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By F. McCarthy, W. Zhang, R. McDonald

"The processing of nickel laterites has been a topic of major interest at CSIRO for almost twenty years. During this period CSIRO has collaborated with other researchers and industry in developing a better understanding of existing processes and been actively involved in testing/developing new beneficiation and process options for these ores. The current paper summarises the results of selected studies and highlights improvements that have been achieved. Key topics to be discussed include enhancements in the mineralogical characterisation, beneficiation approaches, improvements in the understanding and application of leaching technologies, the development of synergistic solvent extraction (SSX) for the recovery of nickel/cobalt from laterite leach liquors and the collaborative development of the Direct Nickel process. Future opportunities and key research questions will be briefly examined.INTRODUCTION Nickel laterite ores comprise a significant resource in Australia and according to United States Geological Survey data nearly a quarter of world reserves are located there (USGS, 2016). More specifically, around 95% of Australian nickel resources (laterite and sulfide) are located in Western Australia (Australian Government, 2017). Given the recent closure of Queensland Nickel, essentially all of Australian nickel production occurs in Western Australia and the primary producers of processed nickel products include Nickel West (Kwinana) with ~84,000 t saleable nickel metal in 2016 (BHP Billiton, 2017), Minara Resources (Murrin Murrin) with 46,700 t nickel metal produced in 2015 (Glencore Australia, 2017), and First Quantum Minerals Ltd (Ravensthorpe) who sold 25,882 t nickel as mixed hydroxide product in 2016 (First Quantum Minerals, 2017). The total sales of nickel from Western Australia in the 2015-16 financial year were 175,722 t. The study of nickel laterites at CSIRO recommenced at the time second generation High Pressure Acid Leaching (HPAL) plants were being commissioned at Bulong, Cawse and Murrin Murrin in the late 1990’s. A combination of technical and engineering issues meant that the ramp-up times at these operations were slower than expected and the outcomes resulting from the attendant problems are well documented (e.g. Griffin & Becker, 2000; Reid & Barnett, 2002; O’Callaghan, 2003) while the issues faced at the BHP-Billiton-built Ravensthorpe plant have been addressed by the current owners of this project, First Quantum Minerals Ltd (Piper, 2012)."

Jan 1, 2017

By Xueyi Guo

The total production of nonferrous metals in China is 31.35 million tons in 2010, which ranks first in the world for the past ten years. Large quantities of solid wastes including slag, residue, ash, and dust are produced every year in the production of nonferrous metals. These secondary resources are renewable, not only contain abundant valuable metals which can be recycled by metallurgical processing, but also could eliminate the pollution to the environment. In this paper, the status quo of the main nonferrous metals recycling in metallurgical industries in China was summarized, and the future development of waste processing and resource recycling was prospected.

Jan 1, 2011

By C. A. Pickles

Microwaves are being applied industrially in a number of fields and possess a number of potential advantages that could be applied in extractive metallurgy. Microwave heating has a number of unique characteristics, which distinguish it from the conventional heating methods. In microwave heating, the absorption of energy occurs at the molecular or atomic level and therefore the heat is generated within the material itself. In conventional heating, the exterior temperature is usually higher than the interior, but with microwave heating, the temperature gradient is inverted and thus the interior temperature can be much higher than that of the surface. The energy densities in microwave systems can be relatively high and this in combination with the low thermal conductivities of oxide ores, can lead to very high internal heating rates. In this research, the application of microwave energy for the reduction of a nickeliferous silicate laterite ore has been investigated. The real and imaginary permittivities are the two fundamental properties which determine the microwave absorption characteristics of a material and these were measured for the ore, both with and without carbon additions using the cavity perturbation technique. The microwave heating and reduction experiments were performed in a 0 to 2 kW CTC microwave system. The effects of power input, processing time, sample mass and charcoal additions on the microwave absorption were investigated. Then reduction experiments were performed and the nickel grade of the magnetic concentrate and the nickel recovery in the concentrate were determined.

Jan 1, 2005

By T. Banerjee, R. deS. Almeida, D. Gudgeon, F. C. F. Batista, L. deÁ. Silva

"Yamana Chapada’s mine is one of the larger copper-gold mines in Brazil. The mine is located in Goiás state, in the central part of Brazil. The mine has estimated Mineral Reserves of 4.1 million ounces of gold and 3.2 billion pounds of copper as of December 31, 2016. While gold and silver are significant, Chapada’s process flowsheet is configured closer to that of copper facilities. This includes a SAG/Ball configuration for grinding followed by flotation. In the case of Chapada, the mineralogy results in higher-than-normal complexity, notably a significant circulating load both in the grinding and flotation circuits. From an operating perspective, the complexities are controllable, but require careful attention to ensure that circulating loads are effectively managed and gold is not lost to tailings. Chapada created an automation roadmap in 2016 designed to increase plant performance (tonnage, recovery and efficiency). Based on strong potential, the project was fast tracked and within 4 months instruments were installed, control algorithms implemented, and training sessions took place to ensure sustainability at site. This paper will follow the Chapada journey from identifying the opportunities through to implementation and testing.IntroductionYamana Chapada mine is a Copper-Gold mine located in Goiás State, Brazil. Although the mine contains large quantities in Mineral Reserve of gold (4.1 million contained oz as of December 31, 2016), Chapada is primarily a copper mine with copper principally found as chalcopyrite. Accordingly, the processing flowsheet at Chapada is comparable to that of other copper mines with a SAG and Ball mill each partnered with a cyclopack, followed by a flotation circuit. While the overall design is conventional, the mineralogy at Chapada results in significant circulating loads both in the grinding and flotation circuits. This does introduce certain complexities for operating strategies and practices, but, importantly, favourable recoveries and elevated processing rates can be maintained, albeit they need to be closely managed. Plant automation helps in this regard."

Jan 1, 2018

By F. C. Lendrum

Introduction The property of Normetal Mining Corporation is in Desmeloizes township, Quebec, twelve miles north of Dupuy on the main line of the Canadian National railway from Quebec city co Cochrane, Ontario. The ore bodies occur within a band of highly sheared and sericitized agglomerate which strikes N.60°W. and clips 82° north. Along a zone 1,000 feet or more in length and of variable width, the agglomerate has been replaced by copper, zinc, and iron sulphides, with copper usually predominant on the hanging-wall side and pyrite replaced in part by sphalerite on the footwall. A northsouth diabase dyke cuts through the ore zone near its east end. The Normetal mill produces a copper concentrate and a zinc concentrate which are shipped, respectively, to Noranda, Que., and Newcastle, Penn., U.S.A., for further treatment. The present paper deals with the milling of ore from what is known as No. 3 orebody. This is a lenticular body of high-zinc ore lying co the east of the diabase dyke, along the line of strike of the main ore zone, which extends westward from the dyke. On its northern side, No. 3 orebody is in contact along most of its length with a narrow band of copper ore which is highly oxidized.

Jan 1, 1948

By A. Kapoor, L. Morin, S. Mortazavi, P. Béedard, Gould. W. D., A. Kuiper

The degradation of thiocyanate in a simulated gold mill effluent was studied using a laboratory scale rotating biological contactor (RBC). Complete SCN- removal was obtained at temperatures of 8 and 12°C, and a hydraulic retention time of approximately 3.3 h. The NH4+ produced by thiocyanate hydrolysis was oxidized by nitrifying bacteria to NO2 and NO3-. The HS- produced by thiocyanate hydrolysis was chemically and biologically oxidized to elemental S, which was subsequently biologically oxidized to sulfate. Incomplete sulfur oxidation occurred in the RBC, particularly at 8°C and elemental sulfur deposition was observed on the RBC disks. The RBC feed exhibited toxicity to rainbow trout but the RBC was effective in removing the acute toxicity of thiocyanate.

Jan 1, 2005

By Graham Davey

"Low speed stirred milling has been employed for many years in the metalliferous and industrial minerals industries. High speed stirred milling is a relatively new method of grinding in the metalliferous process industries. However it has been it has been in wide spread use in the industrial mineral field for over 30 years for various minerals. Many existing metallurgical operations are looking to maximize economic return from existing deposits, requiring new thinking and technologies. By combining low speed and high-speed milling fine and ultrafine grinding efficiency and operating costs can be improved.The correct selection of different fine grinding technologies is covered, when each mill is applicable and when a combination of the VERTIMILL® Grinding Mill and SMD provides the best economic solution.INTRODUCTIONUltra-fine grinding of minerals has been in wide spread use in the industrial mineral field for over 30 years. Within the last 10 years the metalliferous industry has shown interest in the ability to produce ultrafine particles, as chemical, physio-chemical and physical separation processes have advanced to be able to treat ultrafine metalliferous particles. Also as the primary mineral deposits, around the world are depleted, new more difficult deposits must be mined. Existing operations are also looking to maximize economic return from existing deposits, requiring new thinking and technologies.The traditional approach for gold containing refractory material has been to liberate the locked gold by chemically destroying the pyrite through oxidation. Roasting, pressure oxidation, and bacterial oxidation all employ various degrees of temperature, pressure and catalysis to react the pyrite with oxygen to produce iron oxide and sulfur by-products. However all of these methods are economically impacted due to specific operational added requirements and emissions controls. Pressure and bacterial oxidation have very high capital and operating costs."

Jan 1, 2006

By Bruce A. McFarlane

"I WOULD LIKE TO SAY how honoured I am that I have been invited to participate in this panel discussion. I have taken the liberty of narrowing my topic somewhat so that instead of speaking on the Sociology of Professions as a whole I will speak on one aspect of it, that is, on Manpower Problems in the Minerals industry of Canada, with some reference to a new social role for the professionals engaged in this industry. This probably means that I will be encroaching on areas covered or to be covered by other speakers, but I hope that when I do so I will do so from a slightly different vantage point. That is, from a sociological perspective rather than from a historical, industrial, business or professional perspective. I plan to divide my discussion into three areas, namely: (i) problems of ownership and control; (ii) environmental problems; and (iii) manpower and recruitment problems. I do not plan nor am I able to provide clear-cut solutions to the various problems I raise under these three headings. Rather, I hope that my discussion of the problems may form the basis for an extended discussion here and elsewhere. Because of the limitations of time, I will only briefly discuss the first two problem areas noted above – (i) ownership and control and (ii) environmental problems - and I plan to concentrate on the manpower issue."

Jan 1, 1972

By M. Bouchard, B. Cadieux et F. Goutier

Five phases of ice movement were r es pons ible f or glacial dispersion in t he study area. I ce fl ow directi on changed prog r es s ively from SE to SSW and then to the S. All observed glacial sed iments are associated with a south-southwest to south movement; t hey are grouped, on the basis of their texture, structure, morphology and composition, into four distinct lithofacies. A lithological study of the coarse-grained fraction (4-128 mm) of these lithofacies shows systematic compositional differences. These are: 1) variations in the proportions of local bed rock fragments; 2) variations in the horizontal displacement of the maximum abundance peak of a given lithology relative to its source area, and 3) variations in the length of dispersion trains associated with each lithofacies. Although dispersal trains can obviously be mapped without differentiating li thofacies, studies based on the consideration of lithofacies should give more reliable results than conventional methods.

Jan 1, 1984

By H. J. McQueen

Large-scale industrial production of pipe began with longitudinal hot pressure welding of wrought iron by passage of skelp (narrow strip with beveled edges) through a die or bell that curled it about a longitudinal axis until the edges were forced together. Such small to medium tubes could be reduced by rolling or drawing; with threaded connections, they were excellent for distribution of clean water and of illuminating gas for street, home and industrial lighting. Although steel lacks the fluxing slag for pressure welding it has hot strength similar to iron; hot-pressure bell welding was advantageously transferred to steel in long coiled strip with 50% higher cold strength. For pipe without weld-line defects, hot cupping followed by Pilger mill rolling produced tubing that revolutionized bicycle quality and high-pressure service for boilers and chemical processing. Mannesman hot rotary piercing produced long thick walled tube that permitted reduction or expansion by rolling to provide pipe sections up to 60 cm diameter and 12 m long. During 1910 - 1940, oil and gas pipeline technologies, notably welding evolved markedly as they proliferated in the United States, in response to far-flung petroleum fields, expanding industry consumption and the automobile revolution. In the Second World War combat pipelines were laid rapidly, such as: the Canol line through the Yukon to Alaska, and fuel supply lines across the channel and through liberated France. Perfection of welding techniques for both longitudinal and spiral weld large diameter pipe in combination with controlled-rolling of micro-alloyed steels made possible reliable Arctic pipelines. The development of pipe production and utilization in Canada is recounted. The fabrication techniques and metallurgical controls are explained.

Jan 1, 2005

By J. J. McDougall

Until quite recently, the coal in the Cape Breton field was won from comparatively thick seams with light cover, and from submarine areas, and the system of mining naturally followed was pillar-and-stall. This sytem permitted of cheap extraction, and enabled production from localities where other methods could not be employed to good advantage. Thus the pillar-and-stall system, applied to conditions as stated, justified its adoption. Our working seams today, however, are practically all under heavy cover, or are moving in that direction, and with this gradual increase in cover came the increased cost of roadway maintenance. At Princess colliery, the system of pillar-and-stall was followed until roof and bottom conditions became such that further operations were unprofitable, and the longwall method was then adopted as an economic necessity. This fact should be borne in mind when operating costs of both systems are being compared. The longwall method is not held as a cure for all difficulties of heavy cover, but through it these difficulties can be overcome with less expense than by pillar-and-stall. The longwall system of mining, strictly speaking, is one by which a seam of coal is totally extracted in one operation. There are, however, many modifications of longwall, and in some cases it is difficult to determine whether certain practices should be classed as longwall or pillar-and-stall, or a combination of both.

Jan 1, 1928

By E. J. Wasp, T. L. Thompson, T. C. Aude

The paper will deal with some of the more important technical aspects of slurry pipelines as they apply to the mineral field. In addition, the use of these technical concepts in arriving at realistic economic figures will be discussed.

Jan 1, 1970

By A. Klingberg, M. Svensson, N. Smolko Schwarzmayr

"Removal of silicates and carbonates from sedimentary phosphate ores by the use of new synthetic collector/formulations was investigated in a comparative study with traditionally used collector systems as references. In the direct carbonate flotation the new formulations showed higher efficiency, contributed to an improved balance of P2O5 recovery and P2O5 enrichment in the recovered material. Efficiency of the new formulations containing synthetic surfactants was 1.5–2 times better than potassium salt of fatty acid sulfonate based formulations that are traditionally used for that purpose. The new formulations also provided up to 7% increase in P2O5 recovery at the same P2O5 grade. The new synthetic collectors for removal of silicates showed extremely good selectivity towards silica bearing minerals. The selectivity factor for the flotation tests when new formulations were used was 32–52 and for the flotation tests with the traditional collectors: 20–32. The ratio between distribution of an amount of silicates (as SiO2) and distribution of phosphate in the froth (waste) is defined as the selectivity factor. The new formulations provided more than 2% decrease of the amount of SiO2 at the same P2O5 recovery.INTRODUCTIONPopulation growth and decrease of arable land are the main reasons for constant increase of consumption of apatite (phosphate ore) in the fertilization field (Lannefors, Gorochovceva, Klingberg, Lima, & Gustafsson, 2015). Fertilizers play a key role for farmers to produce more with less land. The phosphate component of the fertilizer is vital for producing healthy and large amount of crop. As a result the demand for phosphate rock is growing.The largest producers of phosphate rock are the Unites States, Morocco, Tunisia, China, Russia, and Brazil. The term “phosphate ore” includes all phosphate-bearing minerals and rocks, but only two of them are of industrial interest: apatite (igneous origin) and sedimentary phosphate (Peres, Araujo, El-Shall, Zhang, & Abdel-Khalek, 2007). The majority of the world’s phosphate deposits are of the sedimentary type. There are two different types of sedimentary phosphates: siliceous and carbonaceous which are categorized based on gangue minerals (such as quartz, carbonates, mica, and clay)."

Jan 1, 2016

By N. Tounsi

The use of analytical modeling of continuous chip formation in conjunction with orthogonal cutting experiments was presented in the open literature to identify the coefficients of material constitutive equation within the practical range of stress, strain, strain rate, and temperature encountered in metal cutting. Identification of reliable constitutive data was hampered by a lack of a reliable model for the prediction of the primary shear zone thickness that affects directly the effective strain rate field. An original analytical model to determine the primary shear zone thickness is proposed in this paper. It is based on the mechanics governing the material flow in the primary shear zone. Based on the distribution of the hydrostatic pressure and the forces measured from orthogonal cutting tests, the model that describes the thickness of the primary shear zone is derived. To validate the model, FE simulations of chip formation using DEFORM3D were carried out for different materials and cutting conditions. The results of the analytical model are in reasonable agreement with FEM results.

Jan 1, 2006

By S. Beskri, N. Geoffroy

When metallurgical plants are designed, a lot of consideration is almost always given to material selection and possible damage mechanisms. Materials engineers are generally involved and will strive to select optimal alloys or refractories for the design conditions. Once in operation however, things often change. Equipment is overstressed to increase production, corrosive leaks are not always promptly addressed, proper welding procedures are disregarded, etc. This paper describes various cases from the mining and metals industry where serious mishaps, associated consequences, and costs could have been avoided if simple and proactive steps had been taken. It also presents a strategy, based on safety reviews, to help predict and prevent damage to critical pieces of equipment.

Jan 1, 2015

By B. K. Gorain

"The Air-Metabisulfite (AMBS) process has been developed to treat complex copper, molybdenum and precious metals (gold, silver) bearing ores using brackish and sea water. This process was able to produce significantly better copper concentrate grades and higher recovery than possible using conventional lime and/or cyanide based processes for certain complex ores with high sulphide gangue minerals. The AMBS technology in now used commercially following a rigorous evaluation process emanating from laboratory curiosity to plant applications. In addition, many projects have embraced this technology at a feasibility level involving various complex ore bodies.This paper presents a summary of the findings from testing the AMBS technology on various ores types. Experiences gained from this successful development from bench to piloting and then to plant applications are also presented in this paper.INTRODUCTIONProcessing of sulphide copper, molybdenum and precious metal ores typically involves flotation of copper bearing minerals while depressing non-sulphide and other non-copper sulphide minerals such as pyrite, pyrrhotite and sometimes arsenopyrite. Though in many precious metal ores, the values are in these sulphide minerals as well. The conventional method employed in the industry to produce a saleable copper concentrate requires depression of these non-copper sulphide minerals using an alkaline pH above 9.5, though 10.5 to 11.5 is more common. Alkalinity is controlled by the addition of a pH modifier. Lime is normally employed as a pH modifier due to its relatively low cost; however, the costs associated with adding lime can be significant and the effectiveness of lime as a depressant could be drastically reduced when the process water supplied to the flotation circuit contains high level of dissolved salts. In some cases, a small amount of cyanide is used along with lime to depress non-copper sulphide minerals especially when its proportion to copper sulphide minerals in the ore is higher than three."

Jan 1, 2016

By Terry Braden

"Meeting probable world mineral demand in the years ahead will almost certainly require an ability to economically treat lower grade and more complex ores. Achieving this will require extensive research and technical development across the full spectrum of mineral processing.For mid-sized or smaller companies the most effective way to participate in such extensive programs - and gain access to the technology required to stay competitive - may be through collaborative research.This paper explores the recent history of collaborative research in mineral processing and in particular its ability to attract world-class multi-institutional research teams with sufficient resources to make step-change advances. It chronicles the advances achieved, but also explores the research architecture and administrative structures required to deliver research outcomes and technology transfer mechanisms to a range of often disparate sponsoring companies.INTRODUCTIONIn medieval times the dream of alchemists was to turn base metals into gold. We modern alchemists, of course, don’t waste our time on that sort of foolishness: we turn base metals into dollars. When I see the profit reports filed by some companies recently, I can only conclude that a lot of those present today must be pretty good at this.But the fact that we are here at this conference reminds us that an alchemist’s work is never done; turning base metals into dollars is not a one-trick wonder but an art that we must extensively refine year after year if we are to survive in a competitive marketplace.It is not that demand for metals is likely to slow; most people seem to think that China, India, Brazil and other emerging economies are still at the lower end of their demand curve. They will need significantly larger volumes of metals in the years ahead. The challenge for us as processors is that to supply increasing tonnages of those metals profitably we will almost certainly need to process more complex or lower grade ores and probably to do so with reduced energy inputs."

Jan 1, 2009

By Chi Zhang, Junyi Wu

"The use of permanent stainless steel cathodes for electrorefining and electrowinning of cathode copper had been introduced to the market long time ago and now is a well-accepted technology worldwide. During the last decades, the Chinese copper refinery industry had been growing rapidly and many large scaled production plants had been built. In the modern refineries, permanent stainless steel cathodes are introduced and used instead of traditional starter sheets. The most common steel grade used is austenitic stainless steel S31603 (316L/1.4404), while both S30403 (304L/1.4404) and N08904 (904L/1.4539) have been used depending on the actual working conditions, especially with regarding corrosion environment. While 316L permanent cathode functions well in many plants, different kind of problems, such corrosion and deformation, have been reported. There is therefore an increased need for more suitable material. New stainless steels, such as duplex stainless steels, with better properties have been tried and introduced into the application of permanent stainless steel cathode with satisfied results. The article introduces first the Chinese copper refinery industry and properties of duplex stainless steel in general, and then describes the development of using permanent duplex stainless steel cathode, including the actual working conditions, production of cathode sheets as well as the experiences of application in details. After more than one year’s usage, the advantages of permanent duplex stainless steel cathodes are clear seen.INTRODUCTIONChina has become a major player in the international copper market, accounting for around 40 percent of global refined copper demand. Despite the slowdown of the Chinese economy, the consumption of copper products will still increase, but with a medium and/or low growth which will be the new situation for the coming years. The average growth rate is expected to be around 5 percent per annual. In the coming Five-Year plan for National Economic and Social Development a number of initiatives will be finalized which will require massive amounts of copper. In 2015, the expected consumption of copper products will be over 9 million metric tons. The main driver of the consumption is the electric power industry which accounts nearly the half of the total consumption; followed by cooling application with 15% and transportation with nearly 10%, see figure 1."

Jan 1, 2016

By W. A. Haley

This paper discusses how a large wheel loader should be equipped, with particular attention paid to tires and tread life, and describes the several steps that can be taken to provide favorable working conditions and reduce over-all costs. A comparison is then made of wheel loader production and costs vs those of power shovels, and the present and possible future applications of the wheel loader are outlined.

Jan 1, 1969

By Vic Briccardi

Energy Management Challenges The Holistic Standard to Energy Management Energy Management Information System (EMIS) "Best Practices?: Energy Management Maturity Curve De Beers Canada Profile & Mine Locations Significant ROI Driven by Real-Time Energy Visibility Mining Energy KPI?s Summary: What Does EMIS Deliver? Q&A Session

May 1, 2013