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In order to maintain a production rate of 6,000 tonnes per day from underground at the Williams Operating Corporation, two independent mining areas were required which created a long narrow sill pillar between them. During initial mining of the sill pillar there were a number of significant ground falls [LeBlanc and Murdoch, 2000] and in March 1999, with no active mining ongoing in the sill pillar area, a rockburst of magnitude 3.0 Nuttli occurred. Extensive ground support was designed and installed to withstand events of similar magnitude [Bawden and Jones, 2002]. A mine wide microseismic system was installed to monitor mine induced seismic behaviour over the entire mine. The area most directly affected by the 1999 rockburst was rehabilitated using a highly ductile support design. Along with microseismic instrumentation, the areas were instrumented using conventional SMART Cables and SMART MPBX?s. Subsequent to this, the area was impacted by a large number of high magnitude seismic events [magnitudes between 1.7 and 3.5 Nuttli]. The ground support performed very well during these events, providing confidence in the mine?s ability to control the ground under severe rockburst conditions. Analyses of microseismic and conventional instrumentation, combined with numerical analyses of sequence alternatives, were used to develop an optimal mining strategy for the sill pillar area. The selected strategy involved utilization of instrumentation data and calibrated model results to analyze yield zones in the sill. The analyzed ?yielded? zones were assessed to be low seismic risk. Initial mining in the sill was then concentrated in these low risk areas, with the objective of further concentrating stress into the remaining seismically active area, in order to induce ultimate failure of the sill. Continuing large magnitude seismicity and resulting damage in the remaining ?high seismic risk? area, led to abandoning a second portion of the footwall access and the strategic decision to extract a stope near the centre of this zone in order to force final failure of the sill pillar. During execution of this plan two large magnitude seismic events occurred resulting in destressing and final failure of the remaining sill pillar. The paper provides a detailed description of this ?strategic mine sequence driven self-destressing process? and the implications to final extraction planning in this area of the mine.

Apr 1, 2005

By Paul Staples, Fred Woodcock, Robert Grant, Mike Cooper

"Noranda's Brunswick Mining Division, near Bathurst, New Brunswick, processes 10,500 TPD of complex Cu-Pb-Zn bearing ore. Brunswick uses conventional rod and ball milling techniques to achieve a flotation feed size of 75% passing 400 mesh. Over a two year period, testwork was performed using a Marcy pilot plant ball mill to assess the impact of several key variables on secondary grinding efficiency. Four graded mill charges were used to compare balls and slugs at 25 and 29 mm sizes. Data was evaluated by determining grinding rates using a commercially available steady state simulator. Results were critical in Brunswick's efforts to achieve finer grinds while minimizing cost per tonne.IntroductionBackgroundThe Brunswick orebody is an extremely fined grained volcanogenic massive lead, zinc, copper, silver, iron sulphide body between two metamorphosed sedimentary and felsic volcanic rock units. Pyrite content is about 60% with 20% non-sulphide minerals, mainly silica and chlorite.Size reduction at Brunswick is performed by three separate parallel lines consisting of rod mills, primary and secondary ball mill circuits, all in series. The line 3 grinding circuit is presented in Figure 1."

Jan 1, 1997

By Brian Flintoff

"When I was first asked to prepare this paper and presentation in late June, I thought it might be fun to ""step back and paint the bigger picture."" Having attempted to do this, fun is not the first descriptor that now comes to mind, and speaking dyslexically, I've had 'nuf.'Unlike Nostradamus, or even Orwell, I've discovered that I'm ""clairvoyantly challenged"" and not even the psychic hot-line was of much help, at least with respect to process control! I am somewhat comfortable speculating on evolutionary change, but the radical developments that will arise from revolutionary changes are well beyond my mortal capabilities. Even with evolutionary change, I'm reminded of the lessons of time series analysis which show the prediction error to grow exponentially as the horizon moves into the future. As Macluhan is reported to have said: ""Predicting the future based on the past is a little like driving your car while looking in the rearview mirror!""Having honestly presented my qualifications, allow me to try to look at process control and to offer some conjecture on where we're probably headed. In the end, it is said that: ""The plant of the future will have only two employees, a man and a dog. The dog will be there to keep the man from touching the equipment.1""IntroductionA little less than a decade ago Andy Mular and I co-edited a monograph entitled ""A Practical Guide to Process Control in the Minerals Industry."" The work was commissioned by the senior management of a consortium of Canadian mining companies, since it was widely perceived that control was an area of great economic potential, but one that had not been effectively tapped. The concern was that if the industry could not soon deliver on the ""potential"", the term may well have appeared in the epitaph of what was, to these men, a very attractive investment opportunity. I think it is fair to say that over the past few years process control has clearly established itself as an essential technology in plant operation and optimization. That isn't to say that we get it all-right, all-the-time, but, the circumstances are much different than they were. In the eyes of many, process control has attained the distinction of being considered a mature technology, even though there are still countless avenues for exploration."

Jan 1, 1998

By R. Mohan Srivastava

"The goal of estimation is considered in the light of decision analysis. A simple example reveals the essential elements of decision-making in the face of uncertainty. A second example shows that these elements are also key features of many mining decisions. These two examples cause us to revive an old probabilistic notion that the goal of estimation should be to quantify what is unknown. The conditional probability distribution provides the complete statement of one's uncertainty. Once the conditional probability distribution has been established, one should retain as an estimate the value which minimizes some objective loss function. A third example shows how the ""best"" estimate depends on the chosen loss function. Current practice is almost exclusively based on the least squares method, which assumes a loss function which penalizes underestimation and overestimation equally. This is unfortunate not only because symmetry is an unrealistic assumption but also because mining offers a rare opportunity to state the loss function directly in terms of profitability. Both the theoretical framework and the practical tools exist to allow us to reconsider the conventional notion of the ""best"" estimate. IntroductionThis paper looks at estimation in the mining industry from the point-of-view of decision analysis. Virtually all decisions depend on estimates since few of the important parameters are ever known exactly. In this paper we will be referring mainly to the estimation of ore grades, though the approach discussed here is generally applicable to any decision in which relevant information is uncertain.In the first section we look at a very simple example of decision-making in the face of uncertainty. We will then tum to a mining example and see that the essential features of the simple example still pertain. From these two examples it will be clear that the decision analysis approach rests on two key concepts: the conditional probability distribution and the loss function. A third example demonstrates how different loss functions produce different ""best"" estimates from the same conditional probability distribution. In the final sections we willexamine the current practice of estimation in the mining industry. Though the tools for estimating the conditional probability distribution already exist, a change in the way we think about ""best"" estimates is needed. Very little attention is presently paid to the loss function even though it is readily available in many mining applications."

Jan 1, 1987

By R. Le Houillier, M. Nagamori, A. J. Plumpton

"Asbestos tailings are a typical serpentine, hydrated magnesium silicate, consisting primarily of antigorite and a few per cent of unrecovered fibrous chrysotile. Serpentine has unique thermal properties in that dehydroxylating calcination at 600 to 700°C can yield an amorphous structure in which most of the magnesia is liberated from the original bond with silica and thereby rendered chemically active. The amount of activated magnesia can be quantified by selective leaching with a weak acid such as acetic acid. Many wet processes have been proposed to extract magnesium values from calcined or natural serpentine by means of various acids and their ammonium salts. However, the only commercial utilization of serpentine today is found in dry processes such as the production of fused magnesium phosphate fertilizer .The present paper reviews the physical chemistry of the dehydroxylation of serpentine and also various wet and dry processes in order to provide a general view regarding the chemical transformation of asbestos tailings.IntroductionAsbestos fibers occur as chrysotile, a serpentine polymorph. More than nine tenths of mined asbestos ores consist of massive non-fibrous serpentine, primarily the polymorph antigorite, which is discarded as tailings after fiber extraction. For many decades, Quebec has been a world leader in the production of asbestos fibers. As a result, colossal tonnages of serpentine have accumulated in the Eastern Townships'!'. Serpentine minerals are found in large deposit s throughout the world, and significant research efforts have been made, particularly in Japan and the USSR, mostly in attempts to extract magnesia or silica values therefrom.The chemical composition of serpentine (chrysotile and antigorite) may be ideally expressed as Mg3Si2Os(OH). which corresponds to 43.7% MgO and 43.3% SiO2. Natural serpentines often contain a few per cent of Ni-bearing magnetite and other impurities, and therefore the contents of MgO and Si02are both about 40% or lower.Serpentine (hydrated magnesium silicate) is virtually insoluble in weak acids. However, when dehydroxylated under controlled conditions, ' it decomposes to an amorphous state in which magnesia and silica are isolated and chemically active. The magnesia so activated is readily soluble in weak acids. This unique characteristic of calcined serpentine, first discovered in 1942,, has since attracted the attention of innumerable researchers, whence many processes have been proposed."

Jan 1, 1980

By I. C. L. Webster, G. E. Ray

"The magnetite-rich Heff Cu-Au skarn lies in the Quesnel Terrane of south-central British Columbia, approximately 26 km northeast of Kamloops. The skarn formed close to the northern margin of the Heffley Creek pluton, and is hosted by Carnian (Late Triassic) Nicola Group limestone. The Late Triassic pluton (208.1 ± 6.1 Ma, U-Pb zircon) is a composite body of alkaline affinity that includes dioritic, gabbroic, and magnetite-rich clinopyroxene ± olivine ultramafic phases.The skarn has been discontinuously traced along strike for more than 1 km, and individual skarn layers are up to 40 m thick. The most common non-opaque minerals are garnet, clinopyroxene, and carbonate, with lesser epidote, biotite, amphibole, and chlorite. Apatite locally forms more than 3 vol.% of the rock. Compositionally the garnet is a low Mn grandite averaging Pyr3-Grs41-Adr56 mol.%.Mineralization consists of lenses, up to 10 m thick, containing massive low Ti-V magnetite (avg. 0.03 wt.% TiO2 and 0.01 wt.% V2O3). Magnetite is associated with up to 20 vol.% pyrrhotite, lesser pyrite, and trace chalcopyrite and gold. There is a moderate enrichment in rare earth elements with assays up to 570 ppm La and 490 ppm Ce. The Heffley Creek pluton belongs to a suite of Late Triassic-Early Jurassic alkalic and Fe-rich intrusions that are widely developed throughout the Quesnel Terrane. Some host Cu-Au porphyry mineralization, but less commonly they are associated with magnetite-apatite veins such as at the Glen Iron mine and Magnet occurrence, or with magnetite-rich Cu-Au skarns such as the Heff occurrence.Although abundant low Ti magnetite is present in the Heff skarn, it does not appear to represent iron oxide copper- gold (IOCG) type mineralization. Microprobe analyses completed during this study show that low Ti magnetite is not a unique feature of IOCG deposits, but also characterizes some other types of hydrothermal mineralization. In British Columbia these include some alkalic porphyry-related magnetite-apatite veins in the Quesnel Terrane, as well as the well-known Wrangellia-hosted Fe skarn deposits. Thus, low Ti magnetite appears to be a common signature of many magmatic hydrothermal deposits in contrast to the high Ti primary magnetite found in most igneous rocks."

Jan 1, 2007

By J. M. Houston

"In October 1982, Rio Algom Limited, purchased a tin prospect near East Kemptville, Nova Scotia, from Shell Canada Resources. This purchase led to the development of the first substantial tin mine in North America. This paper deals with the drillingand blasting operations at Rio Algom, in particular the use of emulsion explosives technology.This presentation describes what emulsion explosives and Heavy AN/FO are, and the support system used to deliver these products to the blast site.HistoryThe East Kemptville mine site was discovered by Shell Canada Resources (SCR) in July 1978. SCR started diamond drilling on the tin prospect in March 1979. After 8220 m of BQ drilling, it was estimated a reserve of 56 000 000 tonnes of 0.165% Sn was present.The property, which is located 54 km northeast of Yarmouth, Nova Scotia (Fig. 1), showed, after a feasibility study that, given an ore treatment rate of 9000 tonnes per day, a mine life of 17 years could be expected.GeologyThe tin deposit of the East Kemptville Mine, occurs in granitic rocks at their contact with metasedimentary rocks. The mineralization is in the form of cassiterite with associated sulphides of copper and zinc. The tin occurs in a stockwork of tin bearing Greisen alteration zones.East Kemptville MineThe mine planned an open pit operation with the first five years being mined at a rate of 14 000 tonnes per day, of which 5000 tonnes will be waste and low grade ore. Eventually, the total mining rate will be 21 000 tonnes per day, including 12 000 tonnes of waste and low grade ore. Figure 2 shows the general layout of the mine site.East Kemptville Chooses Emulsion ExplosivesIn December 1984, East Kemptville Mine awarded the Explosives Division of C-I-L Inc. a contract to supply explosives to the borehole. The system chosen gives East Kemptville the on-the-bench choice of regular AN/Fa, or a high density, Heavy AN /Fa product called SuperAN· or a water resistant emulsion explosive called MAGNAFRAC· for holes that cannot be dewatered.Emulsion ExplosivesAn emulsion is an intimate mixture of two liquids that do not dissolve in each other. Emulsions have contributed to our daily lives in such products as insecticides, salad dressings and cosmetics."

Jan 1, 1987

By George J. Cymerman

Since 1978, Syncrude Canada Ltd. has been expanding steadily its oil sand mining and processing capacity while reducing unit energy requirements. At the current rate of ~180 M tonne/year oil sand, the originally adopted Karl Clark?s 80°C version of the Hot Water process would require some 53 PJ (53 x 1015 Joule) heat. If this amount of heat were to be derived from burning natural gas it would cost $369 M/y (at $7/GJ). Fortunately, effective recovery of waste heat from the upgrading operations at the Mildred Lake site obviated the need for water heating with natural gas. The oil sand hydrotransport technology, first utilized commercially in the mid-nineties at Syncrude?s North Mine, reduced slurry temperature from ~80°C to ~50°C, cutting the unit heat requirement from 293 MJ/tonne to 183 MJ/t. However, in the new 100 Mt/year Aurora Mine even a 50°C process temperature would still require 18 PJ of heat energy per year. Only limited quantity of 65°C water could be imported from Mildred Lake site and some waste heat would be available from Gas Turbine Generators. A new, Low Energy Extraction (LEE) process was developed to minimize heat requirements by further reducing process temperatures to 25°C in the slurry pipeline and 35°C in the Primary Separation Vessels (PSV). Unfortunately, when applied to certain ore facies in Aurora, the LEE process yielded disappointing bitumen recoveries, necessitating an increase in slurry temperatures from 25°C to 35°C in the pipeline and from 35°C to 42°C in Primary Separation. In 2004, an Optimized Low Energy process (OLE) was developed and piloted at Syncrude Research using a 2000 kg/hour pilot plant. In the OLE process, most available heat is applied up-front to produce 45°C pipeline slurry at a density of 1.58 kg/l. Once the pipeline conditioning process is completed, the slurry is flooded with cold (10°C) water, resulting in PSV temperature of 34°C. The overall heat and water requirements are the same, or slightly lower, compared to those of the LEE process ? but without the penalty in bitumen recovery. Processing 100 Mt oil sand at 34°C (96 MJ/t), rather than at 50°C (183 MJ/t), will save $61 M/y (@ $7/GJ) and reduce green house gas emissions by ~47 %. The OLE process is currently being implemented at the Syncrude Aurora Mine.

May 1, 2006

By R. M. Graves, C. B. McKenzie, D. Barbour, D. W. Desnoyers

"The prospective Tulks volcanic belt hosts five significant massive sulfide deposits, Tulks Prospect, Tulks East, Jack's Pond, Daniel's Pond and Victoria Mine, as well as numerous showings and indications throughout its 70 km outcrop length. Regionally, the 498 Ma sequence consists dominantly of felsic pyroclastic rocks and flows with interbedded mafic volcanic units and finegrained sediments, commonly graphitic. Contemporaneous granitoid rocks occur in the south half of the belt. Rocks usually display a strong NE-SW, steeply dipping, penetrative foliation and other shear-related high-strain fabrics. Facing directions are normally northwest, although there is local evidence of folding. Sulfide bodies and their alteration systems are deformed and shape-modified in the style of ambient strain.The Tulks, Tulks East and Jack's Pond prospects appear to occupy a similar stratigraphic level, on or near the contact between a thick felsic pile and an overlying broad, conductive package of graphitic sedimentary rocks. All are pyritic deposits with well-developed footwall alteration systems. The Tulks prospect comprises four polymetallic lenses totalling 750 000 t. Three lenses constituting more than 6 000 000 t of sulfide mineralization are indicated at Tulks East but only the 210 000 t ""B"" lens contains significant base metals. Jack's Pond consists of a very extensive, zoned alteration complex in which four lenses of massive to semi-massive pyrite + chalcopyrite are known. The central part of the system, characterized by Mg chlorite and carbonate, is enveloped by pervasive sericitization and capped by intensely silicified and pyritized volcanics. The sulfide lenses are interpreted as part of the footwall zone and are beneath that part of the system most likely to hostpolymetallic massive sulfides.Daniel's Pond differs from the other prospects in such fundamental ways as metal content, associated alteration and structural setting. The deposit comprises strongly tectonized, Ag-rich, Zn-Pb mineralization distinguished by a pronounced Ba-As-Sb signature. Mineralization is confined to a narrow, north-south high-strain zone which separates unstrained mafic volcanic rocks to the east from well-foliated felsic rocks. The deposit lacks an extensive alteration halo and at its north end is associated with a lens of barren, undeformed massive pyrite.The Victoria Mine deposit, the most cupriferous of the five, is related to a moderately dipping structure that separates well-foliated Tulks volcanic rocks from an overlying, less deformed volcanic sedimentary sequence that may be as young as 462 Ma. The structure is also the locus of black chlorite, dolomite and quartz alteration. Structurally remobilized precursor sulfide mineralization is one possible source for the deposit."

Jan 1, 1993

By M. J. A. Ruszala

Aggregates production is a huge global industry which uses an enormous amount of energy and produces a massive amount of unsalable fines. Reducing the amount of energy used per tonne of product and/or the amount of fines produced, would make a quarry more efficient. This reduction would make the quarry more environmentally friendly and profitable. This research looks at modelling Mountsorrel Quarry, a granite quarry in the United Kingdom (UK), using JKSimMet and Split-Desktop software packages in conjunction with the European Union (EU) project, EE-Quarry. Samples submitted to drop weight tests confirmed Mountsorrel Quarry granite as an extremely hard granite. Rock fracture data (t10) and energy of comminution (ECS) data were obtained from analysing the results. Split-Desktop image analysis software was utilized to determine the particle size distribution (PSD) of the primary crusher feed, as it contains particles too large to screen manually. It was also found that <1% of the feed is fines, which at Mountsorrel Quarry are classed as particles smaller than 5 mm, and that no particles were larger than 3,810 mm. JKSimMet was used to create a flowsheet of Mountsorrel Quarry. The crusher product PSDs were simulated and found to have strong correlations with experimental data, calculated by screening samples from conveyor belts, especially in the fines region, with a mean difference of 1%. The simulated primary crusher product PSD showed that it contains ~6% fines. A simulation over the entire quarry showed the product to be within the size range produced at Mountsorrel Quarry, and with a simulated fines content of 13%. When the CSS on the primary crusher was altered from 165.1 mm (the operating size on site) to 100.0 mm, it increased the overall percentage of fines produced by 3%, increased the power draw by 140.6 kW, but reduced the overall plant production percentage of fines by 2%. Two blasts were analysed on adjacent rock faces. They had identical blast designs, but the order of deck detonation varied; the first blast detonated the bottom deck before the top and vice versa in the second blast. For each blast, measurements of the feed PSD to the primary crusher, the number of particles that required secondary breakage on the quarry floor, acoustic levels and vibration readings were measured. No significant difference was identified between the two blasts in any of the parameters measured. In conclusion, a working model of Mountsorrel Quarry has been made in JKSimMet that has been validated against data from site and Split-Desktop has been used to simulate the primary crusher feed PSD, something that was previously unknown. The effect of reversing the order of deck detonation in a two deck blast was also analysed but with no significant difference between the two blasts found.

Aug 1, 2013

By Xuanxue Mo, Zengqian Hou

"Yidun Island Arc in Sanjiang Region is one of the important Kuroko-type volcanogenic massive sulfide deposits (VMS) districts in southwestern China. Tectonically, the region is situated in the eastern portion of the Tethys orogenic belt, and is a late Triassic extensional island-arc. The island-arc underwent earlier arc construction, intra-arc rifting, later arc construction and backarc spreading during its evolution and formed a complete trench-are-basin system, i.e., the Ganzilitang suture zone, forearc basin, outer are, intra-arc rifting zone, inner arc and back-arc basin from east to west across the island-arc.Kuroko-type VMS deposits and occurrences discovered so far are limited to within the intra-arc rifting zone of the Yidun Island Arc and tend to occur in groups or clusters distributed in separate faultbound basins; e.g., Zengke, Gacun and Xiangcheng basins, in which submarine volcanic rocks, especially bimodal volcanic suites, were extensively developed. The VMS deposits formed in the waning stages of volcanic eruption in the late Triassic and are hosted in the uppermost section of acidic volcanic rocks (rhyolitic-dacitic) within a bimodal suite. The orebodies are associated with these host rocks: rhyolitic-dacitic pyroclastic rocks and exhalites and chemical sedimentary rocks.All VMS deposits in Sanjiang are of the Zn-Pb-Cu type. The architecture of the deposits is twofold, consisting of concordant lenses and layers of massive sulfides and an underlying discordant stockwork. All deposits show metal zoning. The hydrothermal alteration related to mineralization is strong and asymmetrical, and is found dominantly within the stockwork zone and host rocks surrounding the ores. There are two alteration patterns: (1) chloritization - sericitization - silicification from outer sides to core of the alteration pipe; and (2) silicification + sericitization - silicification + carbonate from the lower to upper part of the alteration pipe.The mineralization temperatures of ore-forming fluids vary in the range 200°C to 335°C. Thermal evolution of the fluids displays temperature profiles that first increase and then decrease with progression of mineralization processes. The majority of black-ore minerals (Groups I and informed during intensifying stages of hydrothermal activity, and the majority of semi-yellow-ore minerals (Group III) formed during a thermal maximum. There followed the formation of fine-grained black-ore minerals (Group IV), which interacted with barite layers during decreasing temperature phases.Oxygen and hydrogen isotope studies show that the sources of ore-forming fluids for the Kurokotype VMS deposits are two-fold: seawater and magmatic hydrothermal solutions, represented by the Kuroko deposits in Japan and Kuroko-type VMS deposits in Sanjiang, respectively. In the latter case the hydrothermal solutions reacted with host rocks and mixed with cold seawater percolating downward, and circulated through volcanic rocks resulting in development of alteration zones and formation of ore minerals in Kuroko-type VMS deposits."

Jan 1, 1993

By T. Sugawara, H. Sekimoto

Electrorefining of low-grade copper alloys containing various amounts of nickel, lead, antimony, bismuth, arsenic, selenium, silver, and gold in sulfamic acid media was demonstrated. The copper concentration of the alloys used as an anode was 70–90 wt%. The electrolyte contained 100 g L-1 of free sulfamic acid and 40 g L-1 of cupric ion. Galvanostatic electrolysis was conducted at 200–300 A m-2 in the electrolyte using a low-grade copper alloy anode and a stainless steel cathode at 25C. The terminal voltage was approximately 0.8 V at the start of the electrolysis, although it increased periodically to approximately 2.0 V and then shortly returned to its initial value. Nickel, lead, and arsenic from the anode dissolved in the electrolyte and were removed. Antimony, bismuth, selenium, and silver were removed as solids. Consequently, a dense copper cathode was obtained, and the concentration of copper was evaluated by inductively coupled plasma – optical emission spectrometry to be 99.82–99.99 wt%. INTRODUCTION Electrorefining of copper is conventionally carried out in a sulfuric acid electrolyte using crude copper assaying at 99.5 wt% Cu as the anode (Biswas & Davenport, 1994). Elements more noble than copper do not react anodically, and consequently, they are distributed in anode slimes. Elements less noble than copper dissolve from the anode. Nickel and arsenic are stabilized as aqueous species. Lead, antimony, and bismuth react with water, sulfuric acid, or arsenic acid to form barely soluble compounds; thus, they are distributed in anode slimes. An emerging issue in the electrolytic refining of copper is an increase of impurities in crude copper used as the anode (Moats et al., 2013). This is due to an increase in the content of impurities in copper concentrates as well as an increase in the types of secondary copper feedstocks (e.g., E-Scraps, automotive shredder residues, and smelting residues) treated in the copper pyrometallurgical process. An extreme case is a copper smelter that does not use copper concentrates as feedstocks. In such a process, copper-bearing feedstocks are smelted in a top submerged lance furnace to prepare low-grade copper alloys assaying at 80– 90 wt% Cu (Sekimoto et al., 2013). Such low-grade copper is not acceptable as an anode in the conventional copper electrolytic refining process because it is easily passivated during electrolysis. Consequently, electrolytic copper is produced by leaching the atomized low-grade copper in a sulfuric acid solution with oxygen, followed by electrowinning. However, electrowinning should be avoided whenever possible because the electrical energy consumed in electrowinning is 5–10 times higher than that consumed in electrorefining. Therefore, the development of technologies for electrorefining of low-grade copper alloys is desirabl.

Jan 1, 2019

By I. Ueda, S. Ishikawa, T. Nagata

“O-SR process” in which the S-Furnace of the Mitsubishi process is followed by existing reverberatory furnaces (RFs) and Peirce Smith (PS) converters has been operated since December 2007. The S-Furnace smelts copper concentrates to produce molten matte containing 58-62%Cu which is then settled in the RFs and converted to blister copper in the PS converters. The SO2 gas generated from the S-Furnace and PS converters is converted to sulfuric acid in the acid plants. In addition to the smelting copper concentrates, the O-SR process has advantages in terms of recycling various waste/secondary materials. Automotive Shredder Residue (ASR) has been treated in the RF to reduce fossil-fuel consumption in RFs, and to recover various metals included in ASR as well, since 1993. Electronic circuit boards (E-scrap) has also been processed in order to recover not only copper but also rare resources such as gold, silver and PGMs since 2013. Strategic modifications have enabled expansion of the processing volume of E-scrap. Enhancing recycling of wastes and scraps from urban mines while reducing the consumption of natural resources in the “O-SR” process will be demonstrated and discussed in the present paper. INTRODUCTION Onahama smelter and refinery has been operating as a custom smelter since 1965. Smelting facilities were subsequently expanded to two green-charged RF furnaces and five PS converters in 1973. Since RF is a conventional old-fashioned smelting furnace that necessarily consumes a huge amount of fuel to smelt copper concentrates, saving fuel cost has been an important objective. In early 1980’s the fuel was changed from bunker oil to pulverized coal, while utilizing the combustion heat of waste tires. Furthermore, treatment of combustible waste such as shredder residue (SR) was initiated in order to save fossil fuel for smelting concentrates in the RFs. Since enhancing of the treatment of SR requires a reduction in concentrate smelted in the RFs, most concentrates were dried and injected through tuyeres into the PS.converters. These modifications enabled to reduce the amount of the pulverized coal combustion and to increase SR treatment in the RFs. SR treatment capacity has increased to 12,000mt/month because the SR market has grown after the enforcement of the Vehicles Recycling Law. Such business environment has been attributed to establish the thermal-materials recycling system of SR in which the RFs have changed their role from copper concentrates smelting furnaces to waste materials combustion furnaces.

Jan 1, 2019

By X. J. Guo, H. X. Li

The biological heap leaching at Zijin copper mine is currently the largest industrial application of biohydrometallurgy and one of the earliest mines to develop biological metallurgy technology in China. Since 2001, through demonstration plant and different expansion stages, it has been developed to produce 20,000 tons cathode copper annually. However the ore grade of heap leaching gradually decline year by year with copper grade average at around 0.23% now. The copper mineral is mainly the secondary copper sulfide, and symbiosis with higher content pyrite, the sulfur and iron contents is about 15 times as copper in the ore (S/Cu>15), so the acid and iron treatment of leachate, extractant and acid mine waste water is a great challenge. Combined with located in the rainy area of southern China, huge amounts of over 10 million cubic meters acid drainage need to be treated every year, so the recovery of copper from waste water as well as low grade ore is one of the characteristics of this process. This paper in general introduced the operation of heap leaching, solvent extraction, stripping and electrowinning process in Zijin mine, summarized the experience of production and technical practice, and discussed the methods of heap construction, leaching rate enhancement, third phase formation and treatment, mine effluent treatment, resource recovery and heap slope reclamation. INTRODUCTION The Zijinshan gold and copper mine is located in southeast China, Fujian province, and the typical distribution characteristics of gold and copper deposit are "upper gold and lower copper", both are large porphyry deposits. By the end of 2017, the accumulated proven reserves of available gold resources were 318 tons, copper are 2.15 million tons, and the prospective reserves of copper are more than 5 million tons. The gold mining is open pit while the copper mining is open pit and underground. The cut-off grade of gold mining is 0.15 g/t, and that of copper mining is 0.15%. A large number of very low-grade gold ores (grade <0.30 g/t) adopt a combined ore-dressing process of “partial crushing/ore washing/reprocessing/heap leaching (overlying)/ carbon slurry" independently developed, while flotation and bio-heap leaching are adopted for copper mine. Among them, copper ore with more than 0.25% copper content enters the flotation system to produce copper concentrate, while that of less than 0.25% copper content is processed by bio-heap leaching, solvent extraction and electrowinning. Zijin biological heap leaching plant is the first mine in China to achieve the scale of annual output of ten thousand tons of cathode copper since 2006. In 2008, the solvent extraction and electrowinning system were expanded, now with a daily processing capacity of 20,000 tons of ores, an annual output of 20,000 tons of cathode copper, the expanded plant is the largest biohydrometallurgy plant in China.

Jan 1, 2019

By André Chagnon, Héroux. Yvon

"Résumé - Cette étude porte sur l&apos;altération de la matière organique et des argiles dans les boues carbonatés dévoniennes du facies ""F&apos; de la Formation de Pine Point et ses équivalents stratigraphiques la Formation d&apos;Evie et l&apos;unité bitumineuse de la base de la Fonnation de Hom River. La matière organique se compose principalement de bituré solide et de quelques fragments de fossiles (organaclastes). La majorité des échantillons ne renfement que de l&apos;illite et des inter-stratifiées illite/smectite.Si on compare les températures d&apos;homogénéisation (Th = 100°C) des inclusions fluides de la sphalérite et des dolomites associées a la minéralisation aux températures estimées à partir de la réflectance de la collinite (84°C à 117°C), l&apos;on ne peut pas conclure à la présence d&apos;une anomalie thermique dans le district minier de Pine Point. De plus, la réflectance des organoclastes n&apos;est pas plus élevée dans le district minier de Pine Point que dans les localités plus éloignées des gites. L&apos;analyse des minéraux argileux conduit à la même conclusion: aucune anomalie thermique n&apos;est décelable dans les unités échantillonnées à l&apos;intérieur du district minier de Pine Point quelque soit l&apos;indicateur utilisé.La kaolinite et la matière organique altérée, affichant des valeurs anomales de sa réflectance, se trouve essentiellement en présence de soufre et de sulfures. Cela suggère une origine authigène de la kaolinite et une altération de la matière organique reliées au phénomènes de minéralisation.Abstract - The alteration of organic matter and clays is studied in the Devonian Pine Point Formation carbonate muds, ""F"" facies, and its lateral equivalents the Evie Formation and the bituminous unit at the base of the Hom River Formation. The organic matter is mainly composed of solid bitumen with few fossil fragments (organoclasts). Most samples contain only illite and mixed layer illite/smectite.If we compare the Th (100°C) from fluid inclusions of sphalerite and dolomites associated with mineralization to the temperatures calculated from the reflectance (Ro) of the collinite (84°C to 117°C), we cannot detect a thermal anomaly in the Pine Point mining district. This result is based on the reflectance values of organoclasts from the mining district that are not higher than those reflectance values measured on organic matter (OM) away from the ore deposit. A similar conclusion is reached from the clay study: none of the parameters used allow us to identify a thermal anomaly in the samples from the mining district.The kaolinite and the altered OM showing anomalous Ro values mainly occur with sulfides and sulfur. This association suggests an authigenic origin for the kaolinite and an alteration of the OM due to the mineralization events."

Jan 1, 1994

By Jiahao Xu, Namsoo P. Kim, Guikuan Yue

Iron (ferrous ions and ferric ions) plays an important role in the heap leaching of copper sulfide minerals and copper electrowinning. In our previous study, a novel oxidation-reduction potential (ORP) equation only based on the variables of temperature and nominal ferric/ferrous ratio was developed to predict the redox potential of the quaternary H2SO4-Fe2(SO4)3-FeSO4-H2O system, and its applicability was also extended to more complex acidic iron sulfate solutions, especially those generated during the acidic leaching and bioleaching of Printed Circuit Boards (PCBs) to recover copper. In this work, the broader range of applicability of this equation to other complicated acidic iron solutions containing copper ions has been extended and determined. Specifically, synthetic iron-containing solutions with copper ions according to the conditions of industrial electrolyte during copper electrowinning and heap leaching have been used to measure the ORP and test the developed equation. It seems that this equation can still be employed to predict the redox potential of the Fe3+/Fe2+ couple for the simulated solutions under conditions related to copper electrowinning and pregnant leaching solution generated during heap leaching over a wide range of solution concentration, nominal Fe3+/Fe2+ ratio and temperature. It has shown that the prediction and measurement of redox potential is highly useful to estimate and understand the iron chemistry of industrial leaching and electrowinning processes. INTRODUCTION It is well-known that iron (ferric or ferrous) ions are widely involved in the hydrometallurgical production of non-ferrous metals such as Cu, Au and Zn, mainly in the form of acidic iron sulfate solutions. As far as Cu is concerned, in a typical leaching-solvent extraction-electrowinning process, ferric ion plays a central role in the heap leaching process and is reduced to ferrous ions in the pregnant leaching solution. Ferric ion is the most important surrogate oxidant and the dissolved ferric/ferrous couple plays an important catalytic role in accelerating the leaching rate with oxygen as an oxidant (Peters et al., 1986; Schlesinger, King, Sole, & Davenport, 2011). In addition, during the traditional electro-winning process, oxygen is evolved at the anode, and copper is reduced at the cathode. A common idea is that iron in the electrolyte in copper electrowinning cell (with total iron of 1–4.4 g/L) plays an important role in reducing the current efficiency. According to the published results (Winand et al., 1975; Dew et al., 1985; Moats et al., 2009; Khouraibchia et al., 2010), thecurrent efficiency decreases linearly with increasing ferric ion concentration and the energy consumption increase was mainly caused by the decrease in current efficiency.

Jan 1, 2019

By Z. X. Cui, X. D. Ma, L. Contreras, X. Jiang

The bath smelting process is one of the key techniques applied in the current copper smelting production, which includes bottom-blown and side-blown furnaces differently from the direction of gas injection. Liquid matte and slag form the bath in the smelting furnace. To better understand the fluid dynamic of the bath and further optimise the operational efficiencies in the smelting furnace, physical simulation of the bath in the horizontal cylindrical reactor was investigated. The mixing behaviour and wave motion of the bath in the bottom-blown and side-blown furnaces have been studied systematically. The mixing time is reduced with increasing gas flowrate and height of the lower layer, while it increases significantly with increasing the height of the upper layer. The wave motion in the furnaces can be suppressed with the presence of the upper layer, but the bath with a lower density generates higher wave amplitude. Overall, in comparison to bottom-blown mixing, side-blown mixing shows better mixing efficiency and lower wave amplitude. In addition, the plume eye and splash phenomena occurred in the bottom-blown furnace have also been studied. INTRODUCTION The bath smelting process is one of the principal techniques used in the current copper making industry. The bath smelting techniques have some advantages of high smelting efficiencies, low capital costs, low energy consumptions and reduced dust generations. From the direction of gas injection, the bath smelting techniques can be classified into five general types: (1) top-submerged blown, e.g. Ausmelt and Isasmelt; (2) top-suspended blown, such as Mitsubishi smelting; (3) top direct-to-copper smelting, such as Outokumpu smelting; (4) submerged side-blown, such as Noranda and Teniente smelting; (5) bottom-blown, such as Dongying Fangyuan bottom-blown copper smelting furnace (Schlesinger et al., 2002; Zhao, Cui, & Wang, 2013; Perez-Tello et al., 2018). In many metallurgical processes involving bath smelting situations, the objectives of agitation are to accelerate the bath homogenization inside the bath which makes a significant contribution to process efficiency and product quality. Extensive mixing studies have been performed for ladle refining and tundish associated to steelmaking processes through water physical models. Mixing time is the parameter used to quantify the efficiency of mixing in the liquid bath and the first empirical equation predicting mixing time was proposed by Nakanishi, Fujii and Szekely (1975). Later on, more systematic studies have been carried out on ladle mixing and researchers realized that the geometry of the vessel could also have a significant impact on mixing (Khajaviand & Barati, 2010). However, the investigations using ladles which are vertical cylindrical vessels, cannot be directly used in the study of mixing behaviour in horizontal cylindrical reactors. Understanding the fluid dynamics inside horizontal cylindrical bath smelter is useful from the industrial perspective. Recently fluid dynamics of horizontal cylindrical smelter related to copper smelting have been studied by the authors’ group (Shui et al., 2015a, 2015b, 2018a; 2018b; Xu et al., 2018, 2019).

Jan 1, 2019

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 Michel Aubertin

Les haldes à stériles contenant des minéraux sulfureux réactifs constituent un milieu favorable à la production du drainage minier acide (DMA). Au sein de ces haldes, les processus physiques, géochimiques et biologiques qui mènent à la production du DMA sont nombreux et complexes. Un des aspects critiques qui affecte la génération de DMA est la distribution et le mouvement de l?eau dans les roches stériles. La modélisation numérique est un outil qui permet de comprendre, pour éventuellement contrôler, les mouvements de l?eau (et donc réduire la production du DMA) dans les haldes pendant la période d?exploitation de la mine et à sa fermeture. Plusieurs simulations numériques des écoulements non saturés dans des haldes ont été effectuées. Pour ces simulations, on a considéré divers types de matériaux, diverses conditions atmosphériques et diverses configurations géométriques. Les simulations réalisées montrent que l?on peut contrôler les mouvements de l?eau en introduisant des couches de matériaux fins intercalées dans les haldes formées de matériaux grossiers. Des couches horizontales ne sont cependant pas appropriées puisqu?elles peuvent, dans certains cas, favoriser la création de zones humides susceptibles d?amplifier les effets du DMA. Une faible inclinaison des couches de matériaux fins vers l?extérieur permet de palier à ce problème. Les couches inclinées favorisent un drainage des haldes vers la périphérie. Ceci a pour effet de garder sèche une grande partie des stériles et de réduire, par le fait même, la production du DMA.

Nov 1, 2002

By Nitin Bhavsar, Kaushik Vakil, Lakshmikanth Reddy, Sanjay Sarkar, Tathavadkar. Vilas, Bhavin Desai, Raghavendra Adiga

Gold and platinum group metals (PGM) do not dissolve in sulfate electrolyte from anode during electro-refining of primary copper. The PGM form solid ‘slimes’ which accumulates at bottom of the electrolytic cell. Typically, 8 to 10 ppm silver is present in copper cathodes, which is equivalent to almost 2% of silver loss during electro-refining. The silver can be cemented with cathode copper as soon as it is dissolved into the electrolyte from anode or during entrapment of slime particles in cathode. Over a period of time, the concentrates grade has deteriorated and change in type & amount of impurities in concentrate has resulted in higher silver loss during refining process. Therefore, an in-depth investigation was carried out in both fire- and electro-refining processes to understand the root causes of higher silver loss in copper cathodes. The detailed characterization and the plant data analysis were carried out. The results of study revealed that higher silver loss in 3rd crop cathodes as compared to 1st and 2nd crop cathodes from same anode. In anode silver was present in two forms, dissolved in copper (solid solution) and in slime phases such as Cu2-xAgxSeTe. SEM-EDX study of anode cross section confirmed higher silver and oxygen content in central region (core) of anode as compared that in both air and mold sides. This is due to non-uniform cooling of anode which was confirmed by the solidification modeling. Higher concentration of oxygen & silver at core of anode rised Ag+ concentration in electrolyte and slime particles during 3rd crop. The results of study were used to optimize the anode cooling process and also electrolyte chemistry to reduce the silver loss. The details of study carried out are discussed in this paper using the results of modeling, characterization and experimental studies. INTRODUCTION In the electrolytic refining of copper, fire refined copper anodes are used as raw material. Anodes contains copper of the range 99.5 to 99.6%, rest being the impurities. Hence, the purpose of the refining is (1) to remove the impurities so that final cathode conforms to the LME specifications and also (2) to recover the precious metal from the anode copper. When anode is dissolved, most of the impurities reports to the anode slime settled at the bottom of the cell, and rest dissolves in the electrolyte. Dissolved impurities remains in electrolyte and are removed during electrolyte recycling. However, sometime dissolved impurities and slime particles get entrapped in cathode due to disturbances in operational conditions. Metals dissolving in the electrolyte are the elements such as Ni, Co, Fe, Zn. The electrode potential of As, Sb and Bi being close to that of copper, these elements partly dissolve in the electrolyte. Noble metals like Ag, Au, Pt and Pd are generally insoluble and are thus expected to report to the anode slime. A small amount of the sliver content from the anode is dissolved in the electrolyte. Because the dissolved silver electroplates on the cathode at a smaller applied potential than copper, the cathode typically contains up to 8 ppm of silver. This is referred to as ‘silver loss’ in cathode (Cooper, 1987). Fortunately, silver is a rather benign impurity in copper due to its electrical conductivity being higher than copper. However, higher silver loss in cathode is loss of revenue for Copper smelter due to significant difference in their LME price.

Jan 1, 2019