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By F. Wirfiyata

"Accurately modeling and predicting long term mill throughput is one of the challenges facing metallurgists, geologists and mine engineers in their quest to consistently deliver accurate life of mine business plans.Batu Hijau has systematically improved long and short term mill throughput predictions since feasibility and commissioning in 1999. This has been achieved through a combination of ongoing improvement to the geology ore hardness and grade characterisation model, drill and blast optimisation and, by application of these data to model mill throughput.Batu Hijau has demonstrated the ability to consistently estimate long term mill throughput within ±2% accuracy. Aside from reliably predicting expected production rates with the existing plant configuration, this predictive ability provides a solid foundation for identifying operating and design criteria for short term grinding circuit optimisation and future expansions.This paper discusses ongoing throughput prediction model development at Batu Hijau based on geo-metallurgical characterisation. Also discussed are tools used for day to day production performance management. This includes on line ""Mine to Mill"" variable monitoring to improve operations parameter decision making and performance assessment."

Jan 1, 2012

By M. T. Ho, D. E. Wiley

The iron and steel industry accounts for almost 5 % of the total world CO2 emissions. Optimisation of the steelmaking process has led to significant reductions in the energy intensity to the point where it is now close to the thermodynamic limit. Further reductions are not likely to be achieved with efficiency improvement alone and will require the development of novel or breakthrough technologies. This paper will show the costs of implementing CO2 capture at direct atmospheric emission points for a number of iron and steel production processes. These include a conventional process, top gas recycling processes, the Corex and Hismelt smelt reduction processes and the Midrex direct reduction process. Depending on the point source emission, costs of capture with existing chemical absorption technology at iron and steel plants can be similar to capturing CO2 at pulverised coal fired power plants.

Jan 1, 2015

By Ting An Zhang, Chengzhi Jiang, Xiujing Zhai, Feng Xie

The extraction and concentration of nickel from aqueous solutions by emulsion liquid membranes (ELMs) using tributylphosphate (TBP) as extractant has been investigated in this research. The emulsion liquid membrane consists of a diluent (kerosene), a surfactant (Span 80), a mobile carrier (TBP), and a stripping solution (ammonia solutions). Important factors influencing the separation process including membrane composition, feed composition, and mixing speed have been examined. The results show that more than 90% of nickel in the feed solution could be extracted by ELMs under the experimental conditions, indicating the feasibility to use the designated ELMs to detoxify nickel-containing industrial waste solutions.

Jan 1, 2014

By L. M. Dwarkin, D. F. Coates

Crows Nest Industries Limited adopted roof bolting in 1963 to improve roof control and to extend continuous miner utilization in one mine. Bolting was held back because anchorage tests gave inconsistent results. The time lapse between mining and bolting was suspected as a cause, and so a test entry was driven and sections of it were bolted as part of the work cycle in addition to the normal timbering. This paper presents the results of the instrumentation of test entries and discusses the utilization of the data to improve mining procedure.

Jan 1, 1967

By G. E. Norman, R. E. Michelutti

"One of the major objectives of Falconbridge has been and continues to be, to minimize the impact of its operations on the environment around its Sudbury operations.The approach to achieving this objective and the results, are discussed under the following topics .I . Sulphur Dioxide Emission Improvements.2. Effluent Treatment Improvements .3. Effect of the Envrionmental Improvements.Sulphur Dioxide Emission ImprovementsHistoryThe rejection of pyrrhotite in the concentrators is one method of reducing the amount of sulphur to the smelter and therefore the sulphur dioxide emissions. In the 1950s and 1960s, Falconbridge developed the capability to remove 54% of this pyrrhotite. Numerous attempts were made to increase this amount by treating the pyrrhotite for recovery of nickel and in some cases elemental sulphur. Processes tested and operated were: hydrometallurgical pilot plant, roast-leach commercial operation and nickel-iron refinery. None of these processes proved to be commerically successful for both technical and economic reasons. Falconbridge therefore redirected its efforts to reducing sulphur emissions by improving its smelting process under The Smelter Environmental Improvement Project. A major component of this project was the installation of a sulphuric acid plant to recover the S02 in the roaster off-gases."

Jan 1, 1984

IN 1932, the No. 4 shaft at Wright-Hargreaves mine was completed to a depth of 4,000 feet, and the lowest operating level at that time was at 3,900 feet. It was realized that the existing pumping system, using triplex plunger pumps at somewhat irregular depths in the mine, would be in-adequate to take care of the increasing volume of water that would have to be handled as mining operations expanded. Accordingly, in February, 1932, after a thorough study of the whole matter, it was decided to instal an entirely new, automatically controlled, system of pumping, employing centrifugal pumps, with their characteristically trouble-free performance, operated by off-peak power.

Jan 1, 1939

By John J. Laffin

"IN THE BOOK that has been rated the best seller of all time, it is predicted that man will earn his livelihood by the sweat of his brow. Apparently man has accepted the statement as a challenge and has been attempting to refute it ever since, as he continues to transfer the workload to his inanimate servants - the many types of machines and other labour-saving devices that are available to assist or perform for him in the normal tasks of the day. The history of the evolution of the use of energy takes us back to primitive man, who existed in a very low energy environment, the only energy available being his own muscle power. Although man took a great leap forward when he discovered fire, which was used for lighting, heating and cooking, he still depended upon his own muscles for power. Early man's greatest achievement was probably the invention of the wheel, which permitted him to utilize the muscle power of animals. While still in a very primitive state when viewed from the perspective of the twentieth century, man, with fire and the wheel, had achieved a standard of life far exceeding that of his predecessors. Looking beyond the very basic elements of human energy, fire and the muscle power of animals, we find the next additions of energy coming from man's mastery of other elements of nature. The Phoenicians utilized the power of the wind and the Romans adapted the energy of falling water to the water wheel."

Jan 1, 1972

By Marko Lampi, Ross Andrews, Jouni Pihlasalo, Robert Matusewicz

With widespread discussion on reducing carbon, sulphur and other emissions, use of sustainable energy sources and the pivotal circular economy theme, consideration needs to be given to pyrometallurgical operations broadly and more specifically, non-ferrous metallurgy. These themes present a number of challenges in terms of current operations and the view of processing the metals which are largely taken for granted in day to day living. This paper considers how these themes will impact pyrometallurgical flowsheets using the non-ferrous base metals as an example. It will examine the flowsheet chain to offer views on the boundaries of flowsheet optimization and the application of available tools to meet these future goals and challenges. INTRODUCTION The themes of reducing footprint through lowered CO2, S and other emissions, together with process sustainability (e.g. lowered energy) and links to the circular economy are well known to everyone in the metals industries. Whether it is reducing greenhouse gas emissions or analysing the importance of metals recycling in the circular economy, all these themes carry with them the fundamental premise of any change being considered; how can you best optimize a system to meet your aims? Of course, this depends on the available tools and the approach used for optimisation.

Jan 1, 2019

By V. Aprahamian, T. Cheng, M. Tangen, R. Beauprie

The Royal Canadian Mint has implemented significant process additions since 2005. Installation of a whole new highly automated silver refining circuit has allowed recovery of physical silver from gold and silver dorés . To complement this change, a small Top Blown Rotary Converter has been in operation. On the gold refining side, a new hydrometallurgical process to recover precious metals from Miller Chlorination slag has been developed. Finally, new systems have been put in place to improve treatment of waste water, wet and dry fume and dust.

Jan 1, 2011

By G Anders

The effectiveness of two types of powder used in long-wall slashing was compared. The evaluation of the results can serve as a good example of how the application of statistical methods to underground test data can help to minimize the number of tests to be carried out. The conclusions are stated concisely, including a definite assessment of the reliability of the tests. Introduction AN assignment at the Algom Nordic mine called for a performance comparison between 70 per cent Cilgel B and 75 per cent Dygel in longwall stope slashing, particularly taking into account, in both cases, the build-up of bootlegs as dependent on hole deviation. Stopes were usually 8 to 10 ft. high and inclined at about 17 degrees. Starting from a raise, they were widened by consecutive longwall slashes to 60 ft., and, al-lowing for drift pillars, were approximately 300 ft. in length along the incline.

Jan 1, 1964

By J. R. Bradfield

THOSE familiar with the development of the Horne mine can readily appreciate that more and more accommodation bas been required for underground labour as the mine has grown. A permanent fire-proof change house, 30ft. by 75 ft., was built in 1927 to accommodate 194 men. This was extended ro 30 ft. by 92 ft. in 1928 to accommodate 296 men, and to 30ft. by 110 ft. in 1930 to accommodate 398 men. By 1933 this building was again overcrowded and tentative plans for a new change house were drawn up. However, it was realized that future operations would be centred around No. 4 shaft and a proposed new shaft, and the decision as to the location of the new change house had to be deferred until the area which seemed most suitable for the new shaft had been thoroughly explored underground. In the spring of 1934, the basic idea was accepted of drying the wet clothes in open mesh compartments or baskets located between rows of standard steel street-clothes lockers and built so that the covers or lids would serve as seats or benches.

Jan 1, 1935

By Donald Lindell

Safety Share ?Dad receives fryer for Christmas 2009 and makes delicious sweet potato fries ?When the oil fryer was pushed back on the stove for cooling, the back edge comes into contact with the stove top controls, unknowingly activating the cooking element, family leaves kitchen. ?Faint smell of smoke from the melting plastic alerted the family; teenager arrives first and pulls the fryer forward causing oil to spill onto hot stove and burst into flames that reach the microwave ?Teen runs for sink to grab pan of water but is stopped by Dad ?Dad opens refrigerator, grabs baking soda and pours it on fire, extinguishing flames Lessons 1.DO NOT USE WATER ON GREASE FIRE 2.Where is the baking soda in your kitchen?

May 1, 2010

By V. Baboudjian, R. J. Geren, J. Thiriar

"The electrolytic tankhouse at CCR was recognized by management as lagging behind modem refineries in terms of productivity, energy efficiency and controls. The operation was also burdened by high maintenance costs of cells, floors and electrolyte recirculation systems.A bench marking program was started in 1986 to evaluate processes and other technology by visiting major copper refineries in North America, Europe and Japan. The basic principles necessary to optimize the operation were defined, and a program calledCCR 2000 was prepared for approval of the necessary capital investments.This paper describes the results obtained to date and outlines the remaining work to complete the modernization program, in particular, the control of electrolytes, the elimination of the Baltimore groove and studies to modernize the stripping operation or adopt permanent cathode technology.IntroductionThe CCR Refinery of Noranda Copper Smelting and Refining (Noranda Minerals Inc.) , in Montreal East, is one of the world 's largest custom copper and precious metal refineries with a capacity to refine 350000 tonnes of copper per year. The silver refinery, which treats the copper tankhouse anode slime, foreign slime and precious metal ingots, produces 800 000 kg of silver, 26 000 kg of gold and 3800 kg of platinum-palladium concentrate annually. Copper anodes are received from the Horne Smelter at Rouyn-Noranda, Quebec, and Mines Gaspe Division in Murdochville, Quebec. CCR also refines anodes from Hudson Bay Mining and Smelting Co. Ltd. in FIin Flon, Manitoba, and remelts anode scrap along with blister and purchased copper scrap ."

Jan 1, 1993

By D. Assmus, S. Daly

"Poor fragmentation, high toe areas, excessive shovel wear and tear and frequent re-drilling and blasting of certain tough waste rock zones in the Lomex pit in the early 1980snecessitateda better understanding of these zones.A combination of geotechnical mapping, penetration rate data, toe elevation contouring and observations on shovel and drill performance were used to determine the character and extent of these zones. This complementary information was brought together by the geotechnical mapper and the explosives supervisor.Distinct zones with particular geological characteristics were determined. A classification system with three types of blast and dig-ability was developed for the Lomex pit and later applied to the Valley pit, with considerable success. The three blast zone types are called ""poor"", ""f air"", and ""good"". This system will be described in detail.The explosives supervisor adjusted the blasting parameters to each zone, in particular, pattern spacing and burden. The resulting powder factors showed considerable variation between the poor, fair and good zones within each pit as well as between the two pits. Pattern geometry and length of collar were also adjusted to improve fragmentation. Cost savings resulted from less re-drilling and less wear and tear on drills and shovels in the poor zones and more efficient use of explosives in all the zones. An annual estimated cost savings of well in excess of $1,000,000 is realized at Highland Valley Copper. A by-product of the mapping was the determination of unstable structures and water flowing zones. Blasting was then adapted to this information for enhanced slope stability."

Jan 1, 1992

By V. Caps

Gold has been often used as an alloying component in order to increase or modify the catalytic properties of an active metal. For example, in the hydroconversion of methylcyclopentane, Riahi et al [1] shown that the addition of gold to palladium or platinum enhances the activity which becomes greater than that of the pure metals whereas the selectivity towards products resulting from ring expansion increases. Molenbroek et al [2] presented a detailed study on Ni-Au catalysts which exhibit activity for steam reforming and have been proved to be more resistant toward carbon formation than the pure Ni catalysts. Blocking of highly reactive Ni edge and kink sites by Au atoms is assumed to be the reason for the increased robustness of the Ni-Au catalyst. Nevertheless, the own catalytic properties of pure gold have been almost ignored up to the pioneering work of Haruta et al [3] which demonstrates the high activity of gold for CO oxidation at low temperatures. Other reactions such as WGS reaction, propylene epoxidation or benzene total oxidation have then been shown to be catalyzed by gold [4]. This discovery induced the publication of papers devoted to analyze the different factors controlling the activity of gold catalysts. Among them the most relevant appears to be the gold particle size, the nature of the support [5] and the preparation methods [6]. Clearly distinguish between support and size effect is not straightforward. Indeed, the calcination step often needed to synthesize supported catalysts on different supports, leads to different particle sizes showing that particle size and support are interdependent. To circumvent this difficulty, Au-based supported catalysts have been synthesized by using laser vaporization and low energy cluster beam deposition. The as prepared catalysts have then been characterized and tested in CO oxidation reaction.

Oct 1, 2003

By G. S. Cole

By 2025, the U.S. automotive industry will have to average 54.5 mpg (4.3l/100km) Corporate Average Fuel Economy (CAFÉ). While new/improved powertrain technology (turbocharging, electrification, diesels, transmissions and stop/start) will be critical, it is estimated that 25-40% of the new CAFÉ standards will require significant mass reduction, and lightweight structural materials will be required. This presentation examines vehicle mass reduction based on new developments in manufacturing automotive structures and components using light metals (aluminum and magnesium), conventional heavy metals (iron and steel), polymers, and carbon-fiber reinforced polymer composites. Components that used to be sand cast or pressure die cast provided minimal fatigue strength and ductility. But greater mass reduction uses more light metals in structural applications. They require eliminating porosity and inclusions to improve ductility and fatigue strength. Improved casting processing, with vacuum die casting, counter pressure and squeeze casting, and new forging and extrusion applications are being developed for this purpose. New grades of ultra-high strength steels can be made thinner, and save over 1/3 the mass vs conventional mild steels. But more complex and expensive processing, such as hot stamping and in-mold quenching, is required. Most engine block structures have migrated from grey cast iron to aluminum over the past 40 years. But compacted graphite cast iron has higher strength at high combustion temperatures and pressures so that high powered engines can be smaller and even lighter than aluminum. Assembling a range of lightweight materials into vehicle structures requires specialized assembly techniques, including sophisticated structural adhesives that can mitigate vehicles’ unique corrosion environment. The presentation will conclude with discussing lightweighting strategies of Asian, American and, European marques and the materials, component designs and assembly techniques used to achieve 2025 CAFÉ.

Jan 1, 2016

By M. S. Badollet

"The study of the physical properties of asbestos minerals requires a careful isolation of the fiber from the wall rock and, at a later stage, a comparison of these physical properties with those of fibers that have passed through the milling and beneficiation processes.The effects of mineral impurities, loss of fiber length and the formation of extreme fines (asbestic and/or associated minerals) often show up in the formation of special asbestos products as well as in the commercial production of asbestos papers, mill-boards, asbestos cement products, plastics and insulation materials, and in the filtration of blood plasma and wines.Numerous test methods have been developed in Canada and in England for use in the asbestos industry. Special treatments of asbestos fibers have been used to improve their physical and chemical properties and to eliminate impurities.Numerous problems connected with the use of asbestos fibers are discussed, such as the effects of asbestos on filtration, surface area, surface treatments using organic or inorganic materials, the surface charge on the fiber, the presence of magnetite and air pollution elimination. Biological studies on finely ground asbestos, when dispersed in 0.9 per cent sodium chloride solution and then sterilized and injected into hamsters, show that by reducing the dose, the tissue damage can be largely avoided. In these experiments, Arizona asbestos fibers were carefully extracted from the wall rock, finely ground, and examined chemically and micros-copically for any mineral impurities that might be present so that any effect on the hamsters would be directly due to the presence of the asbestos. The harsh Arizona fiber induced more extensive tissue response than the soft fiber when tested in hamsters."

Jan 1, 1969

By D. S. Salonine

Aluminum alloys are widely used in modern industry. Tubes and hollow shapes give great opportunities for structural purposes as well as fluid transport due to their stiffness and lightness, Extrusions on a mandrel or through a bridge die, that requires splitting of the billet with re-welding, produce hollow shapes with varied contours, fins and multiple cavities. Moving and stationary mandrels, mandrel lubrication, tooling for ribbed-tube heat exchangers, and for drilling pipes are considered. Bridge dies can be classified by the bridge position relative to the die face, by mandrel support structure, and by assembly type, The main parameters influencing the quality of the die-welded seams are considered, The difficulties of extruding various alloys through bridge dies are discussed in terms of metallurgical factors, Some approaches to the calculation of the stresses in a bridge are presented.

Jan 1, 2005

By S. Onuki, T. Ando, M. Tejima, R. Enomoto, Y. Okada

"Al–Si–Cu–Mg die casting alloys are widely used in the automotive industry, and recent advancements in high pressure die casting technology enable heat treating products to achieve desirable properties. However, CO2emissions associated with die-casting production lines should be reduced to address the global warming issue. In this study, the relation between the microstructures and thermal stability of precipitates formed during isothermal aging at 423, 485, and 558 K of Al-11.0 mass%Si-1.8 mass%Cu-0.2 mass% Mg (JIS ADC12) was investigated using Vickers hardness tests and transmission electron microscopy (TEM). The hardness tests and TEM results showed that Si compounds and Al–Cu compounds enhanced the mechanical properties of the alloy and that the predominant compound affecting the mechanical properties differed between specimens treated at 423 K and those treated at 558 K. Moreover, additional aging at 423–458 K resulted in a material with a Vickers hardness higher than that of the isothermally single-aged material. Differential scanning calorimetry, differential elemental analysis, and selected-area diffraction analysis using TEM suggested that the combination of Al–Cu compounds precipitated at low aging temperatures and Si compounds precipitated during preliminary aging increased the mechanical strength, resulting in a maximum hardness of 130 HV.INTRODUCTIONAl–Si–Cu–Mg die casting alloys have well-balanced mechanical properties, machinability, and cast ability. These alloys are therefore widely used in the automotive industry because of their superior characteristics, accounting for>90% of the aluminum used in die casting production. As a substitute for iron-based materials, these alloys have contributed to the development of lightweight vehicles.Dong et al. (2014) reported that the heat treatment of die casting materials is effective for changing their dimensions under high temperatures as a result of the precipitation of solid-solution elements. Recent advancements in high pressure die casting technology have led to the application of heat treatments of Al–Si–Cu–Mg alloy products to reduce fuel consumption and satisfy customer needs. Although attempts to reduce CO2emissions have focused on fuel consumption in cars and fuel efficiency regulations have become increasingly strict in recent years, CO2discharged from production lines should also be reduced without adversely affecting the properties of the product. Heat treatments for artificial aging after solution treatment (T6 treatment) and after casting (T5 treatment) are CO2discharge sources, which together with a holding furnace account for >80 % of the CO2discharged during the casting process."

Jan 1, 2018

By Hyumng Sup Choi

The role of the interfacial electrical 'Condition on the adsorption of col-lectors on mineral surfaces has been studied by electrophoretic mobility and adsorption measurements made on zircon. From the investigation of the electrokinetic properties of zircon, H+ and OH-are seen to act as potential determining ions, thus controlling the electrical nature of this mineral. The isoelectric point of zircon occurs at a pH of approximately 5.0, and it is evident, therefore, that the zircon surface would be positively charged below a pH of 5.0 and negatively charged above this pH. The adsorption of collectors therefore de-pends strongly on the pH of the solution; anionic collectors are adsorbed on positively charged surfaces and cationic collectors on negatively charged surfaces. This, in turn, de-fines the effective flotation condition, with respective collectors, for this mineral. The above results have been correlated with the flotation behaviour obtained by the simplified flotation test using a modified Hallimond tube.

Jan 1, 1963