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By J. W. Thomson, H. J. Lloyd, R. J. Taylor

"THE HOLLINGER MINE has been producing gold and by-product silver almost continuously for forty-eight years. The value of current production is $10,000,000 annually from one million tons of ore. Its management •has, particularly over the past decade, increasingly . concerned itself with the problem of profitable operation in a time of steadily rising costs and a fixed price of gold. At one period in the life of the mine, before World War II, production resulted in yearly profit margins that were stable and relatively thick. In winning gold from a series of inconsistent vertical ore lenses, operating management was much better protected than it is today against a general rise in cost or dip in grade of ore. The tissue-like thinness of present-day margins demand more careful handling. A sharp rise in costs, if protracted, could easily rip the tissue to shreds and close down the business. The counter-measure of raising grade and gutting the mine would bring on the end perhaps more rapidly, without having contributed much to the recovery of our national re-sources, nor to community welfare. The alternative is to keep costs under control."

Jan 1, 1960

By Krishna Parameswaran

In this paper, we attempt to answer an often asked question, how can metal mining be compatible with the principles of sustainable development. Starting with the classic Brundtland Commission definition of sustainable development as "development that meets the needs of the present without compromising the ability of future generations to meet their own needs," we make the case that mining is or should be sustainable, using examples of sustainable practices at ASARCO LLC, an integrated U.S primary copper producer. These examples cover the entire mining cycle starting with exploration, mining, beneficiation, smelting, refining, closure and post-closure and post-mining land use. It is hoped that the presentation will challenge the mining industry to even greater innovation as future mineral development projects are planned.

Jan 1, 2015

By H. J. McQueen

Mineral and energy resource consumption were continuously reduced by process improvements as chemical understanding was developed and applied. During the past two centuries, technological improvements increased human productivity that was accompanied by social advances and labour saving products; however, these sometimes proliferated to endanger sustainability, e.g., automobiles. In the steel industry, precisely controlled rolling of HSLA steels required little extra mineral consumption but reduced weight and heat-treating energy. Continuous casting of slabs reduced scrap compared to ingots and energy for the homogenizing soaking pit. Al alloy extrusions were improved by retaining the strengthening in the near-surface substructure, of high strength textures and of press quenching that is suitable for direct age hardening. Continuous bar casting of Al-0.65Fe, coupled with rod rolling and followed by wire drawing with only a final recovery anneal, yielded electrical wiring for households to replace less plentiful Cu and later for light-weighting use in autos and aircraft Looking backwards, the 1970 decade saw the first oil crisis and inspired Ottawa to undertake a campaign to develop an energy strategy that would decrease dependence on imported fuels. One significant undertaking under Energy Mines and Resources was the organization of industrial energy conservation, managed by each industry association,that collected detailed current statistics and set the goals for a 2-year campaign. The metal producing industries, as compared by E.C.N. Perryman to about 7.2 exajoules (EJ) for the nation, consumed about 0.8 EJ, being about one third of all heavy industries. While manufacturing consumed 30.2% of total energy, it created 87.3% of total national dollar value. Within the industrial envelope, smelting and refining utilized 28% (0.67 EJ, mining beneficiation 6.7%, 0.16 EJ); there was a significant contribution to exports: 80% of iron ore and 70% of aluminium in 1973. A general concern was that decreases in ore grade would lead to a rise in energy expenditures countering benefits from processing efficiency.

Jan 1, 2012

By G. V. Sirianni, G. E. Viens, R. A. Campbell, G. N. Banks

A combination shaft-electric furnace for the smelting of ores and the melting of metallized feed is being developed at the Mines Branch. When iron oxide pellets are smelted in this unit, they are preheated and partially reduced in the shaft before being transferred to the electric furnace where smelting is completed. Also, limestone flux added with the pellets is-preheated and calcined in the shaft. It has been demonstrated that, in smelting iron oxide in this unit, the throughput of the 250-kva electric furnace can be approximately doubled and the amount of electrical energy required can be very significantly reduced when the shaft furnace is operated in conjunction with the electric furnace. These benefits are achieved mainly by utilizing the sensible heat and latent energy contained in the arc furnace off-gases.

Jan 1, 1971

By G. E. Norman, A. L. Mckague

"The new smelting process commenced operation in 1978. The pelletizing and sinter plants were replaced with slurry-fed roasters and the blast furnaces with electric furnaces. The existing converter aisle and matte handling facilities remained unchanged.Process DescriptionNickel-copper concentrate is partially roasted in two slurry-fed fluid bed roasters. After gas cleaning, the sulphur dioxide gas is transferred to the acid plant. The roaster product is conveyed to two electric furnaces for smelting to produce a waste slag and furnace matte. The slag goes to the disposal area and furnace matte containing the metal values is processed in the converters for further removal of iron and sulphur.The final matte containing about 75 per cent metal values is shipped to the refinery in Norway.The commercial smelter was designed for 2135 tonnes per day of concentrate, with an availability of 85% . Roasters and electric furnaces were sized at 117 per cent of design, or 1250 tonnes per day on each of two lines. Concentrate storage capacity in the plant is sufficient for two to three days' plant operation.The new smelting process will be discussed under the following headings:Concentrate Slurry HandlingFeed PreparationRoaster OperationRoaster Gas CleaningCalcine TransferElectric Furnace Operation and Process Control Converting and Matte HandlingUnder these headings, process control , equipment changes, and plant performance after three years' operation is reviewed. A brief discussion of accident prevention , and working environment is also included ."

Jan 1, 1984

By A. Tohn, L. May, Adham. K.

The path from process conception to commercial implementation poses significant technical, economic, and sometimes political challenges for every project team. Solving the technical challenges typically distinguishes successful projects from those that fail. Here, the authors provide an outline for technical success based on lessons learned from years of experience in process design and R&D. Challenges faced by new technology developers, with regard to design and definition, are described. Experience-based methods to avoid missteps are shared. Special emphasis is placed on the selection of viable unit operations, definition of known and unknown parameters, experimental screening of options, and piloting for scalable design information. Use of computational models to define, assist, and interpret the pilot operations and results are described. Furthermore, the value of active collaboration amongst the design, research, and owner team is demonstrated.

Jan 1, 2011

By D. S. Hines

The purchase of mechanical equipment for mines is not unlike the purchase of other materials or supplies in general principle, but on account of the major part such equipment plays in the operations, and of the fact that life and valuable property are at stake, the matter demands the most careful attention on the part of the purchaser. The problems and difficulties encountered are dealt with below in their sequence in the purchasing procedure. Requisiting Although it is quite a common practice to submit a tentative specification of requirements to recognized manufacturers of equipment- soliciting alternative propositions or recommendations for study in the selection of certain equipment-as a rule the first step in purchasing procedure is the requisition. Primarily, it is the form that carries to the purchasing department the record of equipment wanted. A full and complete description or specification, and accuracy of record, are the important points to be insisted on in a requisition. Too much attention cannot be given to this detail, as this is one of 'the most important phases of purchasing work. Incomplete information, either in specification or detail, leads to delay in handling the requisition, and, if not detected in the purchasing department, may mean receipt of material which cannot be used for the purpose intended. In addition to description of material or equipment to be ordered, the requisition should also show where or what the equipment is for, whether for operating or new work. If for capital account, the number of the authority for expenditure should be given for record and distribution purposes.

Jan 1, 1930

By James B. Templeton

"IntroductionWith the steady rise of the cost of coal and freight, the time is now ripe for an investigation into the feasibility of using the heat pump for heating purposes in fairly remote industrial areas.The gold mines of northern Ontario seemed to be a most likely place for the application of the heat pump.It was decided that the first step in the investigation would be to determine what economic advantage was to be gained by using the heat pump and thereby determining whether a further and more detailed research programme was warranted.If we can use the heat pump with economic advantage, we can reduce our mining costs and make a worthwhile contribution to our national economy by reducing the import of U. S. coal.The investigation was conducted under the auspices of the Nipissing Fellowship and directed by Professor R. E. Barrett of the Department of Mining Engineering, University of Toronto.With the able guidance of Mr. C. S. Gibson, of the Mines Accident Prevention Association of Ontario, the author visited the following mines: Mcintyre-Porcupine, Delnite, Dome, Lake Shore, Wright-Hargreaves, Kirkland Lake, Macassa, and Kerr Adcliso11.In all cases, the management and technical personnel of these mines were most co-operative and helpful in supplying information and ideas.It should be emphasized at the outset that the design and operation of the heat pump itself is by no means complicated or even new. The reason we hear so much about it today is because there have been improvements in compressors, motors, and heat exchangers in the past few years, and because fuel and freight rates have risen to such a point that, in some cases, the heat pump now has an economic advantage over other methods of heating."

Jan 1, 1950

By B. van Beek, T. Goff, P. Gebski, P. Szyplinski, W. L. Ying

"Monitoring the refractory lining integrity is essential to assure the safety of the operators and to determine the remaining campaign life of a furnace. Early detection of refractory lining degradation is essential to avoid sudden furnace failures and prevent unscheduled shutdowns. In the mid-1990s a stress wave propagation technique was developed and since then it has been utilized by Hatch Non-Destructive Testing (NDT) Group to evaluate furnace linings. For the last 17 years the AU-E technique evolved in terms of hardware, software and signal acquisition and interpretation. Most importantly, based on more than a decade of commercial applications, an extensive database of various failure modes, refractory deterioration trends and material properties has been created. This knowledge base is an integral part of AU-E which progressed from a NDT technique towards a comprehensive approach for furnace condition monitoring. All of the improvements introduced over the last several years have greatly improved the accuracy of the measurements. The data analysis process has also become more time efficient making the critical results available to the furnace operators in a more timely manner. Today the AU-E technology is used on a variety of process vessels in non-ferrous, glass, chemical and iron and steel industries.In this paper we are reviewing the available techniques for furnace refractory lining measurement and discussing the pros and cons of each method. The need for continuous improvement and development of new techniques for refractory monitoring is also emphasized. Finally, we are presenting a number of case studies and comparisons between the physical verifications and the AU-E measurements."

Jan 1, 2015

By C. I. Garcia, G. Zhou, W. Gao, A. J. DeArdo

The development of X-100 and X-120 linepipe steels was investigated using a series of low-carbon Mo-Nb-B steels. The laboratory steels were vacuum melted and processed using advanced thermomechanical processing (TMP) philosophies. Prior to the laboratory hot-rolling experiments, the grain coarsening temperature, the conventional T95 and T5 start-stop recrystallization temperatures and the transformation behavior of y were studied using a computer-controlled high temperature deformation MTS-458 and a Theta-IV High Speed dilatometer systems. The results from these experiments provided the guidelines for the design of the laboratory hot-rolling TMP processing experiments. The mechanical properties of the experimental steels showed yield strengths in the range 700-850 MPa and CVN impact properties of over 80 J at -20°C. The best balance of mechanical properties was obtained by using CCR+DQ+Tempering treatments. The major microstructural features responsible for the observed mechanical properties in order of importance were: a) substructural refinement associated with lower bainite, b) dislocation strengthening, c) fine recrystallized ferrite, and d) small amounts of retained austenite. Fine Nb(C,N) precipitates formed in ferrite were observed, however their contribution to the strength was minimum. Most of the Nb(C,N) precipitation took place in austenite. This precipitation was used to exert microstructural control of austenite during hot rolling. The physical metallurgy and optimum TMP to achieve the mechanical properties are detailed in this paper.

Jan 1, 2005

By William James Kempson

This paper discusses ore handling systems in shafts. These are considered from the loading facility at shaft bottom all the way through to the discharge mechanism in the headframe. These systems will be discussed from the following perspective: i. Intrinsic safety of the systems ii. The efficacy of the systems to perform consistently iii. The maintainability of the systems iv. Overall system cycle times Particular emphasis is placed on the following specific areas: 1. The Shaft Bottom Loading Facilities The various shaft loading systems currently in use are discussed, the selection parameters surrounding these are quantified and the specific selection criteria are outlined. 2. The Various Skip Configurations In this section the various skip configurations in use around the world will be described and the specific design details associated with these will be highlighted. The advantages and disadvantages of these systems will be compared and the overall efficacy of these will be discussed. 3. The effect of the loading and skip configurations on the Load Cycle Times. The overall cycle time which can be achieved by a shaft system is strongly dependant by the speed and efficiency with which the ore can be loaded and transported out of the mine. The potential of the various systems to be optimized will be discussed. The emphasis of this paper is to highlight the lessons which have been learned with respect to ore transport system design and provide a common basis against which these can be compared in future applications.

May 1, 2013

By D. L. Morgan, J. A. Butterfield

"Geological data, production trends and current projects underway suggest that enough molybdenum will be available from more diversified sources to meet the world's growing demands. The growth in molybdenum consumption has been primarily related to its beneficial effects as an alloying agent in steel. This rapid growth has been deliberately fostered by stable prices, adequate supply and application research. The molybdenum industry is now in a process of change which has been seen in several other metals, such as aluminum and nickel. As supply sources have become more diversified, the market has become more competitive. The recent drop in consumption has led to excess production capacity, accumulation of substantial producer inventories and increased market uncertainties. While consumption is expected to increase in the next two to three years, it will take some time to absorb the excess capacity and inventory. The increased proportion of by-product capacity indicates that prices may become more variable. Producer discipline will be required to prevent serious price erosion in times of surplus. Future prices may not continue to increase with inflation. For the longer term, several factors favour the increased consumption of molybdenum. Engineering requirements are becoming more severe and molybdenum alloys can help to meet these changing needs. In addition, consumers can rely on a large and increasing supply of molybdenum. A 7 per cent growth rate in consumption can probably be sustained through the next decade, but new applications and reasonably stable prices will be needed to make this possible."

Jan 1, 1972

By D. Maddocks

"IntroductionThe greater part of the iron ore industry in Canada is located along the Labrador-Quebec border on a geological formation known as the Labrador trough. The Labrador trough is a 700 · mile long geosynclinal segment composed of folded and faulted Proterozoic sediments, volcanics and intrusives, extending from Gagnon, Quebec, to the north west tip of Ungava Bay. This geosyncline can be divided into three parts (Fig. 1).The northern unmined part, extending from southern to northern Ungava Bay, is a low grade metamorphosed iron formation.The iron deposits of the central region, represented by Schefferville, are hematite-limonite ores formed by oxidation and leaching of an unmetamorphosed taconite formation. Average iron content of the ore is greater than 540Jo for direct shipping and 50% for plant feed.The deposits of the southern section (Carol Lake, Wabush, Mt. Wright, Gagnon) extend from just north of Carol Lake to Gagnon and is a metamorphosed silica-iron oxide (specular hematite and magnetite) formation averaging plus 30% iron.The mineral wealth of this area was first observed by Father Louis Babel about 1870 and again by Dr. A.P. Low of the Geological Survey of Canada in 1894. However, the remote location hindered development until after 1945. First production of direct shipping ore from Schefferville was in 1954. Production at Carol Lake commenced in 1962.This area now accounts for sixty million long tons (61 Mt) per year of processed iron ore products as follows:This chapter will concentrate on pelletizing and agglomeration as experienced at the Iron Ore Company's Carol Lake operation. However, whenever possible, reference will be made to alternate methods, procedures, equipment, etc."

Jan 1, 1989

By P. Babak, E. Insalaco, O. Babak, P. Henriquel

"Detection of outliers is an important primary step in geomodelling. Geological datasets often contain errors due to problems such as measurement device limitations and recording glitches. In this paper, a robust Mahalanobis distance–based approach is successfully applied to particle size distributions of the Joslyn lease, an oil sands development site near Fort McMurray, Alberta, Canada. Automatic outlier detection and geological review were combined. Outliers from the Mahalanobis distance approach were compared with their respective core photographs to determine if laboratory measurements and facies classification were correct. A checking procedure for laboratory technicians is proposed.RÉSUMÉ La détection des valeurs aberrantes constitue une étape primaire importante de la modélisation géologique. Les ensembles de données géologiques contiennent souvent des erreurs en raison de problèmes tels que les limitations des instruments de mesure et des pépins d’enregistrement. Dans le présent article, une méthode robuste basée sur la distance de Mahalanobis a été mise en oeuvre avec succès aux granulométries du bail minier Joslyn, un site de sables bitumineux en développement à proximité de Fort McMurray, Alberta, Canada. La détection automatique des valeurs aberrantes a été combinée à une étude géologique. Les valeurs aberrantes de la méthode de la distance de Manalanobis ont été comparées avec leurs photographies respectives de carottes de forage afin de déterminer si les mesures en laboratoire et la classification des faciès étaient correctes. Une procédure de vérification pour les techniciens de laboratoire est proposée."

Jan 1, 2015

"Ore deposits containing rare earth elements normally contain small amounts of the radioactive elements thorium (Th) and/or uranium (U). These are the naturally-occurring isotopes U238, U235, and Th232 (and associated decay-series daughter products) that are ubiquitous in nature, and that contribute a small percentage of the natural background radiation exposure encountered by humans. The presence of these radioactive materials in the ore deposit creates potential hazards to human health and the environment that must be dealt with properly in the mining, processing, and refining of the ores, as well as management of waste streams and residues. This paper presents an overview of the environmental and safety issues associated with U and Th, with particular emphasis on rare earth mining, processing, and refining projects; the regulatory approaches followed to ensure that rare earth deposits are developed, operated, closed, and decommissioned safely; and the development of information during the project predevelopment work and permitting processes that feed into the design, operation, and closure of tailings impoundments and milling/separation/refining facilities. Case studies will be presented subject to the availability of relevant public information. INTRODUCTIONNearly all ore deposits containing economically-recoverable rare earth minerals also contain small amounts of the radioactive isotopes for the elements thorium (Th) and/or uranium (U) and their associated radioactive decay products. Therefore, the handling and management of these materials in mining and mineral processing operations must be performed so that workers and the environment are protected from harm from Th and/or U (and their radioactive decay products), just as they must be protected from any other potentially harmful constituents present in the ore or introduced in processing. Examples of these might include ores with high sulfide content, which may pose a risk of acid rock drainage, or chemicals used in ore processing and metals production.The purpose of this paper is to present information on how rare earth mining and processing projects with ores containing Th and/or U can be developed, operated, and decommissioned safely according to applicable regulations intended to protect worker health & safety and the environment.It should be noted that some countries are considering developing Th as a feedstock for producing nuclear energy, which could have some effect on future development of rare earth ore deposits. To avoid confusion, that issue is not discussed in this paper."

Jan 1, 2012

The Curtin University Gold Technology Group has been involved in surveying, modelling and optimisation of batch centrifugal concentrator type gravity circuits and CIP/CIL circuits for nearly two decades. The most commonly asked question regarding gravity recovery is, “What is the benefit of a gravity circuit”, which can be hard, if not impossible, to quantify. With the help of the AMIRA P420 Project’s Integrated Liberation Leach Model (ILLM) it is now possible to evaluate the effect of gravity recovery on total gold recovery when changes are made to the grind size, gravity and/or leach/adsorption circuits. This paper demonstrates how the ILLM can be used to determine the net benefit of introducing or modifying a gravity circuit and assess the effect of operating conditions (grind size, coarse gold size distribution, leach residence time, carbon activity, etc.) on plant performance.

Jan 1, 2017

Some examples of the results of research projects, conducted in the KOMAG Institute of Mining Technology are presented. Special attention is paid to mining machines and equipment, and improving work safety and comfort of miners in underground workings. From numerous scientific and technical achievements of the KOMAG Institute within the last 2 years, a few design solutions have been selected for a presentation. Some results of European projects on innovative solutions are described as well, highlighting KOMAG?s role in the national and international research area.

Aug 1, 2013

By Leslie S. Weldon

THE Lake Shore mine has been developed by two vertical shafts, with level intervals at 200 feet to the 2200 level and at 125 feet below this horizon. A main cross-cut joins the two shafts on all levels to the bottom of No. 3 shaft, and opening into these cross-cuts are the ore passes and sand passes, which are completed from surface To the 4450 level. In the west part of the mine, additional connections have been made between No. 1 and No. 2 veins, through which the major part of the ore from No. 2 vein west is routed to drifts in No. 1 vein. With the lesser amount of stoping on No. 1 vein, this arrangement permits better haulage to be maintained. The ore passes are driven at 50 degrees from the ends of short cross-cuts off the main ones and are broken through to the levels above at the mouths of the short cross-cuts, to allow for dumping on each level. The passes are controlled at each level by ball-and-chain gates and deliver to crushers and thence to loading pockets, shown in Figure 1. That system is quite flexible in that it is possible to by-pass the crushers at any station and load from either shaft at a number of different pockets. The sand passes are driven from the main cross-cuts at the same inclination as, and parallel to, the ore passes. Each is equipped with a chute and dump hole, so that waste or sand fill may be loaded or dumped at each level. A transfer door, hinged on the bottom, is installed opposite the chute for by-passing fill from one level to the next, and in the closed position protects the opening at the top of the pass. The dump hole situated beside the transfer door is protected by a grizzly with 10-inch spaces. Waste rock may be withdrawn from the system through No. 3 shaft loading pocket at the 2950 level to a waste bin on surface. Levels are developed by drifts in No. 1 and No. 2 veins for their entire lengths. Subsidiary breaks are followed at a later date, when full information has been obtained by exploration, and a considerable amount of development by sub-drifts is carried out in the upper part of the mine, particularly in more or less erratic sections of No. 1 vein.

Jan 1, 1936

By W. L. Ott, J. E. Hawley, C. L. Lewis

"IntroductionTHE APPLICATION of spectrochemical analysis to metals of the platinum group was advocated by Harvey (3) as follows: ""The spectra of the platinum group metals have been studied less than many of the more common metals. The rarity of occurrence of these elements makes the analysis relatively unusual. Potentially, the analysis of this group is an excellent application of spectrographic methods, particularly in contrast to the tedious chemical procedure"".Wichers (8) divides platinum-metal analysis into three broad divisions as follows :( 1) The detection and estimation of these metals in other materials, e.g., ores, where the amounts present are very small.(2) The detection and estimation of impurities in the refined metals themselves ....(3) The analysis of alloys of the platinum metals .....The present paper deals with the second division: analysis of refined rhodium.Research on spectrochemical techniques for determination of trace contaminants in refined platinum metals was begun at Queen's University in 1949, under the supervision of Professor J. E. Hawley. Since 1953, the work has been continued in the Metallurgical Laboratories of Falconbridge Nickel Mines, Limited. Techniques for spectrochemical analysis of refined platinum and palladium have been published ( 4, 5). A technique for analysis of refined iridium has been developed but not yet published."

Jan 1, 1955

By D. G. Klaren, E. F. de Boer

Self-cleaning fluidized bed heat exchangers have demonstrated unparalleled performance internationally for the implementation of indirect heat transfer in severely fouling fluid environments. The ingenious configuration of recirculated cleaning particles through the tubes of vertical shell and tube heat exchangers provides the ability to solve any problems that arise as a consequence of tube-side fouling during indirect heat transfer to process fluids or slurries. In most cases, the cleaning particles consist of chopped metal wire, however other process-specific materials have been used. In addition to the mitigation of fouling effects, a number of other significant benefits for slurry heating are afforded by the mode of operation of the self-cleaning fluidized bed heat exchangers. Increased turbulence at the slurry/tube interface is imparted by the action of the fluidised particles, resulting in very high heat transfers at relatively low liquid velocities. Furthermore, given the thixotropic nature of most process slurries, the action of the fluidised particles imparts additional shear to the process slurry, resulting in shear thinning effects with a consequent reduction in pressure drop and enhancement of heat transfer across the heat exchanger. The benefits provided by the self-cleaning fluidized bed heat exchanger make it the ideal option for the indirect heating of laterite nickel slurry for High-Pressure-Acid-Leach (HPAL) plants. This article explains the principle and application of the self-cleaning fluidized bed heat exchanger technology for the processing of laterite nickel and cobalt slurries in HPAL plants. It also presents an elegant method to revamp existing direct heated laterite nickel and cobalt processing plants into an indirect heated configuration employing self-cleaning fluidized bed heat exchangers.

Jan 1, 2004