Search Documents

By D. Ortiz, J. R. Frias, E. D. Mast, J. J. Fañas

Falconbridge Dominicana (Falcondo) has operated an integrated tpy nickel laterite mine and ferro-nickel processing plant since 1972 in the Dominican Republic. The operation includes mining, a processing plant, an oil refinery, and a power plant. Falcondo has improved process efficiency over the years via modernisation and better understanding of the process. The present business environment of high fuel prices and high nickel prices present a challenge and an opportunity to Falcondo's operation. This paper gives an update of Falcondo's process, improvements in energy consumption, factors affecting energy consumption and how Falcondo is facing up to the current business environment.

Jan 1, 2005

By A. McLean, W. Q. Chen, W. Yan, M. Barati, Y. D. Yang

In order to maximally remove the harmful impurities phosphorus and reduce the loss of valuable elements from Si-based alloy for production of solar-grade silicon, thermodynamic properties of the Si-based alloy were studied. In this work a new model, the Molecular Interaction Volume Model (MIVM) derived from statistical thermodynamics, was successfully used in the Si-based and Si-Fe-based alloy. The calculation started from binary Si-Fe, Si-P and Fe-P systems, then the thermodynamic parameters of ternary systems could be derived based sub-binary systems. Using the activity coefficients of the elements in the Si-based alloys and the saturated vapor pressure of the pure substance of the components, mass fraction of P during vapor-liquid equilibrium can be calculated. The calculated thermodynamic parameters were compared with experimental data available in different publications, and it is found that the thermodynamic parameters calculated using MIVM model are in good agreement with the measured results. The calculated result shows that the mass fraction of phosphorus during vapor-liquid equilibrium of Si-Fe-P melt increases with the increasing phosphorus content and decreasing temperature. This is an important direction for experimental practice in vacuum or low-pressure EML refining of ferrosilicon for potential production of solar-grade silicon without significant vaporization loss of valuable element.

Jan 1, 2015

By Robert B. Parsons

"The Province of Manitoba tabled a Budget on March 11, 1992, which contains some important new initiatives designed to improve the fiscal environment for mining in the province. In addition, the Minister of Energy and Mines has released details of the Mineral Exploration Incentive Program which was originally announced in the 1991 Budget.Introduction""We recognize the important contribution o f mining to the economic activity of our province, including direct and service jobs and export earnings. We are determined to secure its future."" - The Honourable Clayton Manness, Minister of Finance, Province of Manitoba, March 11, 1992.With these words of introduction, Manitoba Finance Minister Clayton Manness announced a number of significant measures aimed at improving the fiscal regime for exploration and mining in Manitoba. At the same time, details of the Manitoba Mineral Exploration Incentive Program (MEIP) were released."

Jan 1, 1992

By G. H. Blackwell, N. I. Norrish

"At most operating mines, geostatistical are reserve estimation methods have been implemented by head office or consulting groups . With recent advances in small computer technology it is now possible for a remotely-located mine department to independently implement a geostatistical package.This paper describes the evolution of geostatistical routines to calculate the mineral inventory for porphyry type copper/ molybdenum or similar are bodies. The problems encountered in down sizing the geostatistical routines to run using limited minesite computing facilities are discussed. The high quality of the results, in spite of some compromises to geostatistical theory, is emphasized.The first stage entailed the development of a mineral inventory based on diamond drill data. The difficulties in fitting variogram models to two metals, copper and molybdenum, and the shortcomings of the mineral inventory due to the mixing of lesser quality exploration data with data from more recent diamond drilling are discussed.To improve the ore reserve estimates for short-term planning, a mineral inventory was produced using both the diamond drill and production blast hole drilling data. This inventory, when compared to actual grades, was found to be quite satisfactory for short-term planning. The inventory also provided a reliable data base for long range pit design and financial planning. By regularly updating the mineral inventory, many of the uncertainties of mining a low-grade orebody were minimizedIntroductionThe comparatively low grades of many Canadian mineral deposit s, the escalation of mine operating costs, and the volatility of metal prices in recent years, has required improvements to both short- and long-term mine planning.One of the prerequisites to improved planning systems is the need for accurate grade prediction. This paper describes the on-site implementation of geostatistical techniques for grade estimation of a porphyry I vein type copper/molybdenum ore body ."

Jan 1, 1987

By P. E. Walker, M. E. Reed, R. C. Sims, B. Snowdon, D. E. Fallas

An advanced Flash Furnace feed system is the key to improving furnace performance. Clyde-WorleyParsons has developed a revolutionary pulseless pneumatic injection feed system technology, capable of delivering a range of benefits to operators of Flash Furnaces. The solution was created by combining the pneumatic conveying and injection knowledge, expertise and technology of Clyde Materials Handling with WorleyParsons' flash furnace process and operating experience. Optimal furnace burner performance requires the feed material to be presented to the burner as a stable, pulseless and accurately controlled flow, distributed evenly around the burner tip circumference. These simple requirements appear obvious, but are extremely difficult to satisfy in industrial environments and are not achieved by conventional feed systems. Our analysis of existing operating furnaces has identified the link between pulses in concentrate feed rate caused by conventional drag chain conveyors and rapid fluctuations measured in the furnace pressure. These fluctuations occur at a timescale close to the reaction shaft residence time and lead to unwanted instability in the primary furnace reaction zone - the flame. Through the use of the solution created by Clyde-WorleyParsons, it is predicted that the much more accurate control of feed rates achieved can lead to substantial improvements in furnace output, increased oxygen efficiency and better control of the composition of furnace liquids, such as matte, blister or slag. All these improvements lead to significant increases in smelter output and efficiency, and deliver high economic value compared to the cost of the feed system. Clyde-WorleyParsons' solutions can be deployed on greenfield sites or retrofitted, and therefore, have the capability to improve feed control at both new and existing smelters. This paper will discuss the field test work undertaken to date, the impact of findings and the ongoing analysis of linkages between instabilities in the various components of conventional feed systems and furnace pressure stability.

Jan 1, 2007

By D. J. MacKinnon

Zinc metal was first produced in India around 1100 A.O. and a zinc industry based on retorting gradually developed in both India and China(1) . The vertical retort method for smelting zinc ores was developed in England in the 1730s; this was followed by the more fuel efficient horizontal retort process developed by the Belgians in the 19th century(2) . The horizontal retort process was the standard method of zinc manufacture until the 1950s when it became obvious that it could not compete with electrolytic zinc technology(2). The present day extractive metallurgy of zinc is dominated by the electrolytic process which now accounts for almost 80% of the world's primary zinc production. In recent years the electrolytic zinc process has seen significant improvements: the fluid-bed roasting of zinc concentrates, improved leaching and residue treatment techniques such as the jarosite and goethite processes, improved solution purification procedures, mechanization of the zinc electrolysis step and of the zinc melting and casting operation. In addition, new leaching processes have been implemented for the treatment of oxidized ores, particularly silicates, and the pressure leaching of zinc sulphide concentrates is now a commercial reality. Although the electrolytic zinc process was first used on a commercial scale in 1916, its history can be traced back to the 1860s. The purpose of the present paper is to outline the early history of the electrolytic zinc process and to trace the significant developments which led to the first successful commercial electrolytic zinc plants.

Jan 1, 1999

By O. Moselhi

The purpose of this research is to evaluate the impact of Building Information Modeling (BIM) on Just-In-Time (JIT) material delivery, with a focus on how the use of BIM can help improve efficient implementation of JIT and reduce the cost of material management. Previous research and a number of case studies have addressed the positive impact of BIM on construction at large but none focused on JIT in construction. This paper presents a methodology for selecting reliable material vendors. It also utilises the integration of BIM and scheduling software to generate quantities of material and its required delivery time to improve the flow process and improve its reliability to minimise related delays and productivity losses arising from idle and non-productive time of equipment and labour on jobsites. 4D visualization is utilized to support coordination and timing of JIT material deliveries in an effort to minimize congestion on job sites. Case studies on JIT material deliveries are presented and the impact of BIM implementation on reducing the cost of material management is evaluated. The joint effect of BIM and JIT on quality control, elimination of waste, reduction of inventory buffers, and on relationships with material vendors are evaluated by analysing and comparing data from case studies. The paper also presents a methodology based on multi-attribute decision criteria for modelling the selection criteria for material vendors. The model can assist in ranking vendors not only based on cost and quality but also on their reliability in delivering material on time.

Aug 1, 2013

By Raymond C. Voige

"The use of current electronic technology in the design of new underground mine communications equipment is providing improved and expanded voice communications which can, in turn, contribute to improved productivity and safety. A review of equipment that is now available or under development Includes the following categories:WIRED SYSTEMSI.Pager phones with selective calling, audible and visual alerting and message indicator.2. Mufti-conversation pager phones that use multiwire cable ormultiplexing techniques.WIRELESS SYSTEMSLow-and medium-frequency inductive systems utilizing ""near"" magnetic fields for both vehicular and personal communications.Wired SystemsCommunication systems in underground mines have evolved slowly in many parts of the world. For many years, magnetotype telephones were the only means of communication from one mine level to another and to the surface. These units were located near the shaft and communications to the working areas were limited."

Jan 1, 1981

By M. Narita, S. Nakayama, M. Fujihara

Hibi Kyodo Smelting Co., Ltd. was founded in 1968 and celebrated its 50th anniversary in 2018. In 1972, we started producing copper cathode with a production capacity of 84 KTPY. Since the company founding, we have undertaken seven expansion projects, and our current copper-cathode production capacity is 290 KTPY. To increase our production efficiency, two tank houses were converted from Conventional process to ISA process in 2006 and 2014. In another investment, we equipped a continuous glue dosing system, which allowed for strict additive-concentration control, yielded quality improvements and reduced the power-consumption rate. Along with an increase in the production of copper cathode, the amount of impurities eluted from the anode increases. To solve this problem, the chelate-resin purification process that was introduced in 1983 was renovated, and impurities could be recovered more efficiently. In this paper, we report various improvements that have been implemented at the refinery since 2000. INTRODUCTION Tamano Smelter and Refinery of Hibi Kyodo Smelting Co., Ltd., founded in 1968, celebrated the 50th anniversary of its founding in 2018. The Tamano Smelter opened its No. 1 tankhouse in 1972, and began operating No. 2 tankhouse in 1984. Thereafter, with continuous production increases and technical improvements, electrolytic copper production was increased from 84 KTPY to 290 KTPY as shown in Figure 1. Table 1 shows the major operating facilities and operation data in 2017.In this paper, details of equipment introduced to continuously dissolve and add glue, various improvements made to the chelate resin process, enhancements made to the crude Ni sulfate process, and another vibrating screen introduced to the copper slime processing flow in accordance with the expansion of copper production capacity since 2000 are reported.

Jan 1, 2019

By Sergio Fuentes

During the past fifteen years, mines utilizing the block caving method have improved performance and systematically reduced total mining costs. This paper describes improvements in mine design, mine planning and mine management, including methods enabling the Chilean and International mining industry to ensure cost savings and productivity growth while using the block caving method. These improvements have encouraged the re-evaluation of underground operations at operating and closed open pits, and challenge surface mining applications as the only low cost mining method. This paper describes a strategy to estimate the optimum open pit to underground transition time during the life of a mine.

May 1, 2003

By Atsuki Sado, Akira Ueno, Kazuaki Takebayashi, Kunio Watanabe

The Saganoseki Refinery of Pan Pacific Copper Co., Ltd., Japan, introduced the ISA 2000® process in 2006 to improve product quality and productivity. After resolving various technical difficulties associated with the process, a current density of 325 A/m2 and electrolytic copper production of 234 000 tons per year were realized in 2018. In recent years, Saganoseki Smelter & Refinery has promoted treatment of recycled materials in addition to copper concentrates. Accordingly, the amount and type of impurities charged to the smelting process have tended to increase. In the electrorefining process, impurities such as nickel and antimony cause anodic passivation and formation of suspended solids, respectively. Although these undesirable phenomena can be avoided by controlling impurity concentrations in the anode and electrolyte to appropriate ranges, this also limits the choice of recycled materials that can be processed by the smelter. To achieve both stable operation of the electrorefining process and flexibility in treatment of recycled materials in the smelting process, Saganoseki Refinery improved the capacity of the impurity recovery processes during 2016 to 2018. This paper describes the expansion of the purification plant to remove and recover nickel and antimony. INTRODUCTION The Saganoseki Refinery of Pan Pacific Copper Co., Ltd., Japan, introduced the ISA 2000® (wax- less permanent cathode method) in 2006 to improve product quality and productivity. Since then, the refinery has gradually increased current density, and has been committed to establishing stable operation and high productivity via various improvements related to the electrolyte filtration and additive management systems. Figure 1 shows the trends of current density and current efficiency at the refinery. Although the current efficiency temporarily dropped when the current density was raised to 322 A/m2, it consistently exceeded 97% thereafter. At present, stable operation at 325 A/m2 has been achieved and continues.

Jan 1, 2019

By Y. Wang

In this paper, the tribological and electrochemical corrosion properties of Al2O3/polymer nanocomposite coatings were studied using a micro-hardness test, a single-pass scratch test, an abrasive-wear test, and finally an electrochemical technique such as potentiodynamic polarization measurement, The coatings containing Al2O3 nanoparticles showed improvement in scratch and abrasive resistance compared with polymer coatings; this improvement is attributed to the dispersion hardening of Al2O3 nanoparticles in polymer coatings, Corrosion test results showed that the embedded Al2O3 nanoparticles in the polymer matrix do not sacrifice the corrosion resistance of the polymer itself.

Jan 1, 2005

By P. Blonde

Recent analysis has suggested that a balanced recovery profile can improve flotation bank performance. Test work was conducted to test the balanced profile concept at the Penhorwood talc mine near Timmins, Ontario, Canada. Plant trials were devised to determine how to control the recovery profile and the resultant impact on grade and recovery in a rougher bank of four cells. Accompanying gas dispersion measurements revealed a maintenance issue with one cell that was corrected. By manipulating air and frother addition it was possible to bring the bank closer to a balanced recovery profile and the down-the-bank grade/recovery improved. Plant production showed an increased talc grade at similar yield with the balanced profile. The results provide justification for a long term plant trial.

Aug 1, 2013

By Y. Kashiwaya, J. Yagi, P. R. Austin

The problems of global environment and resources have become important issues in recent years, and the iron and steelmaking industry is requested to decrease energy consumption and carbon dioxide emission. The improvement of efficiency of ironmaking system is one of the countermeasures for these problems because more than a half of total energy input to the integrated steelwork is input to the ironmaking system. Various approaches to improve the blast furnace process have been made. The authors examined their performances through mathematical simulations of blast furnace operation, and confirmed the improvement of blast furnace efficiency under some operating conditions. The ironmaking system consists of various processes, and the materials and the energy are transported among these processes. Thus it is necessary to evaluate the efficiency of the novel operation of blast furnace based on the ironmaking system. In this study, the balances of material and energy on ironmaking system that consists of blast furnace, coke oven, sintering and hot stove processes were analyzed. The operation status of each process in the system was adjusted according to the results of the operation simulation of the blast furnace under novel operating conditions. The analysis clarified the effect of the blast furnace operation on the energy balance and CO2 emission of the ironmaking system.

Jan 1, 2015

By Edward Martinez

Due to its unique properties, chrysotile asbestos is used in many diversified applications. In recent years, a better understanding of the structure and properties of chrysotile has evolved due to the research efforts of many investigators. A summary of the results of some of these investigations is given. An attempt is made to show the relationships between the properties of chrysotile and its crystal structure. Examples taken from the literature are cited in which methods have been developed for modifying the properties to improve the performance of asbestos in some applications. These include the effect of pH on the positive zeta potential and the addition of sodium silicate to improve filtration characteristics. The dehydroxylation and formation of forsterite when chrysotile is heated are also discussed.

Jan 1, 1966

By C. E. White

The depletion of higher grade mineral reserves will accelerate the trend toward production from progressively larger and lower grade deposits. The discovery of adequate reserves of leaner ores will require the development of improved exploration techniques with a greater depth range. The principal challenges to the Canadian mining industry are to find the mineral resources required to meet fast growing world demand and to develop mining methods and equipment to ensure production costs which will strengthen our position in export markets in the face of in-creasing world competition. The challenges cannot be met without intensive efforts to attract more technical men to the industry and to improve their training.

Jan 1, 1967

By J Petrolito

"To improve the economic and environmental performance of underground mining operations, it is common practice to return the metallurgical waste material underground as backfill. This is called hydraulic backfill and is used to fill the mined-out areas not exposed to further mining. To provide mechanical support for underground mining a cemented backfill is normally used. Since its introduction, cemented backfill has allowed mining companies to increase their ore extraction and improve working and environmental conditions. However, cemented backfill represents up to 50% to 85% of the mine’s operating cost compared with 5% to 10% for hydraulic backfill.These economic pressures have led mining companies to carry out research into the partial or total replacement of cement using a variety of alternative materials. The materials are generally site-specific materials, readily available, and cost-effective relative to cement. Such investigations have led to reduced cost of many backfill mixes while maintaining, and in some cases improving, the physical properties of cemented backfill. However, in most cases, cement still remains an integral part of any binder combination. This can be attributed to the alternative binders investigated being either non-binding materials or capable of generating only low-strength backfills, except when used in conjunction with cement.This paper provides a historical review of backfilling binder materials and their characteristics. In particular, it reviews the many alternative materials that have been proposed to either partially or fully replace Portland cement as the main binder."

Jan 1, 2005

By Timothy D. Dreger

In the spring of 2009, Suncor Energy Inc. technical personnel saw an opportunity to improve planning 0and mining of overburden material in order to address aggressive construction goals and increased mining complexity. By tying together current and historical equipment performance, geological model information, and material observation in the field new operating elevations for the shovels were developed. At the same time, methodology of recording and reporting overburden movement through the Modular Mining DISPATCH system was changed. The result of this first stage of improvements was an increase in construction-grade material available at the face. The personnel involved realized that other opportunities were available to build on the initial successes and establish processes that would stand up to attrition and experience levels. A cross-functional technical team was assembled to identify ways of further improving workflows around overburden mining. Some of the opportunities realized include greater alignment between planning, reporting and operations as well as development of reporting tools that help steward Mine Operations to the plan. All of which have resulted in Suncor meeting or beating its forecast overburden targets. The cross-functional technical team continues to seek out new and better ways of doing business so Suncor can continue to deliver on its commitment of outstanding performance and results.

May 1, 2011

By Dwayne D. Tannant

The Fox Pit at EKATI Diamond Mine reached a depth of approximately 150 m as of September 2005. The pit is designed with 11 m wide benches excavated using a double benching technique leaving 30 m high bench faces. A series of blasting tests were conducted to improve catch bench reliability and increase the percentage of benches that meet an 11 m catch width. The design changes focussed on reducing damage to the bench crest because maintaining the bench crests is the most important factor in achieving good bench reliability. The most significant improvement was obtained by raising the bottoms of the lower trim blastholes by 0.5 m. This change decreases the depth of broken rock below the final bench elevation, and consequently reduces damage to rock that forms the bench crest below. Another improvement was the use of smaller diameter (165 mm vs. 270 mm) blastholes in the A and B rows for the upper trim blast. This change reduces the charge per delay during detonation, reduces the powder factor slightly, and reduces the energy affecting the final pit wall and crest. As mining and the blast testing progressed, the portion of the bench with crest achievements (>11 m) increased from 57% to 75%.

May 1, 2006

Induced microseismicity monitoring is: ?Essential tool in improving the geotechnical understanding about a mine and its inaccessible surrounding rock masses. It helps to determine: -Event timing, location, and magnitude - identification of highly stressed areas -Event source mechanism - the physics of fracturing in its seismic source region -Seismic strain-rate distribution in 5D - identification of stress concentration or migration patterns -Geomechanical interpretation - identification of hidden geological structures or weaknesses in the ground -Strategy for mining e.g. by a block caving method - maximization of mine production and to optimize ground support design -Potential of future seismic hazards -Large event re-entry protocol, to improve mine safety ?The norm as part of mine safety maintenance and long-term mine design practices

Aug 1, 2013