concern in underground mines. A support system is composed of several components such as bolts, mesh, plate, retaining nut, cable ties. Every individual component can deteriorate due to atmospheric or aqueous corrosion and consequently can damage the integrity of the support system. This paper reports the results of a 5-yr study on the loss in capacity of individual support and reinforcement components at selected underground hard rock mines. As part of this investigation corrosion coupons were installed at selected locations at participating mines. A number of these coupons were recovered at regular time intervals and analysed for any signs of corrosion and subsequently tested to quantify any loss in capacity. The testing of the corrosion coupons was complemented by similar tests on recovered mesh and friction bolt specimens from the site. The collected data have provided useful insights on the factors that contribute to the corrosion of support systems. This knowledge can aid in the selection of appropriate support strategies and a reliable assessment of the predicted useful life of a support system and the need for rehabilitation.

Jun 1, 2012

By M. Pelser, H. Gous, J. H. W. M. Brits, K. Voogt

The effect of impurities; iron and selenium, on current efficiency and deposit quality in copper electrowinning was investigated using an at-line cell at the Rustenburg Base Metals Refiners’ Copper Tankhouse. The tankhouse is a direct leach, starter sheet electrowinning operation with a unique electrolyte composition. The effect of iron on the current efficiency in the at-line cell was found to be less severe than reported in literature. However, the distinction between the chemical impact of iron on current efficiency and the physical impact of iron on a starter sheet operation needs to be realised. The effect of selenium on current efficiency and deposit quality is also reported. INTRODUCTION Anglo American Platinum’s Rustenburg Base Metals Refiners’ (RBMR) Copper Tankhouse serves a unique function in the refinery flowsheet in that its primary functions are the removal of copper and production of acid for the leach circuit. This function needs to be performed to specification in order to keep the leach circuit operating optimally. Current efficiency is seen as an indicator of tankhouse performance and efficient energy use. The tankhouse plates starter sheets onto titanium blanks which, after stripping and preparation, return into the production cells for further plating. Approximately 78% of tankhouses surveyed (Robinson et al., 2013) use permanent cathode technology whereas older, smaller operations still use starter sheet technology. Drawbacks of the starter sheet technology are that the starters are thin and bend easily leading to increased shorts, they need to be removed after two days of plating to be manually straightened and are then returned to the cells. In addition, the electrolyte levels in the cells need to be adjusted during the plating cycle to improve loop adhesion to the cathode and reduce loop corrosion. The starter sheet technology is therefore very labour intensive and the final quality of the product is dependent on the quality of the starter sheets produced. In comparison, permanent cathode or direct plating technology lends itself to automation, allows for higher current densities and better cathode quality due to more robust geometric stability in the cell. The present barrier to implementation of permanent cathode plating at the RBMR Copper Tankhouse is the capital cost required to convert the tankhouse, i.e. blanks and stripping machine. At present, alternatives to titanium blanks, such as LDX 2101, are being investigated for the unique electrolyte composition of this tankhouse.

Jan 1, 2019

By H. Miki, S. Wheatley

The addition of precipitated silica greatly enhances chalcopyrite leaching in the presence of sodium chloride at moderate temperatures (65-90°C) in acid media with ferric ions as the oxidant. The beneficial effect increases with the increase in chloride concentration and temperature. The addition of sodium silicate and silica sand has no significant influence. The analysis of solubility data in acid/salt solutions indicates that the solubility of silica as Si(OH)4 as the dissolved species is controlled by the activity of water, as expected from the hydration theory. Kinetic analysis shows the trends that copper dissolution from chalcopyrite in the presence of precipitated silica with sodium chloride follows a shrinking sphere model indicating a chemically controlled surface reaction. The effect of temperature on copper dissolution in the presence of both precipitated silica and sodium chloride was also larger compared to the results in sodium chloride alone. The SEM analysis shows that chloride and silica facilitates the precipitation of sulfur on the surface of the silica particles rather than the chalcopyrite particles which avoids the blockage of the mineral surface and thus improves the leaching kinetics.

Jan 1, 2014

By C. Rodgers, E. (Ted) Warren

"LocationThe Key Lake operation of Cameco Corporation is located at latitude 57°N in northern Saskatchewan, within the southem boundary of the Athabasca formation. The nearest city is LaRonge, located 240 km to the south. Access to the mine is by all-weather road and by private airstrip.Description of OperationThe mill was designed to produce twelve million pounds of uranium oxide (U3O8) a year from a feed grade of 2.4% U3O8. Current production is fourteen million pounds from 2.0% feed.Following grinding, the uranium is leached using sulphuric acid and oxygen in autoclaves. An eight thickener counter current decantation (CCD) circuit is used to separate the uranium-bearing solution from the solid waste residue. The uranium in solution is further purified in a solvent extraction circuit. The purified uranium is then precipitated using ammonia, calcined at 840°C, and packaged in drums for shipping to refineries. There is a crystallization circuit to recover excess ammonium sulphate produced in the process, and a waste treatment circuit.HistoryUranerz Exploration and Mining discovered the Gaertner and Deilmann orebodies in 1975 and 1976, respectively. Between 1975 and 1977, Uranerz conducted laboratory studies and delineated a process for the Key Lake ore known as the ""Bonn process."" In 1977, Sherritt Gordon Mines Ltd. was retained to conduct further studies in cooperation with U ranerz. The technical feasibility of the Bonn process was generally confirmed. Howeve1~ alternative processing methods also appeared feasible, and over the period 1978-1979, a detailed research and development program was conducted to finalize the processes to be used and to provide data for design of the plant."

Jan 1, 2000

By E. S. Allen, P. R. Kruesi, J. L. Lake

An electrochemical process is described for converting concentrates of base-metal sulphides to the corresponding pure metals and elemental sulphur. The application of the process to chalcopyrite is discussed. The process is also of potential interest in processing copper-nickel sulphides, and laboratory data concerning this potential are presented. The process creates neither air nor water pollution.

Jan 1, 1973

By E. Goodwin

The mechanics of formation of wear-metal suspensions in lubricants is discussed, along with the relationship of the concentration of the metals and other particles to the wear of lubricated machinery parts. The importance of particle and suspension analysis of used lubricants in a preventative maintenance program is stressed, in particular with regard to mobile equipment in a mining operation.

Jan 1, 1978

By E. Burdukova

Rheological measurements have found a wide array of applications in mineral processing research. Rheological properties of mineral suspensions are highly dependent on the mineral surface properties as described by DLVO theory, and the relationship between these properties and inter-particle interactions is well established. In this paper, rheological properties of mineral suspensions are used to study the differences in behaviour of isotropic talc and anisotropic zirconia minerals as a function of varying properties of the suspension medium, such as pH and polymer dosage, specifically carboxymethyl cellulose (CMC). It was found that the rheological tests when carried out in parallel with electrophoretic or point of zero charge measurements, clearly reveal differences between behaviour of the suspensions of isotropic and anisotropic minerals. These differences are further accentuated with the addition of carboxymethyl cellulose (CMC).

Jan 1, 2006

By J. Lu, D. B. Dreisinger, G. Houlachi

"Zinc metal is primarily produced by electrowinning from sulfate solution. Zinc electrowinning is very sensitive to impurities such as Co and Ni. These impurities have to be removed to produce high-quality zinc and maintain a high zinc current efficiency. Zinc dusts are used to remove these impurities by cementation. However cobalt cementation is extremely slow and it is typically activated by the addition of Cu and Sb. Even with the use of Cu-Sb activation, cobalt is still difficult to remove. The zinc dust used for cobalt cementation is negligible compared to that consumed for hydrogen evolution. In some plants up to 6-7% of electrolytic zinc is used for cementation. This is a great waste of energy. Cu-Sb activation is not well understood. The objective of this study was to further understand the Cu-Sb activation and then find a way to reduce hydrogen evolution and promote cobalt cementation. The investigation reveals how hydrogen evolution (or zinc dissolution) and cobalt cementation and re-dissolution change with temperature, zinc dust dosage, the concentrations of copper and antimony and time. In the Cu-Sb activation, copper is deposited on a zinc particle to produce a porous shell. The zinc particle as an anode dissolves while the shell as a cathode provides a place where cobalt cementation and hydrogen evolution occur and they are catalyzed by antimony. A certain level of antimony (around 0.1 mg/L) is a key to maintain the catalytic effect of the shell. At a higher antimony concentration, cobalt cementation is accelerated slightly while hydrogen evolution is increased greatly. When a zinc particle dissolves to a certain degree, cobalt loses its cathodic protection and starts to re-dissolve. The change in cobalt concentration is determined by the rates of cobalt cementation and re-dissolution. The operation conditions can be optimized to maximize the cobalt removal and minimize the zinc dust dosage.INTRODUCTIONMost of the world’s zinc metal is produced by electrowinning from sulfate media. Many impurities such as iron, copper, cobalt and nickel are co-extracted into solution with zinc. Iron, mercury, indium, lead and tin are removed by co-precipitation as hydroxides. Copper, nickel, cobalt, aluminum, arsenic and germanium are partially co-precipitated with iron while cadmium, magnesium and chloride remain in solution. Cobalt, copper, cadmium, nickel and etc. are subsequently removed by cementation with zinc dust to achieve an acceptable current efficiency and high purity metal product for the economical production of zinc. Zinc provides a strong thermodynamic driving force for the cobalt cementation:"

Jan 1, 2016

By Wm. L. Giachino

"Over the last 10 years, C-1-L has played a significant role in the major advances that have taken place in blasting technology, among them the following: development and introduction of capsensitive slurries; development of bulk slurry systems both for underground and open-pit operations; development of the TOE-DET and ANODET systems of delay blasting;introduction of the NONEL system of initiation;development of the Vertical Crater Retreat (VCR) system of mining.This paper identifies areasin which we foresee further developments in blasting technology over the next 10 years and outlines how and to what extent C-1-L will become involved."

Jan 1, 1980

By S. Kelebek, E. Yalcin

"Diethylenetriamine (DETA) and/or triethylenetetramine (TETA) are reagents that can generally be categorized under ""flotation modifiers"". These polyamines are known to be effective for the deactivation/depression of pyrrhotite that is present in Canadian nickel-copper sulphide ores in large quantities. Recent bench scale testing on some of these complex ores indicated that chalcopyrite flotation can also be adversely affected under certain conditions involving polyamines, which may be taken to be an evidence of their specific affinity towards chalcopyrite. In general, DETA shows no significant depressant action on chalcopyrite while TETA's promotion of hydrophilicity for this mineral has been observed even in the presence of xanthate. This prompted an investigation on thermodynamic equilibria involving these polyamines and copper ions. Results serve a useful purpose to identify conditions for deactivation phenomena. CuDETA2+ and CuTETA2+ chelates as products of sequestration have large predominance areas covering a wide range of redox and pH conditions, where copper xanthate species are not stable, especially in the presence of TETA."

Jan 1, 2009

By Daniel J. Corkery

Mines in Canada and the United States are subject to regulations limiting ammonia, nitrate and nitrite levels in mine effluents released into the environment. The primary source of these nitrogen compounds is typically explosive used in blasting operations, as ammonium nitrate (AN) remains a significant component of most explosives used in the mining industry. The amount of AN entering a local water drainage system is related to site conditions, explosives used, explosive handling and blast efficiency. Mining operators acknowledge AN loss to mine water from blasting operations. However, the mechanisms by which ammonia, nitrite and nitrate are entering the water drainage system, or the relative contribution of specific mechanisms, may not necessarily be assessed or monitored adequately. Characterization of these mechanisms, through systematic investigations, allows a mining operation to focus its efforts on reducing AN loss. This paper outlines a strategy for investigating the mechanisms through which AN enters the mine water drainage system and methods to mitigate this loss. This strategy includes collection and analysis of data to identify and quantify the AN loss mechanisms, design and implementation of tests to mitigate this loss, and assessment of the results. Such investigations are not intended to be a separate one-time project, but part of a long-term process of continual feedback and optimization that is related to the collection and reporting of AN levels for regulatory purposes. The implementation of the strategy must be tailored to each mine?s requirements and existing conditions.

Oct 1, 2010

By I. M. R. Duarte, J. A. Rodrigues-Carvalho, F. R. S. Rosa, A. B. Pinho

"This paper aims to contribute to the knowledge of the mechanical properties of the shales and greywackes which constitute the flysch-type deposits of the Baixo Alentejo Flysch Group, in the south of Portugal. These formations are flysch-type deposits constituted by sequences of usually thick greywacke beds alternating with thin shale beds, which include sometimes intercalations of conglomerate beds. All the sedimentation of these flysch formations was controlled by tectonics. At the same time, should have occurred along with the first Hercynian deformation phase, a low-grade metamorphic event (chlorite zone), that affected these flysch deposits. This study highlights the influence of anisotropy and heterogeneity of these flysch rocks on their physical and mechanical characteristics. The anisotropy verified in some physical properties and on mechanical properties, due to the foliation makes difficult the sample preparation for the laboratory tests. Besides, it induces a scattering of the properties values measured, as for example, the strength and the deformability. The heterogeneity is related to the main features of these geological formations, which are constituted mostly by thinly stratified greywackes and shale beds, which sometimes may affect the results of the laboratory tests making them less representative. The study is made by using both shales and greywackes that constitute these flysch-type deposits in order to evaluate their geotechnical properties, mainly of the shales. Samples of these two rock materials, are tested accordingly a laboratory testing programme, which includes which included mineralogical analysis (X-ray diffraction), physical tests (bulk density, porosity, and void index) and mechanical tests (uniaxial compression, and deformability tests). INTRODUCTIONOne of the factors that most influence the geomechanical behavior of rocks, as well as rock masses is the anisotropy. The word anisotropy comes from two Greek words ""anisos"" (meaning uneven) and ""tropos"" (meaning direction). A body or material is considered to be anisotropic, where the same property has different values depending in which direction it is measured, therefore, an anisotropic material is one whose magnitude of the properties depends on the direction in which these are studied or measured. Otherwise, it is about an isotropic material. However, the fully isotropic materials are quite rare in nature."

Jan 1, 2015

By A. Abadías Llamas, N. Bartie, M. Stelter

Evaluating the economic viability as well as the sustainability of the Circular Economy (CE) system requires a deep understanding of the distribution of all elements, compounds, alloys, materials etc. in flows. In this paper, the circularity of the copper value chain, including primary and secondary processing, is rigorously evaluated. The studied system comprises the metallic copper production from primary sources (from mineral to metal), copper-containing commodity production (copper is mixed with other metals) and copper recycling through secondary smelting to close the loop. This is linked to photovoltaic (PV) panels and battery storage. A simulation model of this system is created using HSC Sim, considering more than 30 elements (and its various compounds), 180 unit operations and 800 flows. From the mass and energy balances obtained through the simulation, an exergy analysis is conducted to evaluate the resource consumption from a second law (entropy) perspective. Additionally, these results are complemented through a Life Cycle Assessment (LCA), the recovery of technology elements and by-products is discussed, while quantifying the losses through the value chain. Through the digitalization of the complete system, a better CAPEX and OPEX understanding of the metal recovery and losses can be obtained, as well as the associated resource consumption and environmental impacts. New flowsheets and technologies can be evaluated. Several scenarios show how the resource consumption and the environmental impacts are affected by the recovery of different materials to produce different products. INTRODUCTION A key challenge of the circular economy (CE) is the linkage and optimization of both resource and energy efficiency of the (renewable) energy infrastructure and the resource cycle depicted by Figure 1 simultaneously. In addition, the CE requires the linkage of all stakeholders as shown by Figure 1. This has been discussed in some detail by Reuter and Bartie (2019) and Reuter et al. (2019). Copper and all its associated technology elements is one of the key enabling metals that is an economical copper colored thread through CE society (Reuter & Kojo, 2014). The Metal Wheel (Figure 2) shows the linkage of and recovery of various elements associated with copper and other carrier metals. This reveals that copper acts as an important carrier metal because of its properties i.e. the wealth of technology elements it carries from geological ores, but also its capacity to act as solvent of valuable elements and thence a key closer of various complexly connected element and material cycles when these technology elements are released during copper refining. The same applies to all other carrier metals of modern CE society as shown for example recently in a lead policy brief (Blanpain, Reuter & Malfliet, 2019).

Jan 1, 2019

By T. Hidayat

The distributions of minor elements between slag/metal and slag/matte in equilibrium with tridymite in the Cu-Fe-O-S-Si-Al-Ca system have been investigated in the range of conditions of interest to the high- temperature copper production, refining, and recycling processes. An improved experimental methodology has been used involving high temperature equilibration in controlled gas atmospheres, rapid quenching, and quantitative microanalysis techniques using Electron Probe X-ray Microanalysis (EPMA) and Laser Ablation Inductively Coupled Plasma Mass Spectrum (LAICPMS). The effect of oxygen partial pressure on the distributions of minor elements between slag/metal and slag/matte has been accurately measured. The effects of slagging components (Al2O3 and CaO) on the distributions of minor elements between slag/metal have also been experimentally determined. The present study is a part of a larger integrated experimental and thermodynamic modelling research program in the systems relevant to high-temperature copper processing. INTRODUCTION In the high temperature processing of copper, minor elements are distributed between different phases, i.e. liquid slag, liquid matte, and liquid metal. From a processing perspective, it is desired to have the valuable minor elements distribute predominantly in the metal and matte phases rather than in the slag phase, and to have the non-valuable minor elements distribute predominantly in the slag phase rather than in the metal and matte phases. Knowledge of the distributions of minor elements between phases in the smelting, converting, and refining processes is required if the distributions of minor elements between phases in these processes are to be optimized.

Jan 1, 2019