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By Jim Truskoski, Alain Bouchard, Andy Kerr, Germain Labonté, Jim Barrett

"Improving mill grade recovery relationships is always good business. INCO’s Clarabelle Mill has just undergone a $16 million process upgrade that was designed to improve nickel recovery by 2%. The “Mill Redesign Project” was completed on time, under budget and delivered the promised improvement in recoveries.This paper describes the methodology of the Mill Redesign Team, details of the process improvements and the critical success factors that helped the team deliver on its promises.With a payback of under one year, the Mill Redesign Project will play a key role in ensuring a competitive edge as INCO embarks on its second century of operation.INTRODUCTIONIt is not uncommon in milling operations to encounter a crisis. That is the point when the process does not behave as expected and fails to respond to the increasingly desperate efforts of the metallurgists and operators. Flowsheet and process changes are attempted and abandoned. With luck, one or more of the changes achieves some mitigation of the original problem or more usually, the original cause of the problem disappears. Regardless, the metallurgist can sit back and bask in the apparent success of his or her endeavours.Less common is when a problem is carefully diagnosed, a team put together to explore all avenues and recommend a path of action that is implemented on time, on budget and immediately delivers on the promises which are sustained over time. This is one such story. It is the story of the Mill Redesign Project at INCO’s Clarabelle Mill in Copper Cliff, Ontario.BACKGROUNDThe Clarabelle Mill was built in 1971 on the southern rim of the Sudbury basin. At that time it was one of four mills operated by INCO in the Sudbury area. During the 1970’s, 80’s and 90’s, the need for increased process efficiency, higher levels of sulphur rejection to tails and the concurrent development of high capacity mills and flotation cells, resulted in the consolidation of INCO’s Sudbury area milling operations into a single, expanded facility at Clarabelle."

Jan 1, 2003

By J. Bruce See

INTRODUCTION This symposium at Cu 2019 has been organised to honour and celebrate the career and achievements of Dr Phillip John Mackey, an internationally recognised expert in the production of non-ferrous metals, especially copper and nickel smelting and refining. Phillip was born in Epping, a suburb of Sydney, New South Wales, Australia on 19 April 1941 and is one of 4 children of Gilbert and Philomena (nee Bartlett) Mackey. After completing Primary School in Epping, he attended Marist Brothers High School in Eastwood, Sydney and graduated in 1957 as the Dux of the School. Phillip’s father, being on the staff of the Sydney Technical College, in Ultimo, Sydney had the opportunity in the early 1950s to meet the late Professor Sir Rupert Myers, Foundation Professor of the School of Metallurgy at the New South Wales University of Technology (later called the University of New South Wales or UNSW). Gilbert Mackey was impressed by the new young Professor of Metallurgy and encouraged his son to study metallurgy - at the time an expanding industry in post-war Australia. EDUCATION AT THE UNIVERSITY OF NEW SOUTH WALES Phillip commenced at UNSW in 1958, graduating with honours in 1963. His undergraduate education and training included a few years of part-time study while working at British Motor Corporation on sheet metal forming of car bodies. At University Phillip developed his talent for teamwork. He was a contributing writer to the University newspaper, Secretary of the UNSW Students’ Union and was active in the UNSW Metallurgical Society and co-editor in 1963 of “Metallurgical Review,” the annual journal of the UNSW Metallurgical Society. His diverse interests and curiosity about the world around him were likely nourished while at University. Upon completing his Bachelor’s degree, Phillip was awarded a Commonwealth of Australia Postgraduate Research Scholarship. He began his PhD in 1964 on the thesis topic “Studies in Heat Transfer between Dispersed Liquid Metals and Gaseous Atmospheres” working under the supervision of then Associate Professor Noel Warner, an outstanding Professor at the University. Professor Warner is now an Emeritus Professor at the University of Birmingham and is internationally respected for his pioneering theoretical and practical work on established and innovative smelting processes.

Jan 1, 2019

By Martin Froehling, Curtis Mohns, Rahim Rajwani, Michael Fullam

"The Kemess mining and milling complex is operated by Northgate Minerals Corporation and is located in the mountains of north-central British Columbia, 430 kilometers northwest of Prince George. The complex consists of the Kemess South open pit mine and a 52,000 tonnes per day mill. Hypogene, supergene and leach cap ores are processed using conventional crushing, grinding, and flotation techniques to produce gold-copper concentrates with minor by-product silver value.The rougher flotation concentrate is re-ground in closed circuit before being cleaned to final concentrate grade. Historically, gold losses in the cleaner tailings were primarily associated with pyrite, with only minor amounts of free gold. More recently, with the processing of high pyrite ores, the major losses were found to be free gold less than 10 microns in size. The fine grind required for the high pyrite ores resulted in over-grinding of the free gold particles in the regrind circuit, contributing to poor flotation characteristics. It was thought that if this free gold could be recovered by gravity at coarser size in the regrind circulating load, the free gold losses in the cleaner tailings could be reduced.Preliminary test work carried out by Knelson Gravity Solutions indicated the potential for free gold recovery in the regrind circuit. A Knelson XD-30 Concentrator was installed with variable speed capability, and a series of optimization tests were carried out. In addition, cleaner tailings were characterized with gravity operating and with gravity not operating to determine the overall gold recovery benefit. The single Knelson XD-30 installation recovers ~10% of the total gold in the regrind circuit and increases overall recovery by 3% when high pyrite ores are processed."

Jan 1, 2007

By M. Solomon

Abstract -Giant, sediment-hosted lead-zinc deposits in northern Australia formed during development of Mid-Proterozoic extensional basins that overlie Lower Proterozoic basement. The basement in the Mount Isa area, exposed by folding and faulting, contains fractionated, high-heat-producing granites. These granites generate heat at a rate of about 6 ?Wm-3, probably sufficient to form giant lead-zinc deposits either by (a) driving episodic convection of saline basement and basin fluids for periods of 105 to 106 years at temperatures of about 230°C, or (b) heating basin fluids moving under the influence of topographic relief or fault movement. The presence or absence of such granites may form a vital component of the genetic model. Ore-forming fluid flow was probably initiated by continent-scale, extensional basin fracturing.

Jan 1, 1992

By Colin E. Dunn

Abstract-Plants have a remarkable ability to select, use and store metals derived from the substrate. Each species is unique in its requirements for and tolerances to the full spectrum of chemical elements in the Periodic Table. Studies to define the chemical characteristics of common trees and shrubs of the temperate forest are providing insight to their use for exploration, i.e., biogeochemical exploration. Examples of surveys over gold deposits in British Columbia show the effectiveness of sampling various tissues from different species in a range of biogeoclimatic environments. At the Nickel Plate mine in the Montane-Spruce zone, outer bark of Lodgepole pine was effective in defining a large area of metal enrichment; at the Carolin mine in the zone of Coastal Mountain Hemlock, analysis of twigs of western hemlock and Pacific silver fir provided an exploration target considerably larger than that defined by lithogeochemistry; at the Mount Washington gold deposit in the Mountain Hemlock zone, twigs of mountain hemlock and rhododendron were used to outline the mineralization; and in the Interior Douglas-fir zone at the QR deposit analysis of Douglas-fir tops collected by helicopter provided a rapid and effective method of identifying a gold-rich area.

Jan 1, 1995

By E. Michelotti, M. Cardu

This paper presents the results of a new method that has been tested to recover metallic cobalt lost by diamond beads from rock cuttings. When dimension stones are cut using diamond wire saws, the beads become worn and, before the end of their cycle life, lose a certain amount of material; this material is prevalently made up of sintered metal and diamonds. The material is then washed away, together with rock debris, in a dilute pulp. In effect, this process involves the dispersion of economically valuable, but potentially polluting, materials (such as cobalt) that are used to confer indispensable technological features to the beads. This current research aims to develop a waste-processing pilot plant (High-gradient Magnetic Separator or HGMS) to recover metallic components from the pulp by means of a suitable separation. The research\u2019s purposes are two-fold: a. to remove the polluting components from the rock debris before their disposal and b. to start a recycling process of the valuable metals.

Jan 1, 2010

By M. Solomon

Giant, sediment-hosted lead-zinc deposits in northern Australia fonned during development of Mid-Proterozoic extensional basins that overlie Lower Proterozoic basement. The basement in the Mount Isa area, exposed by folding and faulting, contains fractionated, high-heat-producing granites. These granites generate heat at a rate of about 6",Wm-3, probably sufficient to fonn giant lead-zinc deposits either by (a) driving episodic convection of saline basement and basin fluids for periods of IOS to 106 years at temperatures of about 230°C, or (b) heating basin fluids moving under the influence of topographic relief or fault movement. The presence or absence of such granites may form a vital component of the genetic model. Ore-fonning fluid flow was probably initiated by continent-scale, extensional basin fracturing.

Jan 1, 1992

By Nader Golchinfar

The V-shaped breakout zones around excavation boundary have been captured by a variety of numerical methods such as FEM and DEM methods and failure criteria such as linear Mohr-Coulomb and non-linear Hoek-Brown failure criteria. Diederichs (2007) used Hoek-Brown parameters in his spalling parameter approach; however, it is convenient to use the Mohr-Coulomb failure criterion in numerical modeling because the material parameters can easily be determined from triaxial tests. It is shown in this study that when peak and residual strength parameters as well as dilation angle are properly defined, the brittle Mohr-Coulomb failure criterion can be used to model depth of failure near underground excavations satisfactorily.

Jun 1, 2012

RISKGATE is an interactive online risk management system developed by the Minerals Industry Safety and Health Centre (MISHC; University of Queensland) to assist the mining industry in implementing continual improvement in management of major unwanted events so maximising health and safety performance. A comprehensive body of knowledge has been compiled from diverse mining industry experts for risk management of tyres, collisions, fires, isolation, strata underground, ground control open cut, explosions, explosives, manual tasks and slips/trips/falls. This paper presents an overview of the RISKGATE body of knowledge captured specifically for the management of unwanted events that stem from the handling and use of explosives (drill and blast) within surface coal mining operations. The knowledge presented is divided into a series of initiating events (listed below) within which there are further degrees of classification based on design, operation, and management concerns. Initiating events: ? Loss of control of explosives and associated chemicals in storage on site ? Loss of control of explosives and associated chemicals during transport ? Loss of control of explosives and associated chemicals during manufacture ? Loss of control of explosives and associated chemicals during handling and blast operations ? Loss of control of explosives and associated chemicals during disposal The system guides the user in generating substantive and leading-edge controls to assist in the design, management and reporting of drill and blast operations to meet stringent internal and external requirements. From a broader industry perspective, RISKGATE provides an environment for knowledge capture and knowledge exchange to drive innovation and best practice in the identification, assessment and management of risk. By capturing operational knowledge from industry experts, RISKGATE provides a cumulative corporate memory at a time of high personnel turnover in the coal industry.

Aug 1, 2013

By L. W. Vigrass

Porous and permeable rocks deeply buried in sedimentary basins contain immense volumes of hot water with the potential to supply low-grade heat energy. A part of Canada with sizeable potential for low-grade geothermal energy is the northern Williston Basin of southern Saskatchewan. In this region, the University of Regina has conducted a geological study investigating the feasibility of producing large quantities of warm water suitable for space heating in the Regina - Moose Jaw area. The study has shown that the most favourable geothermal reservoirs are in the Basal Clastic Unit (Cambrian Ordovician), which, at an approximate depth of 2,000 metres has predicted temperatures of 71°C to 74°C. We anticipate sustainable flow rates from these reservoirs of 100 to 300 ms/hr. The water contains about 150,000ppm of total dissolved solids, mostly sodium chloride. It is anticipated that the sulphate content will be 3,000 to 6,000 ppm, that the dissolved oxygen and hydrogen sulphide content will be small, and that the waters will be neutral to slightly alkaline. It is anticipated that the piezometric level will be 46 m below the ground surface for reservoirs in the upper part of the Basal Clastic Unit and 141m below the ground surface for the lower reservoirs of the unit. Plans are to build a low-grade geothermal research, testing and demonstration facility at the University of Regina. To be a practical demonstration, the facility will have to handle very large volumes of water. Because of high salinity, the water will be re injected into a subsurface reservoir. We do not anticipate insurmountable problems because of salinities or as a result of corrosion provided that the waters are not aerated during handling

Jan 1, 1979

By G. Simard, D. Boudeville, A. Leclerc, A. Boivin

"The objective of this work is to study the various parameters that affect the overflow clarity of gravity settlers used in the precipitation circuit of alumina hydrate from the Bayer process. A mathematical model incorporating the size distribution of the feed suspension (Multi Size Group model), its diphasic nature (Schiller Naumann model) and the presence of turbulence (Shear Stress Transport model) has been solved numerically using ANSYS-CFX software. Preliminary results indicate that the overflow clarity is mainly controlled by lateral diffusion of fine particles (~20µm) from the exit of the feed well and by their upward transport from the sediment bed interface. Also the turbulence pattern in the settling zone seems to play a significant role in this vertical transportation. The validity of the model has been verified by comparing the measured solid concentrations from a pilot classifier with the calculated ones. This model could provide mineral processing plant operators and designers with a tool to optimize the configuration of classifiers with respect to the overflow clarity.INTRODUCTIONProblemIn the Bayer process, alumina hydrate precipitation from the saturated liquor is initiated in settler by adding crystallization seeds. Most of the precipitated alumina settles to the bottom of the tank while the liquor and the remaining alumina rise to the top, where they are removed at the overflow. Ideally the overflow clarity, which depends on the operational mode of the classifier, should be controlled within targeted limits."

Jan 1, 2016

On the recent trip from Vancouver to Calgary with the President, Mr. C. C. Huston, and yourself, I had the opportunity of outlining a plan based on the following: Among the aims of the Institute are, obviously, the fostering of the confraternity of those engaged in the technical and management fields of the mining and petroleum industries. This may be achieved in a number of ways, of which, to me, the interchange of ideas and experience between different parts of Canada and different sections and divisions of the Institute appears to be one of the most important. I think you and the membership as a whole are, and have been, well aware of this. The annual tour of the President .and Secretary, particularly their visits to Branches, shows this to be true. The interchange of ideas through the medium of the BULLETIN also illustrates the point; indeed, most Institute activities are directed along these lines. I am convinced that much more could be accomplished if it became financially possible to do so. Many able and fine men are, I think, willing and anxious to give their time and energy to furthering these phases of Institute activity, but it is unfair to expect them to assume as well the financial obligations involved. Specifically, I would suggest that the following could be done if sufficient funds were available:

Jan 1, 1952

By Jim Wickens, Andy Cole, John Pekrul

"The roaster facility at Barrick Goldstrike Mine treats double-refractory sulfidic/carbonaceous gold ore. Prior to oxidation in the roasters, the ore is ground in two parallel dry grinding circuits utilizing 19’ Ø x 75’ double rotator mills. The design plant throughput was 12,000 dstpd. However, process improvements have significantly increased throughput rates by 25-50%. The current daily throughput record is 20,078 dstpd. Grinding circuit improvements contributing to this success include feed size reduction, ball size optimization, automatic ball charging optimization, and operating strategy changes. In addition to the changes already made, this paper discusses future optimization initiatives including on-stream particle size analysis and “real-time” ore hardness determination techniques.INTRODUCTIONBarrick Goldstrike Mines is located 29 miles Northeast of Carlin, Nevada, USA. Through 2001, the property has produced over 23 million ounces of gold making it one of the premier gold operations in the world.Prior to Barrick’s ownership, the property began producing gold from a small heap leach operation in 1975. The small-scale heap leach production continued through 1986, and in January 1987, Barrick acquired the property. Increased exploration activity by Barrick significantly increased gold reserves. In August 1988, a 4,500 dstpd mill facility was commissioned to treat high grade oxide ore. Also, heap leach operations had significantly expanded. In 1990, the mill was expanded to 6,000 dstpd, and the first autoclave was commissioned to treat refractory sulfide ore. By the end of 1996, the mill and pressure oxidation facility had expanded to 16,000 dstpd and heap leaching had ceased as oxide reserves were exhausted. In 2000, a roaster facility was commissioned to treat double-refractory sulfidic/carbonaceous ore."

Jan 1, 2003

By Leiting Yue, Peng Ren, Yu Shen, Zhihong Liu, Haibao Shao, Longgong Xia, Feng Yu

The Kennecott-Outotec Flash Converting technology has been proven as an advanced and mature process in 5 individual plants during the past 2 decades. High grade copper matte (65–72%) produced in the flash smelting, or other smelting technologies is granulated to 3-5mm granules in a water torrent, and further crushed to fine powder (≈50µm) and dried to contain less than 0.3% H2O. Oxygen enriched air, together with fine copper matte powder and lime flux are injected into the reaction shaft by a matte burner. The copper making and slag making reactions will happen in very short time and distance during the particle falling and settling. However, industrial practice has found negative effects caused by sodium contamination. Na is introduced in the copper matte granulating process, and appears as Na2SO4 on particle surface. When Na content was high, scaling problems in the boiler will be worse, and the processing air will be blocked by the growing accretion around the matte burner, and as-produced blister copper is always high in S and O. In this present study, an industrial matte sample was used in the experimental work. Na was introduced into the matte powder by Na2SO4 solution soaking. The burning behaviour of the doped copper matte powder has been investigated as a function of the impurity concentration and processing temperature. Morphology and composition of these samples explained how Na2SO4 converts and reacts in the oxidizing atmosphere, and how they or their converting species influence the burning behaviour of matte particles. Cross-sections of as-prepared samples were analyzed with SEM-EDS, and the reaction mechanism has been carefully interpreted. Results from the present study can benefit both academic and industrial people. INTRODUCTION "Flash Converting" technology was developed jointly by Kennecott Utah Copper Smelter and Outotec (Finland) OY in 1992. The first industrialization of the technology was in Utah Smelter in 1995. Since 2006, it has been successfully applied in Xiangguang Copper, Tongling Jinguan Copper Branch, Fangchengang Jinchuan Copper, and Ningde Southeast Copper. The technology has also been further developed in those smelters. At present, roughly 2 million tons blister copper is produced annually through the Kennecott-Outotec Flash Converting technology, accounting for more than 10% of global primary copper production. The technology has advantages of high efficiency, high sulfur capture rate, good in environmental issues, mature equipment supporting, high automatic control level, low comprehensive energy consumption and flexible connection with the smelting unit, which make the technology to be one of the best choices in investing a new large-scale copper smelter or updating an old copper project in the world.

Jan 1, 2019

By Yan-Jun Shen

The rock mass classification system, BQ (basic quality), is the only national system that is suitable to most kinds of rock engineering in China. It uses two main aspects of the rock mass, the intact uniaxial compressive strength (UCS) and the rock intactness index (KV), to obtain the rock mass BQ. The index KV could be measured by the acoustic wave method. However, because this method is an indirect approach to characterize the rock mass structure, misfits often occur between the test results and the actual rock mass characteristics. Therefore, a new parameter KGSI expressed by the geological strength index is proposed to replace the original KV, and a new method is presented to express the value of BQ as a function of the UCS and the KGSI. Then, the underground excavations at five hydropower stations were chosen as examples to study the relationship between the revised BQ and the each of the international systems (RMR, Q or RMi). In addition, the applicability of the RMR, Q, or RMi system is discussed for China?s rock characteristics and geological conditions, and suggestions are given for improving the revised BQ system.

Aug 1, 2013

By J. Schnarr, D. Deever, E. Johnson

"The above committee sent out a questionnaire to the gold mines for the purpose of learning what units and methods are currently in use in the mines as the first step in an attempt to agree on standard units to be used in any papers or reports that may be given to other mines or presented at meetings. The next step is to try to arrive at acceptable standard units for reporting and methods of making tests. It was suggested by Mr. J. Jardine of Eldorado Mining and Refining that the use of the metric system should be seriously considered. It was also brought out that there was no intention of having any mine change their methods to the standard for internal reporting as this would involve too much change. However for external reporting there shouldn't be too much difficulty in converting to the accepted standard units.On the following pages are the reports of those mines that replied to the questionnaire.MALARTIC GOLD FIELDS LIMITEDP.A. Coulter1. All assays - Ounces per ton2. Consumption of reagents - Pounds per ton3. Reagent strength of solutions - Pounds per ton4. Reducing Power - As described in C 0 I.L, Analysis of Cyanide Solutions5. Pulp Densities - Grams per litre6. Screen Analysis (Tailings) A sample of 150 gms is washed on a 200 mesh screen. The plus 200 mesh material is dried and ro-tapped for fifteen minutes. The plus 200 mesh portions are weighed cumulatively (the balance is considered -200 mesh) and reported in per cent."

Jan 1, 1967

By D. J. Scarpato

"Slope construction in shale can present some interesting challenges for geotechnical design engineers and contractors alike. There are challenges that can be expected and designed-for; however, all too frequently, such challenges manifest themselves as “surprises” in the field. Common constructability challenges can include those such as drill hole deviation during drilling for controlled blasting; and, excavation slope instability arising from inconsistent perimeter control drilling. Drill hole deviation results from the cumulative effects from both drilling mechanics and rock mass conditions. Once a hole has initiated the deviation trajectory, it is difficult to rectify drill steel position. Although such challenges are not necessarily unique to shale, they are often exacerbated by weak, weathered and transversely isotropic nature of bedrock conditions. All too often, the working assumption is that shale is “soft” and easily excavatable; however, this blanket assumption can prove to be costly. This paper is intended to provide design professionals and contractors with the practical considerations needed to avoid the “surprises” associated with drill hole deviation, and minimize the potential for costly claims.INTRODUCTIONFor all the slopes that have been excavated worldwide, and for such advancements in excavation technology and field characterization, one might be tempted to believe that the industry almost has slope development down to a science. This is frequently not the case, especially for weak/weathered and anisotropic bedrock. Excavation contractors are still pushed to the limits of what their technology can achieve, and engineers are all too often called to the field during construction, to make potentially risky onthe- fly decisions relative to excavatability, short and long-term slope stability, and project safety. Although there have been a host of other research papers and journal articles that have been written on the subject of deviation over the past 30 years (Brown, Geen, Sinha, 1981), the problems associated with drill hole deviation are still all too frequent. This fact is especially true for civil engineering surface excavations in bedrock."

Jan 1, 2015

By Turgut Yalcin

"High-grade concentrates are achieved in flotation columns primarily due to the use of thick froth layers and wash water, both of which facilitate the drainage of hydrophilic minerals from the froth. However, conventional columns employ tall, non-agitated recovery sections for bubble-particle attachment that require high headroom and special gas spargers as well as imposing particle size limitations. These disadvantages can be all alleviated by carrying out the recovery part of the process in a mechanical or pneumatic cell which generate froth more conveniently and efficiently.This paper describes the combining of mechanical and column flotation in a single unit and discusses the influence of various parameters on the performance of the system.INTRODUCTIONIn a flotation process, some of the minerals lifted up to the froth phase may drain back to the pulp due to various reasons such as weak attachment of particles to air bubbles, bursting of air bubbles, agitation of froth, etc. Weakly floating and entrained hydrophilic minerals drain at a faster rate than the strongly floating minerals, and effective exploitation of such differential drainage can lead to cleaner concentrates.For a given mineral, if the rate of flotation from pulp to froth is k1 (min·1) and the rate of drainage from froth to pulp is k2 (min""1), then the net (overall) flotation rate of the mineral, k (min-1 ), will be [Lynch et al., 1981 ]:"

Jan 1, 1997

By L. Chunpongtong

Compared to equipment used in hard rock mines, the lifespan of equipment deployed in oil sands operations tends to be shortened due to the abrasive nature of the material and soft ground conditions in which it operates. One of the challenges of oil sands mine planning is to determine the most cost-effective replacement time for aging equipment. For cost engineers dealing with aging equipment, the options become an economic trade-off between taking the chance of higher frame failure or buying new equipment. Therefore, the ultimate question is: “When is the best time to replace the equipment?”

Jan 1, 2012

By Jian Li, V. Y. Gertsman, David C. Katz, M. Elboujdaini

Analysis of stress corrosion cracking (SCC) usually involves high-end analytical tools including scanning electron microscope (SEM) and analytical transmission electron microscope (TEM). In recent years, focused ion beam microscope (FIB) has found many applications in materials science fields. In this study, high-resolution FIB images have shown details of crack morphology and a plan-view TEM specimen containing the selected crack-tip was successfully prepared. The preparation of cross-sectioned samples containing crack tips was of paramount importance for subsequent TEM analyses.

Jan 1, 2004