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By S. Nikolic

"Calcium ferrite slags are currently used in a number of copper-converting processes. Despite the industrial importance of this system the phase equilibria have not been fully investigated. Characterization of this slag system is necessary to improve the control of process parameters, including fluxing and operating temperatures. Recently, a modified experimental method has been developed; this involves rapid quenching of slag samples equilibrated at high temperatures with the resulting phase assemblages analysed using electron probe microanalysis (EPMA). In the present study, experiments were completed under controlled temperatures and oxygen partial pressures using CO/C02 or H2/C02 gas mixtures. The investigated slags were supported during equilibration by a substrate of the primary phase. This technique removes the limitations arising from the use of crucibles and facilitates rapid quenching of the melt. Experiments were carried out at 1200°C and 1250°C (1473 Kand 1523 K) and in the composition range 0-40 wt.% Cu20, 0-25 wt. % CaO and 45-80 wt. % Fe203. Liquidus and solidus data are reported for the primary phase field of spinel between the oxygen partial pressures of 10-4.5 to 1 o- 6-5 atm. The analyzed compositions of liquids and solids are used to construct the phase diagram of ""Cu20"" -CaO-""F ez03"" system in equilibrium with metallic copper at fixed oxygen partial pressures."

Jan 1, 2007

By Youngjib Ham

Understanding energy performance of existing buildings is vital to increasing their efficiency and reducing the overall energy consumptions. This entails facility managers to systematically monitor building energy performance and reliably identify and analyze potential problems. Currently, infrared thermography is widely used as a primary diagnostic tool for the detection of building performance problems. Nonetheless, applications of thermal images for building inspection are mainly restricted to manual and labor-intensive identification and qualitative assessment of heating or cooling loss. Automated identification of potential problems and reliable cost analysis of the associated energy loss can help homeowners to minimize financial risk of retrofits and maximize energy savings. To that end, this paper presents a new automated method for calculating the cost of energy loss for building diagnostics. In the proposed method, first, using a hand-held thermal camera, the auditors collect digital and thermal imagery from the buildings under inspection. Then, using a recently proposed method for Energy Performance Augmented Reality (EPAR) modeling, an actual 3D spatio-thermal model is generated and superimposed with a computational fluid dynamics (CFD)-based expected energy performance model. The resulting EPAR model is placed into the method proposed in this paper for cost analysis of the energy loss. Through a new 3D thermal mesh modeling using k-d tree structure and nearest neighborhood searching, performance deviations between these models are automatically calculated. Using a temperature threshold, the areas associated with potential performance problems are detected in the EPAR model and are visualized using a metaphor based on traffic light colors. Then, the actual R-values of the detected areas are measured at the level of 3D points. Based on the measured R-values and the estimated air change rate for the detected air leaks, (1) the heat loss or gain caused either by poor insulation or air infiltration/exfiltration and (2) the associated energy costs are automatically calculated. The proposed method is validated on several locations of existing residential buildings. The preliminary results show the potential of the proposed method for minimizing the inspection time as well as the risk associated with the cost analysis of retrofitting potential building performance problems.

Aug 1, 2013

By Neville Jordison

Indirect, gravity flow, heat exchangers have become a well established technology in mineral and metallurgical process plants. The technology is a conventional heat exchanger using high efficiency plates, with a free flowing bulk solid on one side of the exchanger and a fluid on the other side. This simple concept leads to many opportunities for achieving greater energy efficiencies in process plants. Indirect heat exchange is much more efficient than direct heat exchange using air such as in a fluid bed or rotary device. When air is used directly, large fans are required, it may also be necessary to chill the air, both high consumers of energy. By contrast, using water as the cooling medium requires only low horsepower pumps, typically only 10% of fan HP. Furthermore there are no stack emissions with the requirement for removal of dust or emissions. Indirect heat exchange also creates the opportunity to recover energy. This can work in two ways: energy can be recovered from a hot bulk solid, to heat pressurized hot water for steam generation or preheat air. Alternatively recovered energy from elsewhere in the plant in the form of hot water, steam, air or thermal oil can be used to preheat a bulk solid.

Jan 1, 2011

By J. Parreira

This paper presents a deterministic/stochastic model that was created to compare an autonomous haulage truck system to a manual one by calculating and estimating benchmarked Key Performance Indicators (KPIs) such as productivity, safety, breakdown frequencies, maintenance costs, labour costs, fuel consumption, tire wear, and haulage cycle times.

Aug 1, 2013

By The Staff

BEFORE going into detail on the subject to be presented, a brief outline of the Company's earl y history would not be out of place. Prospecting and mining on a small scale was started in 1876 on the site of the present open pit at Thetford Mines. The property was purchased from the Crown in 1878 and Johnson's Company was incorporated in 1885. It is owned and operated today by descendants of the original shareholders. Many employees, through their fathers and grandfathers, have service records dating back three generations. The principal asbestos deposit at Thetford Mines is pear-shaped, with surface dimensions of about 2,200 feet in length by 1,300 feet in maximum . width. Its long axis strikes northeast and the dip is nearly vertical, but irregular in detail. It is known to extend to a depth 1,200 feet below the original surface, but its area at that depth has not been determined. Ownership of this deposit is divided among three active Companies: the Asbestos Corporation, Limited; Bell Asbestos Mines, Limited; and John-son's Company. Johnson's Company owns a section about 1,000 feet in length and 500 feet in width, bounded on the northeast by the King mine of the Asbestos Corporation and on the northwest by the Bell pit. On Johnson ground, there was originally a large outcrop o~ asbestos rock which dipped toward the south below overburden. This was mined until recently by open pit, the overburden being stripped off as far southward from the original outcrop as was economically possible. As the. pit was deepened, within side walls maintained at a maximum safe slope, its floor area, of course, became progressively smaller, and eventually the pit would have wedged out against the Bell property line. It became necessary, there-fore, to introduce some other method of mining before production became seriously curtailed by a shrinkage of the pit area.

Jan 1, 1941

By A. Moyano

The development of the traditional converting process performed in a PeirceSmith or Hoboken converter is limited by the investment magnitude associated to the fulfillment of the environmental regulations. Thus, the continuous converting process rather than a conceptual process alternative is becoming a necessity for a smelter facing limited converting capacity and/or lacking of fulfillment of the environmental regulation with its maximum converting capacity. The objective of this paper is to present the progress of the Codelco continuous converting process evaluated at pilot-scale level when converting solid mattes or white metal into blister copper. These tests allowed for gathering of relevant data to be considered for a new stage of evaluating the Codelco continuous converting at industrial-scale test. The pilot-scale tests were done in a Teniente Converter pilot scale unit at the Codelco Norte Smelter. The results of processing solid copper mattes (65-75% Cu) and producing low sulfur content blister copper with production of a constant S02 gas concentration, and the production of liquid slag with low copper solubility was achieved and is discussed in the present paper.

Jan 1, 2007

By Philip J. Bangerter, Chris Twigge-Molecey

Design for safety is critical to metallurgical plants, due to the inherently dangerous nature of their processes. Two significant areas of concern are: 1. preventing catastrophic process failures that cause damage or injury; and 2. operational safety that directly affects those working in or living near the plant. Process safety involves human behaviour, but the designer can eliminate or control hazards by engineering approaches, and control impacts through the design of the operating procedures. The tools available to guide safe facility design include bowtie analysis, hazard analysis, and hazard and operability studies. Clean plant design principles can guide the design process to address in-plant occupational health and safety issues. Auditing and review is a key part of the overall design process.

Jan 1, 2015

By The Staff

"THE Wabana iron ore mines, owned and operated by the Dominion Steel and Coal Corporation, Limited, .are on Bell Island in Conception bay, on the east coast of Newfoundland. Mining began on surface in 1895 and, although open-pit work is still done on a small scale, the entire output may be considered to•be derived from extensive submarine workings. In 1958 the average daily production of hematite ore was close to 12,000 tons, almost all of which was concentrated in a heavy-media plant. SUMMARYThe character, occurrence, and extent of the submarine bedded deposits enabled early operators to meet prevailing market demands with the minimum attention paid to exploration. Mechanization of the mine and the pressure for sustained high tonnages since 1955 have emphasized the importance of an expanded exploration and development programme.A serious handicap has been the impossibility of utilizing normal diamond drilling methods to explore ore conditions in advance of mining faces. Drilling between tl1e bedded zones has been done but the major difficulty has been to delineate ore reserves in the lower bed, which has the greatest ore potential of the three mineable seams."

Jan 1, 1960

By H. Al-Kazzaz

The 2-mm butt joints of ZE41A-T5 sand castings were laser welded using 1.6 mm EZ33A-T5 filler wire and a continuous wave Nd:YAG system at a power of 4 kW, surface defocusing and various welding speeds, Compared with the base metal, the fusion zone showed significant grain refinement due to high cooling rate, No grain coarsening was observed in the heat affected zone (HAZ). The porosity area percentage and total solidification crack length in the fusion zone (FZ) were reduced as the welding speed increased from 4 to 7 m/min, Fusion zone area, total penetration depth, and weld width decreased with increased welding speed, The hardness in the FZ was similar to or higher than the base metal after a natural aging of about one year, but there was a drop in the hardness of the HAZ, The HAZ width decreased with increasing the welding speed, Tensile test showed that a joint efficiency of approximately 75 ? 90 % was obtained.

Jan 1, 2005

By S. Espley, T. Nyabeze, D. Beneteau

"Many mentorship programs are available to Canadian mining industry employees. Some are company-led initiatives, whereas others are provided through educational institutions or nonprofit organizations. In 2016, a national survey was launched to gain insight into perceptions of what mentorship is, learn about available programs, and collate experiences with formal and informal mentorship opportunities. This paper outlines survey findings and delivers recommendations to industry for consideration in employee mentorship programs. In addition, mining industry leaders share their mentor/mentee perspectives. The intent of this paper is to bring awareness of best practices that can help employees grow and develop in their profession.RÉSUMÉ Les employés de l’industrie minière canadienne ont accès à de nombreux programmes d’encadrement. Certains sont des initiatives menées par les sociétés, d’autres sont proposées par le biais d’établissements d’enseignement ou d’organismes à but non lucratif. En 2016, une enquête à l’échelle nationale a été lancée en vue d’obtenir des informations quant à la perception de ce qu’est réellement l’encadrement, de découvrir les programmes proposés et de comparer les expériences aux possibilités d’encadrement, officielles ou non. Cet article présente les résultats de cette enquête et fournit des recommandations à l’intention de l’industrie afin qu’elle les prenne en compte dans ses programmes d’encadrement des employés. En outre, des chefs de file de l’industrie minière partagent leurs points de vue conseillers/protégés. L’intention de cet article est de sensibiliser les employés aux meilleures pratiques, ce qui les aidera à évoluer et à se développer dans leur profession. INTRODUCTIONThis paper about mentorship in the mining industry is based on voluntary responses to a cold survey, written and circulated by the authors. In 2016, a link to an online mentorship survey was circulated to males and females in the mining industry with the belief that mentorship programs should be available to everyone. The link was delivered via the authors’ personal networks in mining, the CIM Reporter, Women in Mining (WIM) email blasts, LinkedIn, and Facebook. This paper summarizes the answers to the survey questions. The paper is a follow up to one by the same authors (Nyabeze, Espley, & Beneteau, 2010), which was written to gain insight into why women join and stay in the mining industry, and to learn why the overall representation of women is low."

Jan 1, 2018

By Constantin Pitis, Paul Slatter, Behnam Pirouz, Laura Contasti, Markus Zeller, Sadegh Javadi

"The centrifugal slurry pumps feeding cyclones are critical components used in the grinding process. It is well known that for this type of pumps the performance degradation is very intense. To minimize downtime a complete stand-by slurry pump is always installed in a parallel circuit. The replacement decision of slurry pumps is sometimes set on specific periods of time that are empirically determined, based on previous experience; unless a pump failure triggers the second (standby) pump. Given the significant energy costs in the grinding process and a desire to increase competitiveness, engineers and scientists started research in this field while manufacturers also took actions in order to improve pumps reliability and performance. The lack of standardization regarding the methods used to benchmark and evaluate the energy performances of cyclone slurry pump systems in the mining industry makes it difficult for an enterprise to take informed decisions concerning the replacement or optimization of its process based on energy benchmarking of such slurry pump systems. This paper proposes a new methodology of benchmarking slurry pump performances using a new concept of Benchmark Energy factor (BEF) based on Mathematical Model Benchmarking. The concept of BEF has been proven successful in other industries. A new standard addressing the guidelines for benchmarking the energy performance of slurry pumps for cyclones was proposed within the Canadian Standards Association. This standard will provide a unified and consistent methodology for performing measurement activities with the ability to measure and verify the system energy performance in the field through the BEF approach. Practical examples based on the new concept are presented with comments."

Jan 1, 2017

By John L. Mero

"The ocean has served humanity as a source of raw materials for thousands of years, but only on a minimal scale relative to its potential. Exploration programs have shown the ocean to contain a large number of mineral deposits of great extent and attractive grade. Recent research has indicated that a number of these deposits can be economically exploited with present-day technology and that the cost of winning many industrially important minerals from the oceanic deposits is potentially much less than that of winning similar minerals from land deposits. Although the finding of mineral deposits in the sea is a relatively simple matter at the present time, the exploitation of many of these deposits has lagged due to the lack of the availability of specific mining techniques for the individual deposits. Within the past two years, however, several developments have taken place in the design and testing of ocean mining systems in depths of water as great as 12,000 feet which indicate that the problem of mining in the ocean may soon be solved.Within the next decade, the ocean should prove to be a major source of many minerals for society and should come to dominate as a source of such metals as copper, nickel, cobalt, manganese, etc. Within a few years of the initiation of the mining of the deep-sea metalliferous nodules, land sources of such metals as nickel, cobalt, copper, manganese, etc. will be seriously affected and it is conceivable that the present structure of the world mining industry will undergo a substantial change in character."

Jan 1, 1972

By E. S. Malloch

THE Great War forced the peoples of the world to recognize the importance of the wise development and use of the world's natural resources. Not the least, and perhaps the most, important, is the world's fuel supply- solid, liquid, and gaseous. Without fuel our civilization would be impossible, and mankind would of necessity have to congregate in the torrid zones of the earth's surface for at least six months of every year. Of the three classes of fuels the solid ones are the most plentiful, as well as being the most widely distributed, since few countries are entirely devoid of solid fuels of one kind or another. Until a hundred years ago wood was the fuel most generally used in this country, but since then coal has supplanted wood as a fuel in all its uses, except in the outlying districts and among the farming communities. For many years the supply of coal was thought to be unlimited, but as years went by more thought and study were given to the world's coal resources, until today not only are the limits known, but in one instance at least their depletion is predicted to be almost within the age of living men, unless more provident methods are put into practice for their winning and utilization.

Jan 1, 1928

By M. Fafard, F. Chevarin, D. Ziegler, H. Alamdari, M Kavand

"Carbon anodes, used in the Hall-Heroult process, are consumed by the electrochemical reaction to produce metallic aluminum. It is also consumed by parasitic reactions with air and CO2. The carbon anode is made of petroleum coke with different particle sizes, butts (recycled anodes) and coal tar pitch. The mixture of fine particles (less than 150 µm) of coke together with the pitch material forms a matrix, binding the large coke particles together. It is generally thought that the binder matrix is more reactive than the other anode constituents. This conjecture was not clearly proved in the literature. The present study is focused on the CO2 reactivity of binder matrix and anode constituents at 960°C, both under chemical regime (100% of CO2) and under a concentration gradient (diffusion). The apparent reaction rates of these materials were measured. The role of the binder matrix in anode consumption and its disintegration (dusting phenomenon) was discussed.INTRODUCTIONThe metallic aluminum production is one of the most important industries in Canada. The Al metal is obtained by the Hall-Héroult process. The principle of this process is the electrochemical reduction of alumina in molten cryolite carried out by an electrical current between carbon anodes and cathode at 960°C (Equation 1). The carbon anode is typically composed of calcined petroleum coke (65 wt.%) and recycled anode (called also butt, 20 wt.%) with coal tar pitch (15 wt.%), playing the role of cement to ensure the cohesion of the anode block."

Jan 1, 2016

By S. Hopkins, J. Nolan, S. Gillis

"Cast in place concrete shaft linings have been used in many salt and potash shafts sunk in North America over the last 100 years. A large number of these shafts have exceeded their initial design lives and as producers look to extend the life of their operational assets, maintenance costs and shaft downtime will, in many cases, continue to rise unless repair work is undertaken. Successfully implementing concrete liner repair schemes in operating salt and potash shafts is complicated due to their age, environment and time constraints during inspection, detailed design and construction. This paper outlines a general approach to the repair of concrete-lined portions of these shafts, based on lessons learned from the authors’ involvement in a recent repair project. INTRODUCTION Prior to the recent boom in potash mine construction many of North America’s potash mine shafts were entering their sixth continuous decade of production (Table 1). Of North America’s salt mines, one has been in continuous production, for nearly nine decades.As would be expected, considering the environment in which these liners operate and the age of the material, the concrete-lined sections of the shafts outlined in Table 1 have been noted by the authors to have lost both cross-sectional thickness and strength over time. Since construction, three principal factors have contributed to this loss in section/strength; (1) physical degradation (impact, freeze/thaw or rebar expansion), (2) chemical degradation from brine/water inflows (Neville 1969; Bothwell, 1972) and (3) overstressing of the liner. These factors may act in combination, in which case they can produce more significant distress than individually. Physical degradation There are three main causes of physical degradation of concrete shaft liners. The first is impact from falling debris/tools or equipment (whether large or small), which may damage specific sections of concrete lining as they fall through the shaft. Impacts tend to damage infrastructure fixed to the shaft liner more than the liner itself, so damage from this mode of failure is usually localised, for example, where bolts fixing a shaft services bracket to the wall have been pulled away, pulling out the concrete around the bolts with them."

Jan 1, 2019

By Gordon Jackson

"There are two accomplishments of air and gas drilling: a new series of economic and mechanical challenges; and, acceptance as a standard drilling and completion tool.The new challenges are related to the concept of using a gaseous circulating medium in drilling for oil or gas. For purposes of discussion, a two part division has been made: the challenge of fluid invasion control and that of equipment and tools. Great strides have been made in the development of materials and techniques to combat formation fluid invasion. Chemicals and the ""mist drilling"" technique, now in use, have the versatility to cope with a wide range of downhole fluid entry conditions.Equipment and tools have been developed to meet the challenges of better, more economic drilling and completion possible with a gaseous circulating fluid. Economic and operational challenges remain.Acceptance of air and gas drilling as a normal operating tool was reached with difficulty. It is now established as a means of reducing costs in exploratory and develop-mental well drilling, exemplified in a recent study of 226 wells covering 419,407 feet of hole in the United States. Air reached the projected depth in 85 per cent of the operations, although formation water was encountered in 48.7 per cent of the holes. Slim hole bit performance and cost all compared for overall bit averages as part of analysis."

Jan 1, 1961

By F. Chevarin

The reaction of O2 with the carbon anode is considered as the main parasitic chemical reaction affecting Hall-Heroult process anodes. The current study aims at investigating the influence of the microstructure of baked anode on its overconsumption. Samples were removed from different positions of an industrial anode. Density, porosity, Lc and BET specific surface area were measured. The anode reactivity was evaluated based on the weight losses for the samples resulting from the reaction of anode with air at 550°C after 7h. The essential parameters determined to control the air reactivity are closed porosity, Lc and pores with a pore entrance radius of 1.5, 8.5 and 12 p.m. The knowledge of effects of these parameters allows better understanding of the reactivity of anodes and consequently reduction of their overconsumption in electrolysis bath.

Jan 1, 2011

By Mark Kennedy, Allan MacRae, Cameron Hams

New technology projects, particularly those involving first-of-a-kind metallurgical facilities, have a poor track record of achieving their overall financial targets, as they incorporate technological risks in addition to normal project risks. Traditional project management tools focus on risk from concept development through implementation, but typically fail to address the additional risks associated with a new technology project including slow start-up, slow ramp-up, and failure to achieve design performance (quality or throughput). These additional risks affect future cash flows produced by the project and hence its value, typically measured as net present value (NPV) or internal rate of return (IRR). Common accounting practice is to reduce the present value of future cash flows by applying a chosen discount rate, often reflecting the corporation's cost of capital. This discount rate does not contain an allowance for technological risk, which is often underestimated or misunderstood by both the financial and engineering project managers. This paper will focus on the topic of project risk and new technology, and how these play a role in the probability of achieving the predicted future cash flows. By properly addressing technological risk in the form of risk-weighted returns, marginal projects can be prevented from proceeding, while sound projects can be given the additional time and resources required to achieve the optimal level of front-end-loading (the level which returns the maximum risk-weighted net present value). A simple set of mathematical tools should enable engineers and financial professionals to establish a common level of understanding, thereby leading to a more accurate assessment whether a new technology project is ready to pass through its next level of approvals.

Jan 1, 2011

By W. Beres

Many non-commercial operators are currently faced with the need to operate fleets of legacy gas turbine engines. How long such engines can be kept in service safely, without replacing a significant portion of their aging structural components, has become a growing concern to engine life-cycle managers, due to uncertainties in the remaining lives of critical components of these engines. This paper describes the application of the damage tolerance methodology to predict safe inspection intervals (SII) for critical components of gas turbine engines, using components of a turboprop engine for a transport aircraft as examples. High temperature components of this engine are made of advanced aerospace alloys. The methods of predicting three-dimensional fatigue crack growth at the critical location of turbine discs and spacers using both commercial and in-house developed algorithms are presented. Sensitivity analyses are performed to determine the effect of variations in material parameters on the predicted safe inspection intervals. In addition, spin rig tests performed for both turbine discs and spacers are described. Finally, crack growth rates predicted by numerical analyses are compared to those obtained from spin rig testing and the damage tolerance of the turbine components is assessed.

Jan 1, 2015

By M. Board, R. Pakalnis, S. Seldon, R. Brummer

The Kidd operation mines roughly 10 000 tpd of copper and zinc ore from underground and employs about 700 personnel. In the late summer and fall of 1997, major movements in the proximity of the east wall of the Kidd open pit had been observed. The Kidd pit had been mined from 1965 to 1977 to depths of 260 m (850 ft), followed by subsequent mining by underground methods to current depths in excess of 1830 m (6800 ft). The No. 1 Mine (2600 Level to pit bottom) is approximately 90% extracted, with most of the remaining reserve between 2000 and 2500 levels. Although initial concerns centred on the stability of the pit walls, the potential ramifications of the movements to the underground were recognized and measures were implemented to ensure the safety of personnel as well as to minimize the potential damage to existing operations. In late October, damage to underground operations was observed as deep as the 2000 Level. In the final assessment, the global mobilized mass was a “wedge”-shaped hangingwall block extending from surface to about 610 m (2000 ft) below surface. The “wedge” boundaries are defined by a fault and shear zone which have continuous lengths in excess of 1070 m (3500 ft); its base by shearing through the host rock mass; and its eastern face by deep tension cracks (Fig. 1). Mined and filled excavations at the western face of the “wedge” allowed mobilization of a mass in excess of 30 M tonnes. Movements in excess of 75 cm (30 in.) per day were recorded on the surface stations that preceded the complete shutdown of operations on October 29, 1997. The evaluations in the days following the shut-down were centred on mitigation of immediate and future possible negative impacts on infrastructure and mining of the remaining No. 1 Mine reserves while ensuring the safety of the operators. This effort required the rapid assessment of the potential damage of the block movement on underground infrastructure, stope access, drainage and ventilation, as well as airblast potential due to the falling of a large block into the pit near the ventilation intake at the base of the pit. These assessments were presented in a previous paper (Seldon et al., 1999). In total, the lateral movement of the block on the ground surface was over 4.3 m (14 ft). This paper describes the detailed studies performed to understand the failure mechanism and to assess the impacts on future mining in No. 1 Mine.

Jan 1, 2000