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By Arthur Barnes, Mika Muinonen, M. J. Lavigne

"The carbothermic reduction of chromite ore to produce high carbon ferrochromium is among the most energy intensive metal extraction processes performed, due not only to the highly endothermic nature of the reduction reactions but also the very high operating temperatures required for the smelting operation to separate the chrome-containing alloy from the discard slag.KWG Resources and XPS have collaborated over the last 3 years in developing a patented (Winter) processing alternative to the traditional smelting operation in which all processing takes place in the solid state at temperatures many hundreds of degrees lower than those required for liquid processing. Amongst the attractions of the process are much lower capital costs, as well as reduced operating costs, particularly of energy.A techno-economic study on the new process identifies a reduction in overall energy consumption of 70% against conventional processing and approximately 40% lower than the current best practice. By utilising more natural gas than coal based energy sources, the KWG process is able to show an overall 50% reduction in greenhouse gas emissions compared with the most energy efficient current practice. The impact of the new process on future processing is therefore regarded as highly significant, with global energy reductions equivalent to the effect of completely eliminating energy demand from a country the size of Italy.The study concluded that the potential for this process to completely revolutionise the global ferrochrome industry should not be underestimated. Its impact reaches far beyond exploitation of a regional natural resource."

Jan 1, 2015

The concept and practices of co-extraction of coal and methane have emerged in recent years to improve coal mining safety and productivity, utilise methane resources, and reduce fugitive emissions in environments that involve multiple coal seams with low gas permeability. The system of co-extraction integrates two previously separate operations of coal extraction and methane drainage. The coal mining operation reduces the coal seam gas pressure and creates strata fractures that enhance gas migration and capture from mine workings and surrounding coal seams. An effective methane drainage operation produces a consistent and quality clean energy product and, at the same time, reduces the methane concentration in underground workings and the methane content and pressure in the adjacent coal seams. This is a significant benefit in preventing gas explosions and outbursts, and promotes a safer and more productive coal mining environment. In addition, the co-extraction with enhanced utilisation of coal mine methane directly leads to a reduction in greenhouse gas emissions. Presented in this paper are key results and outcomes of a major Asia Pacific Partnership project carried out from 2008?2012 by the Commonwealth Scientific and Industrial Research Organisation in collaboration with Huainan Mining Industry (Group) Co. Ltd., to develop and demonstrate advanced technologies at Pansan mine, Huainan, that promote the concept and practices of co-extraction of coal and methane. A comprehensive approach was adopted to assess fundamental strata and coal seam methane conditions during mining, and optimise mining sequences and coal mine methane capture systems. The project has not only demonstrated a practical approach and procedures of advanced co-extraction of coal and methane systems but also delivered significant benefits and outcomes in improved mining safety and efficiency, increased methane capture and utilisation, and reduced fugitive methane emissions at the Pansan mine. The total mine gas drained increased from 25.36 Mm3 in 2007 to 47.0 Mm3 in 2011, and the mine gas utilisation increased from 4.94 Mm3 in 2007 to 21.15 Mm3 in 2011. The improved methane capture resulted in reduced coal and gas outburst risks and methane concentration levels at the mine workings, provided a safe working environment for coal production, boosted the mining efficiency, and eliminated methane related incidents over the last few years at Pansan mine.

Aug 1, 2013

By G. Scamans, J. Lazaro-Nebreda, Z. Fan, J. B. Patel

"Melt quality is crucial for both continuous and shape casting of light alloys and in order to improve it, removal of excessive inclusions, accumulated impurities and unwanted gases becomes necessary. To address this problem, a new multi-purpose high shear liquid metal treatment technology, based on intensive melt shearing by a rotor/stator unit, has been developed. The device ensures achieving uniform temperature and chemical composition and an efficient dispersion of gas and solid phases in the melt with minimal disturbance of melt surface, and can be used, among other things, for de-gassing and de-ironing of Al-alloy melts. Efficient degassing is achieved by dispersing each argon bubble into many small ones, which significantly increases the overall surface area of the bubbles and the time they remain in the melt capturing hydrogen before reaching the surface. This allows using much lower inert gas flow and mixing times than conventional rotary degassing. When applied to Al-alloy scrap, with accumulated iron, the high shear melt treatment speeds up the nucleation and growth of primary Fe-rich intermetallic particles, allowing a faster removal rate. Therefore it reduces processing times, increasing recycling productivity, and facilitates full metal circulation of secondary Al-alloys.INTRODUCTION Aluminium and magnesium alloys are widely considered in various industrial sectors for the purpose of weight saving (Polmear, 1995). In particular, they are used in the automotive sector, where components are mostly manufactured by high pressure die casting (HPDC) because of its simplicity and relatively low cost, but efficiency and mechanical properties are quite low compared with other processes. To date, the main focus to overcome this problem has been for improving the HPDC machinery (Dahle, 2001) but little attention has been paid to the opportunities of controlling the nature and quality of the molten metal supplied to the die. In this way, liquid metal treatment, which involves a variety of physical and/or chemical processing methods to improve melt quality prior casting, is crucial for both continuous and shape casting products."

Jan 1, 2018

By J. B. Mawdsley

A LITILE north of the geographic centre of the Province of Saskatchewan, 150 miles north of the city of Prince Albert, is a narrow green-stone and sedimentary belt of pronounced structural characteristics. This belt, generally known as the Sulphide Lake belt, is about two and a half miles wide. During the past three years prospecting has uncovered numerous gold-bearing showings occurring chiefly along the centre of the belt for a distance of at least nine miles. The number of these showings, the nature of some of them, and their relationship to strong structural features, make it altogether likely that intensive work will eventually locate ore-bodies that will be of economic importance. The discovery of gold in the fall of 1938 on the south shore of Mackay lake, about five miles northwest of the Sulphide Lake gold-bearing belt, indicates that there are neighbouring zones of interest. This paper, an attempt to outline the present status of the interesting mineralized belt, is based largely on the information gained on a five-day tour of this district, made in August, 1939, on behalf of the Department of Natural Resources of the Province of Saskatchewan. The Sulphide Lake belt is named after a small lake centrally located in it. This lake and others are just north and within short portage distances of some of the long bays along the north shore of Lac La-Ronge, an irregular, island-studded lake, about twenty miles in diameter, in relatively rocky Precambrian country, just north of the Palaeozoic contact. The fur-trading post and settlement of Lac La-Ronge is on the west shore of this lake and a road, now under construction, will shortly link this community with the city of Prince Albert. In the past, the most direct route was an indifferent canoe route, in part following Montreal lake and river; more recently, the aeroplane has made this section easily accessible.

Jan 1, 1940

By Hugh S. Spence

This paper deals with an occurrence of radium ore near Wilberforce, Haliburton county, Ontario, upon which development work has recently been undertaken and which seems more likely to prove of commercial grade than any other deposit' of radioactive minerals hitherto found in Canada. This occurrence is sometimes called the Richardson property, after Mr. W. M. Richardson, the discoverer, and will be so referred to in the present paper. Occurrences of radioactive minerals are not uncommon in eastern Canada, and a number are recorded in the literature. The earliest of such references is probably that in Geology of Canada, 1863, where is mentioned an occurrence of uraninite at Mamainse, on the east shore of lake Superior. The mineral was first described by J. L. Leconte, in 1847, under the name of coracite, and was said to occur in a two-inch vein at the contact of trap and syenite. Search for this locality in recent years has proved unsuccessful. Obalski, in 1894, mentions (1) the occurrence of uraninite at a mica mine near Murray Bay, Que. In 1903, Obalski records (2) tests made on this uraninite by Rutherford and the Curies and the determination in it of the then newly-discovered element radium. In 1901, he mentions (3) the occurrence of uraninite at the Villeneuve mica mine, on the Lievre river, and of samarskite at the Maisonneuve mica mine, in Berthier county.

Jan 1, 1930

By J. S. Brock

Magnetic, electromagnetic and gravimetric surveys have played an important role in the mineral exploration leading to the discovery of three major massive sulphide deposits in the Anvil-Vangorda area of the Yukon Territory. During 1964 and 1965 a saturation prospecting program, relying heavily on the integrated use of airborne and ground geophysical survey techniques, led to the discovery of the Faro deposit, which was subsequently proven to be a 63-millionton lead-zinc orebody. Locating the Faro deposit, the largest found to date in this overburden-covered region, involved an exploration sequence requiring the selection of a favourable geologic environment, aeromagnetic and electromagnetic surveys, property acquisition of anomalous areas and detailed ground geophysical surveys, followed by rotary drill testing, detailed gravimetric surveys and diamond core drilling.

Jan 1, 1973

By Brad Wells, Wayne Bull, Wayne Dickinson

"Antiscalants were evaluated for control of calcium carbonate (CaCO3) in gold processing applications. Under severely supersaturated conditions, 100 percent inhibition was achieved with 30 ppm antiscalant. Laboratory and field testing established that an antiscalant could both inhibit scale buildup and remove an estimated 0.5 kg/m2 per annum of pre-existing scale. A program was developed to control CaCO3 at a gold mill experiencing severe scale buildup. Annual accumulation of as much as 3 cm of scale in process piping was reduced to unmeasureable levels when 10 ppm antiscalant was applied. No scale-related upsets in mill operation occurred during a five-month trial period.INTRODUCTION Inorganic mineral scale is a crystalline deposit that forms when dissolved mineral constituents exceed the solubility of the respective mineral phase. Formation of mineral scale adversely affects a wide range of industries and is of particular interest in mining and metals processing. Scale affects numerous stages of metal extraction processes. Restricted flow in piping, nozzles, valves, screens, pumps and other components used to transport mineral slurries, metal concentrates, and tailings as well as scale in millwater and thickener overflow circuits are primary concerns (Alfano & Boffardi, 1994). Heap leaching, comminuation, flotation, vat leaching, carbon adsorption, and heat exchangers as well as oxidation steps used in processing sulfidic ores are among key unit operations that may be adversely affected (Simmons & Gathje, 2003). Antiscalant chemicals are designed to prevent formation and growth of mineral scales such as CaCO3. These chemicals, which include two primary classes – phosphonates and anionic carboxylate polymers and copolymers - are added to the gold processing stream at low parts-per-million (ppm) concentrations to interfere with nucleation and growth of scale forming crystals and to disperse fine particulate material. Application points may be located throughout the gold extraction process. Evaluation of the performance of antiscalants plays a critical role in determining the best product for a specific application. Performance evaluations include laboratory testing, pilot scale studies, in-plant trials, and ongoing performance monitoring during mill operation."

Jan 1, 2014

By P. Mageau-Béland, È. -M. Proulx, M. -C. Patoine

Over the past six decades, Hatch has helped several industrial processing facilities in debottlenecking their operations, allowing them to produce more with the same equipment, to reduce and even eliminate expenditure investments, or to increase the return value of their expansion projects. These successes result from the application of a proven analysis approach that can be applied to any industrial facility. A five-stage methodology is discussed and demonstrated with a specific example of a nickel concentrator optimization study. The first stage is an observation stage which allows to meet key actors at the plant, develop mutual understanding of problems, understand operating philosophy, and efficiently collect large amounts of operating and maintenance data. Following is a data compilation stage during which data is analyzed over a representative time period to identify parameters that significantly affect the production, to evaluate data reliability and to define the focus of the upcoming analysis. Quantitative metrics are defined using statistical tools such as pivot tables, histograms, percentiles and MDR (Maximum demonstrated production rate during 3 to 7 consecutive days). Then, the production bottlenecks are identified by a thorough analysis of the facility’s control philosophy, process throughput, equipment capacity, availability, downtime causes, and interaction between components of each circuit. Understanding the maintenance practices and frequency of planned shutdown is also critical to this analysis. Opportunities for improvement are identified in collaboration with the operation, maintenance and engineering teams, ranked as a function of their impact on the bottlenecks and prioritized. The final and most critical stage involves engagement with the plant stakeholders, namely the operators and the maintenance staff members, to present the results of the analysis and obtain their participation in the implementation of the solutions. The benefits of the case study translated into: 10% production capacity gain, improved maintenance planning and avoidance of several million dollars of investment.

Jan 1, 2016

By H. D. B. Wilson, W C. Brisbin

The Thompson-Moak Lake nickel belt lies along the root of a Precambrian mountain range of the island-arc or alpine type. This range coin-. cides with the boundary between the Superior and Churchill blocks of the Canadian Precambrian shield. The nickeliferous peridotites and nickel ores occur along a negative gravity strip, which also coincides with strong thrust faulting and the axis of greatest deformation of the mountain range. Similar structures and highly nickeliferous peridotites occur in present-day island arcs. Much of the belt is covered by Paleozoic rocks, but a length of 270 miles may be explored by present-day methods. Nickel deposits have been located along 60 miles of the belt. The length of the favorable structure and the size of the known deposits suggest that this will be one of the world's major nickel regions. The regional gravity anomalies, which consist of a branching negative strip bordered by two positive strips, are best explained by major warps of a crust consisting of a granitic and basaltic layer. The ore deposit

Jan 1, 1961

By Robert E. McIvor

"The design/optimization of the pump and cyclones to maximize grinding circuit efficiency first requires a concise understanding of, and clearly defined specifications for, desired grinding circuit performance. Subsequently, the pump and cyclone performances that provide the desired grinding circuit performance can be defined. Once the performance requirements of each process unit are determined, selection of physical equipment parameters that will deliver those performances can be carried out.The Functional Performance Equation shows that there are two distinct efficiencies in closed circuit ball milling. One of these, “Circuit Classification System Efficiency” (CSE), is the fraction of “coarse” material inside the ball mill upon which grinding energy is deliberately expended, versus the remaining fraction of “fines” or finished size material inside the mill, upon which grinding energy is wasted (on over-grinding). The role of the pump and cyclones is to maximize CSE, which is the desired grinding circuit performance. The obtainable target CSE for any given circuit can be estimated, for example, by referring to a plant data base of CSE’s. Design/optimization guidelines then allow us to specify the pump and cyclone performances that will achieve the target CSE.This paper outlines the step-by-step, systematic method of pump and cyclone selection which maximizes CSE. Numerous examples of its successful application are provided.THE FUNCTIONAL PERFORMANCE EQUATIONObservation of the feed and product size distributions going into and discharging from the mill in grinding circuits with low versus high circulating load ratios initially led to the definition of “Circuit Classification System Efficiency” (or CSE, McIvor, 1988a), and subsequently the discovery of the Functional Performance Equation (McIvor, 1988b; McIvor et al, 1992). The CSE is the fraction or percentage of “coarse” (usually in reference to the plus P80) size material inside the mill, versus “fines” or product size material finer than the circuit P80. It can be readily calculated by taking the average of the percentage of said coarse material in the mill feed and mill discharge streams. As this also represents the percentage of the mill energy expended on targeted, coarse size material, it is directly proportional to overall grinding circuit efficiency and production rate. This is all clearly expressed in the Functional Performance Equation for ball milling circuits, for which the derivation has often been presented (e.g. McIvor, 2006)."

Jan 1, 2011

By P. C. Benedict

Introduction and Summary The Northern Empire mine is a mile east of Beardmore, and 100 miles northeast of Port Arthur, district of Thunder Bay, Ontario. Production started in March, 1934, and terminated in September, 1941. During this period, the mill treated 425,866 tons of ore, from which 153,103 ounces of gold were recovered. The lowest level from which ore was mined was the 1900, but considerable drifting was performed on the 2075 level and 800 feet on the 2415, the deepest level. The following description of the geology of the mine is recorded by the senior author but is based on the observations and complementary mapping of both authors. The vein strikes about N.72°E. and has an average dip of 80°S. (Figure 1). In stoped sections, the quartz averaged about two feet wide. On the 1725 level it was drifted on continuously for more than 7,000 feet, but in the mine as a whole practically no commercial ore was found beyond points 1,400 feet west and 1,800 feet east of the shaft. Conspicuous wall-rock alteration extended throughout this section but not much beyond its limits. There was some splitting of the vein and widening of the alteration halo on the lower levels. The average general colour of the quartz changes with depth. It may be generalized, from top to bottom, as light grey to dark grey to brownish. The brownish quartz first appeared near the bottom of the ore.

Jan 1, 1947

By H. Wotruba, L. von Ketelhodt, M. Kowalcyk, C. Kleine, M. Robben

Sensor-based sorting is a financially and technically viable technique that is operating with little or no water and relatively little power consumption. Sensor-based sorting has already proven its operational stability at two gold applications in South Africa. Sensor-based sorting cannot only turn waste dumps and diluted mining blocks into reserves. The implementation can also cause a decrease in specific operating costs of mill and mine when for example replacing selective mining by bulk mining methods with subsequent sorting. Successful installations, operational experience, test work data and flow sheet integration from mine-to-mill underline the impact and potential that sensor-based sorting can have on the gold mining and processing industry.

Jan 1, 2011

By M. E. Grimes

"The future of the uranium industry in Canada during the next twenty years will be very dependent on political and social issues on a world scale. Technology, as such, will tend to be of lesser importance. Nonetheless, some technical changes can be anticipated.This paper deals with milling of uranium ore, leaving further processing and nuclear power production to specialists in these fields. An attempt has been made to look at uranium production technology in Canada in relation to that in other countries, and to draw interference regarding future changes that seem probable in the Canadian context. In particular, recent advances in mill equipment are considered.The chemistry of uranium and its relatively low concentration in most ores has been responsible for a completely hydrometallurgical approach to mill processing, and this should continue. In spite of little commercial success to date, pre-concentration of lower grade ores will be researched further in order that these ores can compete with higher grade deposits in Canada.The discovery of the relatively high-grade ores of the Athabasksa region will undoubtedly influence choice of mill processes and equipment. The potential effect on innovations is discussed"

Jan 1, 1986

As land resources decrease, commodity prices increase, and technology evolves, deep sea mining is becoming a viable alternative to meet the increasing demand for minerals. Successful deep sea mining operations are built on sound identification of the resource, proper selection of equipment, a thoughtful production plan, and good project management. These four key activities can be further optimized by analyzing how the spatial variability and uncertainty of the ore body properties impact the final mining operation. To address this problem, IHC Merwede is in the process of developing a risk quantification framework in the context of deep sea mining, which makes use of state of the art geostatistical simulation methods and transfer functions to quantify geological uncertainty and translate it into decision or project risk. The paper introduces the Local Average Subdivision method (LAS) for generating simulated models of the deposit and presents a new extension to incorporate point measurements of geotechnical or ore grade properties. Due to its computational efficiency, the presented method is suitable for simulating largely extended sea floor deposits. The second part of the paper illustrates, through example case studies, the significant benefits of a risk based approach which translates geological uncertainty into financial or operational performance indicators. In particular, the focus is on assessing financial project risk and on the design optimization of the deep sea excavation equipment by analyzing cutting forces, specific energies, and power requirements.

Aug 1, 2013

By F. R. Archibald

Introduction It is the purpose of this paper to review the subject of roasting as preparation of refractory gold ores and concentrates for cyanidation, with particular reference to operations at the mill of Beattie Gold Mines (Que.), Ltd., Duparquet, Quebec. Two earlier papers relating to the Beattie roasting operations are cited as background to the ? present discussion, and more general reference is made to other publications relating? to geology and metallurgy at Beattie. The Beattie roasting plant was built in 1937 as an addition to the existing flotation and cyanidation plant to permit complete processing of the ore at the mine property. Previously, the flotation concentrate had been cyanided, yielding 70 per cent of the gold values, followed by re-flotation of a concentrate from the cyanide residue. This re-floated residue was shipped to a smelter for recovery of gold values unavailable from direct cyanidation. The roasting plant itself is of interest through application in its design of multiple-hearth roasters and a Cottrell plant for separate recovery of dust and arsenic. In the laboratory and plant studies that accompanied development of the plant into a dependable and efficient working unit have been found principles and ideas applicable to other roasting 'problems. Before enlarging on these aspects relating particularly to the Beattie problems and plant, brief consideration is given to roasting in general.

Jan 1, 1949

By K. J. Palmer, D. A. Silva

"Evaluating resources and reserves requires the reliable modelling of geological domains and their grades. “Multiple point statistics” simulation is a relatively new geostatistical method to generate complex, high-resolution geological models by extracting high-order spatial relations from training images. A method based on combining multiple training images is developed to obtain the correct amount of large-scale continuity and short-scale variability. A calibration process matches the geological spatial variability between the final realizations and the drillhole dataset. A case study with data from the Red Dog mine, Alaska, United States, shows an appropriate reproduction of short-scale variability along boundaries between geological units.RÉSUMÉ L’évaluation des ressources et des réserves exige une modélisation fiable des domaines géologiques et de leur teneur. La simulation par « statistique multipoint » est une méthode géostatistique relativement nouvelle pour générer des modèles géologiques complexes à haute résolution par l’extraction de relations spatiales d’ordre supérieur à partir d’images d’entraînement. Une méthode basée sur la combinaison de multiples images d’entraînement est développée afin d’obtenir la bonne quantité de continuité à grande échelle et de variabilité à petite échelle. Un processus d’étalonnage fait correspondre la variabilité géologique spatiale entre les réalisations finales et l’ensemble des données de forage. Une étude de cas avec des données de la mine Red Dog, Alaska, États-Unis, montre une reproduction adéquate de la variabilité à petite échelle le long des limites entre les unités géologiques."

Jan 1, 2015

By John A. Hansuld

Geochemical dispersion of metals under various environmental conditions is discussed within the frame-work of Eh (oxidation potential) and pH (acidity). In general, two aspects are considered -(1) the oxidation of certain primary sulphides in the outcrop or sub-outcrop environment, and (2) the movement of metals in different dispersion media. Practical applications of each are illustrated by means of exploration case histories representing environmental conditions in the Canadian Shield, the southwestern United States and the Caribbean.

Jan 1, 1966

By J. B. Mawdsley

Introduction The writer was instructed to visit the Chibougamau region during the field season of 1927 and report on the mineral discoveries that had been made there since 1911. lt was deemed advisable to obtain detailed information regarding the rocks underlying the area in the vicinity of these recent discoveries. Accordingly an area 60 square miles in extent was mapped. The outcrops were studied along the water courses and along bush traverses spaced at half-mile intervals between these water courses. The completion of the rest of the summer's programme allowed only three weeks for this work. lt is from this small, mapped area, and this necessarily cursory survey, that the material for this paper was obtained. Location And Means Of Access The name Chibougamau district is applied loosely to an ill-defined area of about 1,000 square miles lying mostly north and west of Chibougamau lake in the Province of Quebec. The lake is approximately half way between lake St. John and James bay. It lies 150 miles north of the Canadian National railway and 40 miles south of Mistassini?lake.

Jan 1, 1928

"9.1. IntroductionThe application of the electron microprobe for in-situ analysis of platinum-group minerals (PGM), first reported by Borovskii et at. (1959) and Genkin (1959), has resulted in a large and growing number of analyses of unidentified PGM. Figure 9.1 charts the increase in the number of reported unnamed PGM from 3 in 1959 to a total of 140 by 1979. All these minerals, with the exception of UN1968-5 and UN1976-1, were analyzed with the electron microprobe.There has been no recognised or consistent manner for reporting these unidentified PGM. The term ""unnamed"" has been used for PGM that are considered to be new species without a name as well as for PGM which have not been exhaustively compared to named and unnamed PGM in order to determine whether they are unique. Many of the so-called unnamed PGM are only unnamed because of poor microprobe analyses or because larger than usual elemental substitutions (e.g. Bi for As) made it difficult to calculate the true stoichiometry. Some of these unnamed minerals have been unnecessarily reported with non-stoichiometric formulae, as discussed by Cabri (1980). Better analytical data should reduce the number of such proposals.Another unfortunate practice, possibly used to by-pass the scrutiny of the Commission for New Minerals and Mineral Names, I.M.A., is to report a ""new"" mineral by referring to it by a name made up of its constituent elements. This has been deplored on a number of occasions (cf. discussion in Fleischer et at., 1976, p. 179), but some journals continue to publish such material. The Commission on New Minerals and Mineral Names has not recognised such ""names"" and these PGM are therefore included in this chapter with other unnamed minerals.A further example of inconsistency in reporting unnamed minerals is the report of a specific ideal stoichiometry with no further details (not even an analysis!); sometimes with a note that this will be reported in greater detail in due course. I have also been guilty of similar optimistic statements and, unfortunately, it is not always possible to follow through. Some authors give data on unnamed minerals in such a discrete manner that their reports are sometimes missed in literature searches."

Jan 1, 1979

By E. Wraith, W. W. Culver, B. Wesstrom, P. J. Mackey

Electrodeposited copper of the 1860s was of unprecedented purity, although the profound significance of this achievement was not fully realised until the dawn of the electrical age a decade or so later. By the 1870s there were three somewhat large (4 to 4.5 tonnes Cu/day) electrolytic copper refineries in Germany based on J. B. Elkington’s process, first patented in the United Kingdom in 1865. More such refineries were planned throughout Europe. At the same time, copper output in the U.S.A. was starting to expand and with the spread of European electrolytic copper refining technology across the Atlantic, the door opened to major increases in North American output. The technology was first taken up in 1879 by James Douglas at the Chemical Copper Company in Phoenixville, Pennsylvania, where he was Superintendent. Douglas was assisted in this pioneering work by Edward Weston. The copper refinery at the Chemical Copper Company was small, not unlike the first plants in Europe. The present authors contend that the electrolytic copper refinery at the Chemical Copper should be regarded as the first copper refinery in the United States. The Balbach Copper Refinery in New Jersey, which commenced operations in 1883 with an initial production of about 2 tonnes Cu/day, has been erroneously considered as the “first commercial refinery”; it rightly belongs in second place. The early developments at these plants are discussed in this paper. INTRODUCTION In the mid-1800s, the main uses for copper were as sheathing on the wooden sailing ships of the day to protect from marine growth, boiler components in locomotives and steam engines, along with some construction uses. Copper ores were generally smelted, and further fire-refined for market. The recovery of gold and silver, if present in payable amounts, was a slow and relatively expensive step. This situation regarding copper would change by the 1870s with advances in the generation and use of electricity. The introduction of the dynamo led to major developments in electrorefining. First demonstrated in principle by Faraday in 1831 (Faraday, 1832), the dynamo was subsequently adapted and further developed by J.S. Woolrich for electro-metallurgical applications in 1842 (Woolrich, 1842; Napier, 1845). It provided a new source of power with the unprecedented potential to significantly change the scale of metal production by electrometallurgy. Interestingly enough, copper would be needed for the electrical age just beginning. By 1869, advances in dynamo design offered relatively reliable large machines, which enabled J. B. Elkington in the United Kingdom to use the dynamo in the radically new Pembrey copper electrorefinery — the first copper electrorefinery in the world (Wraith, 2013). Initial production at Pembrey was small — in the range of 1 to 2 tonnes/day — while gold and silver were recovered more readily by the treatment of the slimes than with methods used hitherto.

Jan 1, 2019