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By Dennis L. Murr, James E. Wennen

"The through-put and energy efficiency of an autogenous (AG) grinding mill are adversely affected by variability in rock size and rock competency. This applies to both fully autogenous and semi-autogenous (SAG) grinding circuits. In this paper we focus on an approach to overcome the problem of inconsistent mill through-put related to variability in mill feed size and rock competency. The focus is on ores containing hard, competent rock. This approach consists of preparing feed to an autogenous mill that contains 20% coarse media rock and 80% of material crushed to pass 37 mm. Results of pilot-scale testing for two iron-ores will be presented to show that a 10% to 12% reduction in unit energy consumption is possible with prepared feed, compared with feeding the mill with conventional primary crusher discharge.INTRODUCTIONIn the past 30 years or so, autogenous grinding and semi-autogenous grinding have been the comminution technologies of choice for most mining and mineral processing operations. These technologies saved both capital and operating expenses associated with the installation and operation of multi-stage crushing and screening plants required for conventional rod mill – ball mill circuits. However, SAG and AG are inherently inefficient in terms of energy consumption, especially for very hard ores. In cases of hard ore, changing characteristics of rock fed to the mills causes wide fluctuations in mill capacity, which contributes to the inefficiency. Rising electric power costs make this the most expensive unit operation used in the extraction of valuable minerals from an ore. The objective of the concept discussed here is to reduce the energy consumption in AG grinding for hard ore and eliminate the use of large-diameter steel grinding balls that are required for SAG grinding"

Jan 1, 2012

By K. J. Heale, G. G. Richards, D. J. Rioux, R. L. Stephens

Slag fuming has remained a key process for the recovery of Zn, Pb, and minor elements in the integrated flow sheet at Teck Cominco's Trail Operations for more than 75 years. Since the start-up of the KIVCETTM process and the #3 slag fuming furnace in 1997, a range of process intensification projects have been completed to improve metals recoveries and throughput based on improved process control, mechanical modifications, and, most recently, the implementation of oxygen enrichment of the blast air. This latter project, initially named 'nitrogen depletion' and now 'nitrogen oxygen performance enhancement' (NOPE), is the primary focus of this paper. NOPE reduces the amount of heat required to heat the inert nitrogen gas, and therefore more of the energy input can be used for reduction. It also frees up boiler capacity because the inert nitrogen gas does not then have to be cooled down. A dynamic METSIMTM model was developed to determine the opportunities to improve the process capacity and heat balance to both assist with justifying the project and to verify the observed furnace behaviour. Several process safety management issues were also addressed and a few key minor mechanical modifications were made to allow the project to proceed to commercial implementation at 25% blast air oxygen enrichment. Short term plant trials have confirmed the model predictions. The first three months of a long term, continuous trial showed a 6% increase in zinc fuming rate from average furnace performance despite the implementation of a KIVCETTM fluxing change to assist with minor element recovery that was expected to negatively impact the zinc fuming rate by 3 to 5%. This encouraging result is also in line with the model predictions.

Jan 1, 2008

By Gary Walters, Thomas Gonzales, David George, William Davenport, Andreas Siegmund, Suping Yao, Shijie Wang

The previous survey of world copper smelters was in 2016 (Copper, 2016). The copper smelting industry has grown and improved considerably since then, including continuing growth in China and modernization in Japan (Extraction, 2018). Outotec flash smelting and Outotec flash smelting/Kennecott - Outotec flash converting continue to be adopted while newer processes continue to be adopted in China. In addition, some of the world's original flash furnaces have been completely rebuilt (Extraction, 2018). This paper provides recent industrial production data and discusses these new developments. INTRODUCTION A world copper survey was redone in 2016 after a thirteen year lag since 2003. Some of the notable changes were the significant increases in production particularly from China. Since then, several smelters have gone through modernization processes and decommissioning of older technologies. This paper will review the notable changes since the last publication at Cu2016. In the last paper, Copper Smelting: 2016 World Copper Smelter Data, the author gave an audible sigh after observing that copper smelter sites as well as new and notable smelters have been spreading like wildfire in China since 2003. Indeed, seeing is believing. Figure 1 shows the Ningde Copper Smelter (double flashing, 400,000 MT Cu/Year capacity) that started up producing copper in 2018; Figure 2 shows the Nanguo Copper Smelter that is under construction with 300,000 MT Cu/Year capacity (first phase, side blown smelting and continuous top blown converting). We should not only admire the Chinese copper industry’s significant technological developments, but also the copper price support that it has provided throughout this century.

Jan 1, 2019

By M. B. Kime

"Discrete-element method (DEM) modelling is a powerful tool for studying particulate systems within the mineral processing industry. DEM simulations were conducted to investigate the power draw, load behaviour, and impact energy profile of an experimental ball mill under different milling conditions. The variables considered were mill rotational speed (percent critical speed), ball size, and lifter face angle. The simulation results indicated that the grinding efficiency would be enhanced by using 80% critical speed, 30 mm ball diameter, and 45° lifter face angle. These findings can be useful in guiding actual ball milling tests involving an ore sample.RÉSUMÉ La modélisation par méthode des éléments distincts (MED) est un outil puissant qui permet d’étudier les systèmes particulaires au sein de l’industrie de traitement des minerais. Des simulations par MED ont été menées de façon à étudier le profil de la consommation énergétique, du comportement de la charge et de l’énergie de rupture d’un broyeur à boulets expérimental dans diverses conditions de broyage. Parmi les variables prises en compte figuraient la vitesse de rotation du broyeur (vitesse critique en pourcentage), la taille des boulets et l’angle de coupe de la cornière élévatrice. D’après les résultats de la simulation, on pourrait améliorer l’efficacité de broyage en utilisant une vitesse critique de 80 %, un diamètre de boulet de 30 mm et un angle de coupe de 45 ° de la cornière élévatrice. Ces résultats peuvent se révéler utiles pour les essais concrets de broyage à boulets impliquant un échantillon de minerai.INTRODUCTIONComminution is a very energy intensive process. It consumes approximately 5% of the electricity produced worldwide and more than 50% of the total energy used in mineral processing plants (Pokrajcic, 2010). Among all the comminution stages, ball milling is one of the most energy intensive processes. In ball mills, rotational movement provides the rise of the load and the media that are projected and impact on the mill shell at lower angular displacement, resulting in particle breakage. Ball mills are able to reduce particle size over a relatively wide range of particle sizes. This explains their wide applicability in research laboratories and the mineral processing industry."

Jan 1, 2017

By G. Couture

In the introduction to this presentation, we will cover the market of motorized recreational products. We will introduce the public to what is produced and sold worldwide, what is the nature and general behaviour of the customers for such products. We will cover the evolution of this market and put in evidence how drastic must be the changes in the manufacturers organizations in order to, in one hand, constantly adjust to the customer demand, and in the other hand, react to the competitors' offensives on the market.

Jan 1, 2006

By J. E. Dutrizac, R. J. C. MacDonald, J. B. O'Reilly

"Sometime around 3000 B.C., primitive metallurgists working in the mountainous regions of Asia Minor bordering on the Black Sea (Pontus) produced a soft, easily fused metal today known as lead. It appears certain that the first metal was made by reductive smelting of galena, but whether this recovery arose by the accidental inclusion of galena in the stones of a fire hearth or whether it occurred as a consequence of simple pyrometallurgical experiments on a series of interesting ""stones"" will likely never be known with certainty. The properties of galena, high metallic lustre, great density and facile cleavage, must have excited the ancients, and such ""stones"" would have been the object of primitive testing111 - Shortly after the discovery of lead, the ancients found that the controlled oxidation of this metal at elevated temperatures yielded smaller amounts of a more interesting material, silver. Again, it is uncertain if the production of silver by primitive cupellation techniques was the result of a fireside accident or the consequence of a deliberate experiment, but the important fact is that silver was produced shortly after the discovery of lead. The techniques for making lead and silver spread gradually throughout the entire civilized world, likely as a result of both technology diffusion and independent rediscovery. The physical properties of lead could not have been overly attractive to the ancients, but silver was a different matter altogether. The gleaming white lustre and relative immunity to oxidation quickly assigned silver to the precious materials category, a status it still enjoys. In early times, argentiferous galena was inevitably processed only for its silver values; lead was generally an unwanted byproduct and was frequently discarded as litharge (PbO) during the cupellation process. The silver was eagerly sought, however, and resulted in considerable mining activity culminating in the famous Athenian silver mines at Laurium at the southern end of the Athenian peninsula."

Jan 1, 1999

By Robert B. Parsons

"Canada doesn't really have a tax system for mining - it has eleven separate tax systems! The consequent maze adds some undefinable margin of difficulty to making investment decisions in Canada. But, this 11U1Ze is not likely to be simplified. Solution: learn it and sell it! Intricate Network of Winding PathwaysWebster's New World Dictionary defines the word ""maze"" as follows: ""a confusing, intricate network of winding pathways; labyrinth ... a state of confusion or bewilderment"". Webster's does not go on to give an example of a maze, but the dictionary could easily have referred to the taxation of a Canadian mining operation. The uninitiated would almost certainly look upon such taxation as a maze of the most perplexing sort.Twenty years ago, Canada's tax system was really quite simple. It is true that Canadian mining profits were subject to three levels of taxation (federal income tax, provincial income tax, and provincial mining tax), but this didn't pose a problem. Prior to 1974, at least the provincial income tax systems were somewhat the same in terms of rules .and rates, and even the provincial mining tax systems resembled one another. Mining profits were subject to pretty much the same rules, no matter what province or territory hosted the mine. Those were the “good old days” one could even dare to generalize about tax rates without fear of being labelled an imbecile!"

Jan 1, 1994

By W. J. D. Stone

Discussions with people knowledgeable in the insulating material field revealed that materials on the market would be considerably improved if there was a greater meeting of certain very desirable criteria. Such criteria include: (1) the material should not burn, even at higher temperatures; (2) at an elevated temperature, the material should not give off toxic gases or produce smoke; (3) the material should have a low energy input; and (4) vermin would find the material unattractive. Theoretical discussions led to the conclusion that an insulating material made by foaming a mineral, preferably of a platy nature, with an inorganic binding system that could be converted to a rigid structure at low temperature would likely meet all the above requirements. It was also theorized that the use of microwaves in the converting stage would be beneficial in the creation of a cellular structure by aiding the foamer through creating vacules of steam. Talc was selected as readily meeting the theoretical mineral requirement and the material of Baker Talc Limited was used as the basic filler. The early results obtained led to an agreement between Americ Mines Limited and Baker Talc Limited pertaining to commercial production in a specific geographic area. It was recognized that due to the economics of shipping, the availability of the basic filler material should be geographically widely spread. Samples of materials were requested and many received from all over North America and one from Britain. Enough work has been done to show that they respond to the basic process in a similar manner as the Baker Talc material. From the data acquired, it is considered that the process is applicable for the production of loose fill insulation, moulded insulation for pipes and structural steel, ceiling tile, batts, sheet and for incorporation into other products such as various roofing board materials. Sufficient development has been done to enable a budget to be prepared for the construction and operation of a loose fill insulation plant.

Jan 1, 1979

By William Ferguson, Claude Deveau, Wade Hazel, Stephen R. Young, Allen Lussier, Robert Copeland

"LocationSometimes known as the Bernie Lake mine, the mine is located about 180 km east-northeast of Winnipeg on the northwestern shore of Bernie Lake, close to the Nopiming Provincial Park and the Manitoba-Ontario boundary. The mine is accessed from Lac du Bonnet which is linked to the provincial road system.Brief Description of OperationTantalum Mining Corporation of Canada Ltd. operates an underground mine employing ramp access, room and pillar mining, and shaft hoisting for the production of tantalum, lithium and cesium minerals. Daily campaigned crushing of the tantalum and lithium ores supply separate concentration circuits. Tantalum recovery employs conventional gravity equipment together with recently developed centrifugal concentration methods. All tantalum concentrates go to Cabot Performance Materials for the production of tantalum chemicals and metal. Lithium minerals are recovered using heavy medium separation and silicate flotation to produce spodumene and montebrasite/amblygonite concentrates. The lithium concentrates are shipped worldwide for use in ceramics, specialty glass and mold powders. Cesium processing involves the dry grinding of pollucite as feed stock for the recently built on-site chemical plant dedicated to tl1e production of cesium formate, a high-density drilling fluid for use in the oil industry."

Jan 1, 2000

By D. G. Osborne

"The paper describes current 'tools' available to the coal preparation engineer for carrying out the evaluation of data, process design, selection of equipment and layout and design of coal preparation plants.Laboratory and pilot-scale equipment is widely available and test data can be used to provide valuable design information regarding capacities and sizing for specific applications. Pilot plants, unless they fit closely to the basic design envisaged for the eventual commercial plant, C(In often provide only limited useful information.Computing aids such as equipment simulation, plant modelling, etc. are becoming widely applied for establishing design criteria and investigating flowsheet options . Other computer tools such as computer-aided design systems are taking over some of the time-consuming tasks of detailed layout and design and estimation of quantities, etc. and providing the means for detailed examination of more than a single option.Besides computer modelling there is also physical modelling of plant buildings, plant sites and entire proposed mining areas; the former can be especially useful in finalizing design and threading' pipework and electrical reticulation systems through the plant without the resultant risk of impairment of flow, obstruction or wastefulness. Not the least of the benefits of plant models is the assistance provided for training new operating and maintenance staff."

Jan 1, 1985

By F. Baczek, S. S. Rocks, D. Chaiko, T. Walters

The atmospheric leaching of chalcopyrite concentrates using acidic ferric sulfate lixiviants is well known to suffer from slow leach kinetics and poor copper recoveries. A number of approaches have been proposed for improving both leach kinetics and recoveries in this system. Many of these, while effective, suffer from high CAPEX and/or OPEX. As many mine sites begin transitioning from heap leaching of copper oxides to processing of primary copper sulfides, cost-efficient leach processes that are compatible with existing SX/EW processes will be needed to maintain existing cathode production. To this end, FLSmidth is exploring process options and reactor technology for the hydrometallurgical processing of primary sulfides. One approach that appears to be highly effective at increasing copper recoveries takes advantage of the enhanced reactivity of transitory, surface-defect structures generated during particle fracture. Significant process efficiencies are gained by matching the rate of grinding to the rate of electrochemical leaching in Mechano-Chemical leach processes. The patent-pending FLSmidth® ROL process uses a Stirred Media Reactor (SMRt reactor) to achieve copper recoveries of 97+% in 6 hours or less. This approach overcomes many of the surface passivation problems that have hindered other atmospheric leach processes. New insights to leach mechanisms are presented.

Jan 1, 2015

By Kiran B. Chaudhuri, Michael Koch, Jorg Lema Patino

"Stricter pollution regulations together with other factors have stimulated interest in the modernization of the traditional sinter - blast-furnace lead operation. In this context, direct smelting methods have again come into prominence. Consequently, the Kivcet Lead Smelting Process, which belongs to this group, has attracted the attention of the lead producers of the world. The Kivcet Process offers the advantage that lead and zinc can be simultaneously recovered in a single furnace unit. KHD Humboldt Wedag A G, Koln, Federal Republic of Germany, has signed a contract with the Sociedad Complejo Metalurgico de Karachipampa of Bolivia for the delivery of a turn-key Kivcet plant, which is expected to be the first plant of its kind in commercial operation. This paper describes the design and expected operating data of the plant."

Jan 1, 1980

By G. L. Spence

Prevention of cuprous and cupric oxide formation on stored ETP copper rod is a major concern for copper rod and wire producers. During normal storage periods copper oxide layers can increase from less then 100 A to more then 1000 A exceeding ASTM specifications and discoloring the rod surface. Various types of corrosion inhibitors are tested and compared in effectiveness for prevention of copper oxide formation on stored copper rod. Aromatic triazole compounds are also compared to a non-azole containing compound.

Jan 1, 2007

By J. W. Reynolds

Use of crushed waste rock recovered by sink-float separation from normal ore production for backfill is an established procedure at Commco's Sulhvan mme, Kimberley, British Columbia. Need for a safe method of placement in voids which were difficult to reach by gravity methods led to a co-operative venture with Radmark Engineering Ltd. in the development of a workable pneumatic transportation system for rock material. This paper reviews work done to date in a current program, and includes comments on the nature of the fill so placed, options for cementing such fill, implications for other aspects of mining and references to other applications of the system by other organizations who exchanged experiences with the Sullivan mine staff during the five-year period reviewed.

Jan 1, 1972

By Ajit K. Sinha

"Abstract - Electromagnetic surveys were conducted over the Yava sandstone-hosted lead deposit in Nova Scotia to evaluate the usefulness of such surveys for detecting and mapping sedimentary­ hosted metallic ore deposits. Both transient and multifrequency systems were used for that purpose. The deposit consists of three zones of disseminated galena which also contain minor amounts of pyrite and sphalerite filling the interstices of the sandstone grains. Each zone overlies a basement depression and is separated from the adjacent zone by an intervening basement high. A conductive shale layer underlies the galena-rich sandstone formation at all three zones.Because the concentration of galena (3% to 4% ) and other sulfides is too low to affect the resistivity of the sandstone formations for detection by ground electromagnetic (EM) methods, the strategy for our survey was to look for areas of basement depressions and the presence of conductive shale in those depressions by EM depth soundings. The presence of the galena-rich sandstone formations could be inferred because of the close association of these two features with the deposits in the Yava area. Both transient and multifrequency EM systems were successful in mapping the basement depressions and detecting conductive shale at the three known mineralized zones. The technique, therefore, seems to offer good prospects for mapping similar stratabound sedimentary-hosted sulfide deposits."

Jan 1, 1993

By John D. Godfrey

Precambrian Shield rocks, exposed in the extreme northeast corner of Alberta, provide the only possibility for a granitic building stone development in the province. Among a wide variety of granitoid rocks in the Shield, the Chipewyan Red Granite is one of the most favourable prospects. Geological mapping and exploration has revealed two prospective sites within a major pluton situated close to navigable water. Cleaned outcrop surfaces show clearly the pattern of joints and lithologic variations within the granite at prospective quarry sites. Other features include: basic dykes, quartz veins, and sheeting fracture zanes. Systematic orthogonally arranged fracture sets and the sheeting zanes are auributed to a tectonic origin. onsystematic irregular fractures are related to surface and nearsurface processes, such as decompression through unloading .

Jan 1, 1984

By M. Azzaz

In this paper, we report on new mechanical tests, at high temperatures, performed with a supposed better aluminium nitride (A1N) material, containing fewer oxygen. Our purpose was twofold: (i) check whether creep resistance is modified and hopefully enhanced and (ii) determine the elementary mechanisms controlling plastic deformation through transmission electron microscopy (TEM) observations of deformed samples up 10% strain in compression at elevated temperatures (1823-1923 K) under constant stress in the range 150¬250 MPa. Stationary rates are lower by an order magnitude than those previously measured in MN with higher oxygen content. All dislocations imaged by TEM look undissociated, which clearly relates the formerly observed wide dissociation to oxygen in excess.

Jan 1, 2004

By P. Cielo

"Nondestructive inspection is an important quality control tool in the material processing industry. Being nondestructive, such a control may be applied to the whole production, as long as the available techniques are fast and easily automated. Ideally, nondestructive testing (NDT) methods should operate in a noncontact configuration in order to be deployable on-line with minimum perturbation of the production process.After a short introduction to the most common NDT techniques, with particular emphasis on ultrasonic, radiographic and electromagnetic methods, a few new approaches which are under development at the Industrial Materials Research Institute, (Boucherville, Quebec), are reviewed. Noncontact techniques such as laser ultrasound, thermoelastic and thermographic methodologies will be described, and their applications to materials of industrial interest will be discussed."

Jan 1, 1989

By L. Torres, C. S. R. Rondestvedt, M. Bustos

In February 2010, Teck’s newest Concentrator at Mina Carmen de Andacollo (CDA), Andacollo, Chile was commissioned. The Concentrator is a single line configuration, comprising of one 36 ft diameter x 20 ft long SAG mill driven by an 18,000 hp gearless drive. The SAG mill feeds two ball mills each 25 ft in diameter x 40.5 ft long, each driven by a total of 19,000 hp through dual pinion drives. A series of four phases will be reviewed from operational readiness, mechanical completion, commissioning, and ramp-up. Also, now after 6 months of operation, this paper will review the significant steps taken during ramp-up enabling the announcement of commercial production, in October 2010.

Jan 1, 2012

By D. Laguitton

The basic chemistry of a1•senic related to its dissolution and subsequent precipitation in gold-mine waste waters is discussed. The lime addition methods provides the most economic treatment of arsenical slurries, but requires a careful control of the oxidation of Asm into Asv, of the pH (>12) and the filtration of the precipitate. If arsenic levels below 0.5 mg/ l are required, a modification of the method by phosphate addition must be considered.

Jan 1, 1976