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By L. S. Rivett, U. M. Oko

The Strathcona mine, with a large new underground operation and concentrator, was recently brought into\ production by Falconbridge Nickel Mines Ltd. The tailings disposal and water utilization problems at Strathcona are described in this paper, with sections devoted to the Moose Lake watershed system, tailing impounds, the construction of dams and the operation of the Moose Lake neutralization plant for the elimination of acidity, including the equipment used.

Jan 1, 1971

The comminution circuit at Tarkwa Gold Mine was commissioned as a Single Stage SAG mill operated in closed circuit with hydrocyclones designed to process 4Mtpa. The circuit was later expanded by adding a secondary ball mill in closed circuit with hydrocyclones with a view to treat 12Mtpa. The change in the circuit configuration and assigning the low aspect ratio SAG mill for primary grinding application makes the Tarkwa experience unique in terms the optimisation strategy and operating philosophy. This paper reports the findings from a series of surveys performed on this plant. The surveys reported include data obtained when the SAG mill was operated as a single stage mill in closed circuit with hydrocyclones and also SABC mode under two different feed conditions. The differences in operating philosophy between the initial single stage SAG circuit and the current SAG/Ball mill circuit are discussed.

Jan 1, 2012

By Michael S. Moats, Alex Luyima, Tomas Oliveira

Some commercial copper electrowinning facilities use Cyquest N-900 (a polyacrylamide) or HydroStar (a modified polysaccharide) to improve the density and smoothness of copper electrodeposits. However, the effects of these additives have not been studied extensively in the open literature. Thus, the electrodeposition of copper at 40 oC from a non-stirred synthetic electrowinning electrolyte (40 g/L Cu2+, 160 g/L H2SO4, and 20 mg/L Cl-) in the presence of various concentrations of either additive was evaluated using cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). CV results show that neither additive has much effect on the nucleation overpotential of copper electrodeposition on stainless steel. However, Cyquest N-900 polarized the copper deposition reaction upon the return sweep. The EIS data indicates that Cyquest N-900 increases the reaction’s charge transfer resistance and creates a second low frequency loop. HydroStar had minimal effect on the electrochemical data generated by CV or EIS. Thus, the mechanism by which HydroStar affects the copper deposition reaction still needs to be determined.

Jan 1, 2014

The fracture behavior of second phase particles and the role of matrix material on the wear resistances of the three Al-Si alloys containing 8, 17, and 19% Si were investigated using single pass scratch testing technique by applying normal loads between 0,15 and 5,00 N, in ambient air, Optical microscopy and SEM with EDS were used to analyze microstructures and morphologies of scratch tracks of the Al-Si alloys, The results showed that needle-like Si particles fractured under a load of 0.50 N, while block-like Si particles fractured at loads above 3,00 N, The Al-17% Si alloy with large number of needle-like particles (area fraction 16,4%) exhibited the highest coefficient of friction (0,8) and the widest scratch track, The Al-19%Si alloy containing high Si percentage and larger number of block-like particles (area fraction 16%) exhibited the lowest coefficient of friction (0,37) and the narrowest scratch track width. Presence of block-like particles was effective in reducing the amount of material transfer from Al-Si alloy surfaces to the counterface.

Jan 1, 2005

By Jessica Egan, Daniel Hodouin, Mohammed Reza Khalezi, Steve Bellec, Claude Bazin, Carl Duchesne

"A model for gold leaching was developed and implemented into a simulator. The simulator uses a description of the ore that is based on the mineral composition and precious metal content. The model accounts for the distribution of minerals and precious metals through the size intervals. An ore texture model based on precious metals and minerals grain sizes within the ore is used to predict the exposed surface of the species in the various size intervals. A model is proposed to predict the rate of dissolution of any species dissolution using the exposed surface, particle size, cyanide and oxygen concentrations, temperature, pH and agitation. The flow of slurry through a leaching tank is modelled using a parallel arrangement of perfect mixers to simulate a bypass and a Cholette-Cloutier mixer model. The simulator can be used for circuit optimization but was developed to provide an environment for learning the basic concepts of process analysis methods. Examples are given to illustrate the application of the simulator for planning tracer tests and sampling campaigns.INTRODUCTIONThe constant pressure to improve the operation of processes that are already close to optimum imposes to plant engineers to be aware of the available process analysis tools and to be able to use them to assess process operation and make a diagnosis to possible problems. Some of these tools are:•,Sampling the streams of a process;•,Data reconciliation;•,Analysis of mixing in reactors;•,Estimation of rate parameters;•,Optimal tuning and flow sheet modification;•,Automatic control and real time optimization.Although some of these tools are part of the curriculum of many university engineering programs, the students are not exposed to actual process analysis problems. In addition the complexity of the ore dressing processes compounded with unavoidable measurement errors and plant disturbances can discourage many motivated engineers. These factors often lead to an incomplete valorization of the collected data and a poor return on the investment associated with the sampling, testing and analysis of the samples.Simulators are readily available for process optimization (Yalcin and Shang, 2006) by allowing:•,The simulation of various flow sheet configurations;•,The simulation of a change of operating conditions;•,The simulation of various control strategies;•,The training of plant operators.However few simulators have been developed with the objective of providing an environment for training plant engineers and technicians to the use of tools for process analysis and optimisation."

Jan 1, 2008

By Stephen B. Cheeseman

The quantity of data available and the rate at which we access such data are rapidly increasing. Electronic data capture systems, fleet management systems and a host of other technological advancements have created a constant stream of real-time, tactical data. However, are we taking advantage of this data? Are we converting data into useful information to aid in efficient decision-making? Mining operations are struggling with ?information overload?, finding it difficult to extract the benefits from vast stores of data. Without the necessary tools to facilitate a data filtering and information reporting process, most operations revert to old practises such as re-entering data into multiple spreadsheet reports. As a result, the ability to make effective use of data still eludes many mining operations. Some operations have taken audacious steps to rectify this situation. The De Beers Venetia mine in South Africa has implemented an integrated mining information technology solution that transforms their data into practical, usable information allowing staff and management to make decisions that improve efficiencies and reduce costs. In the absence of quantitative justification or ROI, De Beers took a risk in implementing change. Today, they are realising the benefits. This paper will unearth the information technology issues that surfaced during the Venetia implementation, then identify the benefits De Beers has obtained from deploying an integrated mining information technology solution at the Venetia mine.

May 1, 2002

By M. D. Quinn

THE sand and gravel used for backfilling at the Hollinger mine is obtained from deposits in a low range of hills some three miles north of the mine, where the Company owns a number of claims. The material is transported to the mine by aerial tram. Shipments from these deposits to the Hollinger mine commenced in June, 1927, and since May, 1936, sand has been supplied also to the McIntyre mine. During 1942, Hollinger requirements were 1,700 tons per day, and 900 tons per day was delivered to McIntyre. For the past seven years production has averaged 900,000 tons annually, and total deliveries to the end of 1942 were 13,129,022 tons, of which 11,075,339 tons went to Hollinger and 2,053,683 tons to McIntyre. Some years ago, when the original pit was approaching exhaustion, new workings were opened on claims east and south of the tramway terminal. It soon became apparent that the sand varies considerably in character from place to place. The weight per cubic foot was found to range from 85 to 130 lb., and the water percolation rate from 2 to 50 inches per hour. As the mine requirement is a sand with percolation rate of 6 inches or better per hour, it was evident that in certain parts of the deposits the material was not suitable for use as backfill. As a consequence, it was decided to carry out a programme of systematic sampling of the claims in order to select the areas containing suitable material for back-fill and at the same time estimate the tonnage available.

Jan 1, 1944

By A. Brown

IN INTRODUCING the subject of rock pressures, it may safely be assumed that mining men are only too familiar with the physical effects of strata stresses that accompany the extraction of minerals. It may be further assumed that they have, as individuals, arrived at certain conclusions regarding their nature, based upon years spent in observing such phenomena and in learning how to continue mining in spite of them. Such hardly won experience forms the core of what is often referred to as 'pit sense'. This essential type of knowledge is not ?based on theoretical considerations, nor can it be found in text books. It is highly individualistic in nature and almost impossible to pass on from one generation to another in terms of precise rules for guidance. It is this aspect of individual judgment based on practical experience that has led to the significant phrase The Art of Mining.

Jan 1, 1956

By S. Gaulocher

Gearless mill drives (GMDs) are the workhorse in the mineral processing industries, more specifically when it comes to grinding crushed ore and cement (in various production stages) in semiautogenous (SAG) mills and large ball mills. They are renowned for their excellent reliability and robustness, long lifespan, and little need for maintenance, and thus yield a low total cost of ownership (TCO). A GMD represents a major investment for a mineral processing plant, and its availability is pivotal for the grinding process. As a basic rule, shut-down periods are to be minimized, but even much more important is that unscheduled shut-downs be avoided. In this contribution, we will present a portfolio of innovative remote diagnostic that consist of the following three key components: 1. Trouble shooting is a form of corrective maintenance and is based on state-of-the art remote access technology, thus enabling highly skilled engineers to access the current sensor readings anytime and from anywhere in order to resolve urgent problems together with the GMD user. 2. Periodic maintenance reports are a form of preventive and predictive maintenance and aim at continuous improvement based on long-term historical records and analyses of multiple measured signals. These detailed reports highlight the health and operational status of the GMD and are periodically (e.g. 3 months) submitted to the customer. 3. Remote condition monitoring spans across preventive and predictive maintenance and is based on continuous recording and automatic analyses of relevant signals using advanced algorithms. The main issue is how to handle the enormous flood of data in an intelligent manner. The results of these analyses are made available to both the GMD user and supplier in real time in order to increase the availability and reliability of the GMD. In this paper, we consider various parts of the GMD, e.g. the cycloconverter, the ring motor, the auxiliary devices (e.g. cooling and lubrication systems), and also phenomena related to the mill itself (e.g. state and quantity of charge). The signal analysis techniques range from simple threshold-based analyses to complex time and frequency domain analyses. We will illustrate the benefits of the proposed approaches with some selected examples.

Jan 1, 2012

By K. V. Lindell

Introduction This paper describes a recent innovation in the design and construction of mine headframes. A reinforced concrete headframe was built by using sliding forms. A concrete headframe of conventional design was originally considered, but investigation of this project showed that it was doubtful if the bearing strength of the soil was sufficient to support the great weight of a structure of this type. In addition, the slope and the fractured condition of the serpentine bed-rock did not permit satisfactory piling. A conventional steel headframe with storage bins was then designed, but, due to the steel situation, delivery promises were set back many months. The concrete headframe was again investigated, and a design was adopted incorporating a circular headframe lower in height than that first considered, with skips discharging into a smaller surge bin. The upper section of the shaft collar was strengthened to result in a stable structure which would be supported by bed-rock, as well as by the concrete and steel lining of the shaft itself.

Jan 1, 1948

By A. Grimod

The European Guideline ETAG 027 - 2008 (?Guideline for European Technical Approval of Falling Rock Protection Kits?) defines the procedures to test rock fall barriers. Nowadays, this guideline is essentially the only test and construction framework utilized by manufacturers and it is also starting to enter in the mentality of designer who can clearly specify the performances of rockfall barriers. ETAG 27 (and the related European Technical Approval and the CE marking) represents a milestone for the rockfall barrier market, because it gives the possibility to compare the performances of different fences and it ensures the quality of the certified product. For these reasons ETAG 27 presently constitutes the base for tenders all around the world. Although rockfall barriers are in common use, designers and consultants do not have a clear overview of the real performances and the technological limits of these structures. The first problem can be solved using ETAG 27 criteria, which allow designing rockfall barriers at ultimate and serviceability limit state. Even though ETAG 27 uses crash tests performed with the Service Energy Level (SEL) and Maximum Energy Level (MEL), design with these concepts is not obvious or in common acceptance. Some preliminary questions must be solved. When can these energy levels be correctly applied? In the case of rockfall simulations, what probabilistic approach must be used for the evaluation of the barrier? Unfortunately ETAG 27 does not give any information or tests relating to the technological limits of the fences. Therefore some important questions arise. How do the site specific aspects of installation affect the barrier performance? What is the behaviour of the barriers under extreme conditions? And finally, the main question lies in the background: what is the functional reliability of ETAG 27? All of the above questions require comprehensive answers, which is consistent with the experience of designers, installers and producers. Officine Maccaferri S.p.A., with its 130 year experience in the field of rockfall protection, collected a large number of case histories with barriers impacted by single or multiple blocks, debris flows, and snow avalanches. Throughout these case histories and in accordance with a recent Italian standard code, it has been possible to implement a reasonable design approach that considers the efficiency of the barrier, the uncertainties of the input data, and the fore

Aug 1, 2013

By Nawshad Haque, Leanne Smith, Hal Aral, Joseph Cho, Warren Bruckard

"Water availability is one of the principal parameters in determining the feasibility of mining projects in arid and semi-arid regions. The volumetric water footprint (VWF) of a conceptual model of a copper flotation plant was found to be 2.45 kL/t Cu ore, compared with an actual measurement reported in the literature of 2.72 kL/t Cu ore. The flowsheet considered included mineral processing stages such as crushing, screening, grinding, classification, separation, flotation, thickening and filtration. The effect of a number of variables on the VWF was evaluated, including solid/liquid ratio, feed mass flowrate, ore loss, water loss, moisture content of ore, ore grade and water recycling. The use of seawater with recycling provided the most environmental and economic advantage among several scenarios evaluated. The study assumed a price of $1/kL freshwater, $4/kL for transport over a 200 km distance at 2,000 m altitude and $4/kL for water treatment. The water related cost of the desalinated seawater use scenario was A$493/t Cu concentrate, while the water related costs of fresh water and blended water scenarios were A$308/t and A$268/t Cu concentrate, respectively. The water related cost (fresh water scenario) accounted for 44% to 49% of the entire mining and processing costs that included drilling, blasting, loading, hauling, crushing, grinding and concentrating. The total overall cost was A$435/t Cu concentrate for the seawater with recycling, compared to A$451/t Cu concentrate for the fresh water with recycling case.INTRODUCTIONReducing the water footprint (WFP) by utilising alternative water sources has been a focus of mining projects due to increasing concerns about water scarcity and growing energy costs. The global mining industry can expect to experience fresh water shortages in the future, and saline or hyper-saline water may be the only available water source to process minerals in arid regions. Extensive studies on alternative water sources (e.g. seawater, desalinated seawater, blended water) and the reuse of process water have recently been conducted (Moreno, Aral, Cuevas, Monardes, Adaro, Norgate & Bruckard, 2011; Aral, Mead, Cuevas, Davey & Bruckard, 2010). Such studies provide sustainable and economic strategies for mines and concentrators in the arid or semi-arid regions of the world such as in Chile, Peru, Indonesia, and Portugal. More work, however, is needed to confirm water consumption data for different base metal flowsheets and use this data to develop water models that can lead to reduced WFPs and more sustainable water usage in the mining industry."

Jan 1, 2016

By P. W. Ware

The majority of all refined copper is consumed to produce electrical conductors. Most copper conductors are drawn into wire from 8 mm ETP copper rod produced from high purity copper cathodes. Southwire Company has more than 40 years experience using, designing, fabricating and marketing a process for continuously producing ETP copper wire rod. This process is called the SCR® (Southwire Continuous Rod) process. Today, approximately half the copper wire rod produced in the world, or more than one third of all refined copper consumed, is produced using the SCR process. Southwire has sold 75 SCR copper rod mills to metal producers and wire manufacturers around the world. Southwire is North America's largest electrical wire and cable producer. Southwire operates a 48 metric ton per hour SCR® copper rod system in Carrollton, Georgia. This allows Southwire to provide technical support for existing SCR® system customers based on first-hand knowledge. Rod fabricators and their wire customers are always striving for copper rod that improves productivity. They are looking for improved surface quality, finer wire sizes and fewer wire breaks per ton of rod drawn. This paper will present a brief history of the SCR® process, a description and recent process developments.

Jan 1, 2007

By A. Torkian

Process water from production of concentrates in Meydook copper sulfide mine is transferred to the 8.3 million m3 tailings dam and a water retention pond after initial thickening. Elevated concentrations of heavy metals, sulfate, and TDS and decrease in pH as well as seepage into the aquifers have been the concern of the regulatory agencies since the start of activities. In this paper the results of a 6-month monitoring program from 4 wells are presented. The wells were located approximately 1.5 km from downstream of tailing dam (0.4 km from water retention pond) as well as upstream background well (2.28 km from water retention pond and 1.27 km from tailings dam). The objective was to study possible effect of accumulated tailings on the groundwater resources. Water levels in sampled wells were on average between 20 and 40 m. Results showed high levels of lead (5 ppb), copper (0.17-0.46 ppm) and selenium (73.1- 29.1 ppb). High levels of selenium and lead were partly due to natural geological settings of the area with high levels present in unaffected soils in the vicinity including water wells of villages upstream of mining operations. High copper levels were attributed to both mining operations as well as deposition from particulate air deposition onto the soil and transport to ground water by rain.

Aug 1, 2013

By Maurice A. Roche

Introduction Most of the Flin Flon ore-body, like many others in northern Canada, was covered by water. The original discovery was made where the ore-body outcropped on a strip of land jutting out into Flin Flon lake. The outcrop could be traced for a distance of 600 feet across the strip of land, but disappeared under the lake on both sides of the peninsula. Following the discovery or location of the property, in 1915, and subsequent to its examination by the H.P. Whitney interests in 1925, an extensive diamond-drilling programme was completed, which proved the existence of an ore-body at least 2,600 feet long and 900 feet deep. In plan, the central part of the ore-body at surface attains an overall width of about 450 feet; including waste horses, and gradually becoming narrower to the south. To the north, it stretches out as a much narrower tongue. The main body is a solid sulphide ore containing gold, silver, copper, and zinc. Adjacent to, and on the footwall side of, the solid sulphide ore-body, there are considerable widths of talcy disseminated copper ore, particularly in the upper 300 feet of the deposit, where the maximum widths occur. The ore-body occurs in a greenstone area, the rock being quite hard on the hanging-wall side, with the footwall schisted, talcy, and much softer. The greater part of the ore-body was overlain by 12 to 15 feet of water and from 15 to 90 feet of mud and clay, this material requiring eventual removal, regardless of the system of mining adopted. The total of mud and clay overburden was estimated at 1,000,000 tons. After considerable study, it was decided to mine the upper 300 feet of the ore-body by open-pit methods; the balance of the ore to be recovered by underground mining . The present paper gives an account of the methods adopted in both operations, and of the problems encountered.

Jan 1, 1935

By T. G. Edgeworth

Some of the historical background of the industry is reviewed, with reference to the different types of reduction cells in use for aluminum smelting. Factors to be considered in cell des1gn involve capital, power, and operating costs. The trend is apparently toward larger cells. The industry is studying new construction materials for cell linings, as well as alternate electrolyte compositions and other design changes which will improve productivity and energy efficiency. The aluminum smelting activity in other countries is briefly reviewed. TODA Y'S industrial production of aluminum is still based on the simultaneous discoveries made in 1886 by Charles Martin Hall in Ohio, and Paul Heroult in France. Up to that date, only about 50 tons of aluminum had been produced in the world, and the price at that time was about $5 per pound. Sucl1 figures must be contrasted with the present world aluminum smelting capacity of over five mil-lion tons per year, and a price of about 25 cents per pound.

Jan 1, 1962

By Chris Rule

This paper tells the story of the rapid commercial application of stirred milling technology at Anglo American Platinum?s many Concentrators. The first stirred mill ? a 10 000 litre IsaMillTM; the largest at the time, was commissioned in late 2003. The project development work was presented at SAG 2001. This operation was ?proof of concept? and vindicated the decision to scale up the technology; allowing a rapid and extensive roll-out of mainstream regrind mills as well as several further flotation concentrate regrind mills, over the next six years. Currently 23 stirred mills are in operation with 64 MW of installed drive capacity ? this paper describes the projects? roll-out and the significant results achieved to date. Many operational problems have been solved along the way, some of these will be described. The introduction of the technology has seen a step change in metallurgical results and progressively decreasing operating costs.

Jan 1, 2012

By M-d-N. Gagnon, P. Okono, Y. Bergeron

In the mining industry, decisions regarding the type and number of comminution tests to be completed typically rely on geologists? observations and conclusions when studying drill cores. Given that these decisions are based on visual observations, they are essentially approximate and often inaccurate from a comminution viewpoint, causing a sizeable margin of error in estimating characterization test needs. Consequently, companies are often forced to perform more tests than necessary, requiring a significant quantity of material, and accruing significant costs. Recently, a new device, called the Hardness Index Tester (or HIT), was developed, offering users a low cost in-house mechanism for estimating the comminution parameter A*b and the Bond Ball Mill Work Index at any mine site, with potential applications on fragments up to 25 mm from drill core. In late 2016, Agnico Eagle Mines Limited initiated a trial to investigate if having an HIT device installed in a core repository would make it possible to identify the different rock properties more accurately and determine the number and type of comminution tests required. The application of the HIT was not to replace the standard comminution tests, but rather to generate a high number of comminution and geomechanical parameters for the rock mass. Ultimately, the objective would be to determine the uniformity of the rock mass and, therefore, easily distinguish any potentially problematic zones. With this method, the appropriate number of standard tests could be determined, making the HIT not only an excellent complement to the standard laboratory tests, but also an indispensable device for a geometallurgical characterization. This paper presents the results from the HIT trial using samples from the Odyssey Project, which is a Mine Canadian Malartic property.

Jan 1, 2017

By W. E. MacDonald

This paper relates the story of 100 years of mining in the Harbour Seam at the Princess Colliery, Sydney Mines, Nova Scotia. Several interesting anecdotes are included along with the discussion of the evolution of coal mining methods in the area. Finally, some of the recently introduced equipment at Princess Colliery is described, and prospects for the future of the industry are outlined.

Jan 1, 1968

By A. Deneys

This paper reviews industrial gases used in primary copper production. Copper smelting industrial gas demand has steadily increased since the first commercial oxygenconcentrate smelting in 1952 [1]. In copper production oxygen for smelting is the dominant industrial gas use followed by oxygen for converting. Nitrogen is finding increased use in copper smelters. Nitrogen is used for porous plugs for copper converting and anode refining [2-5]. Nitrogen can be used for concentrate drying [6,7] and is also used in some Ni-Cu smelters as a coolant in Peirce-Smith converting [8,9]. Industrial gas supply options of cryogenic or adsorbent based on-site plant or cryogenic liquid delivery are detailed.

Jan 1, 2007