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By Roderick Guthrie

Gas injection into liquid steel baths is widely practiced, ever since the early days of Bessemer’s pneumatic steelmaking process. What has not been fully appreciated is the critical role of bubble sizes for delivering higher quality commercial steels than is presently possible. This was first proposed by Prof P. Hayes and his research group. Using a full-scale water model of a typical 4-strand Ladle-Tundish-Mold system, we demonstrate the potential advantages of modifying a typical ladle shroud, to generate microbubbles within the water flowing into the tundish. This is possible by taking advantage of high shear rates and turbulence kinetic energy available in that region. These microbubbles enhanced the removal of “micro-inclusions” (hollow glass microspheres) in the 5–50 micron size range, to the upper surface of the tundish. There, they were absorbed into an overlaying “slag” phase. Accompanying CFD studies confirmed that no microbubbles in the size range generated (500–900 μm), pass through the submerged entry nozzles into the moulds.

By K Barbosa, G Wilkie, F Reyes, V Jokovic, C Evans

The idea behind Grade Engineering is to exploit the natural heterogeneity of an orebody (spatial, temporal) in order to divert low-value waste out of the mining value chain. Essentially, this involves rejecting material at relatively coarse particle sizes (10 mm to 200 mm). However, lack of knowledge about the inherent particle grade distributions in these coarse particle size ranges limits the opportunities for optimisation. Particle grade distributions are essential for quantifying and modelling gangue liberation and yield curves. These curves can then be used to predict the mass and value flows that will go towards the accept and the reject streams. Particle grade distribution information for particles coarser than 10 mm can be collected based on chemical assays of sufficient number of individual particles. However, for smaller particles (1 mm to 9 mm), a significantly larger number of particles is required for assays. Moreover, in some cases, the mass of individual particles is smaller than the minimum mass required for chemical assaying. Also, other quantification techniques such as automated mineralogy, eg Mineral Liberation Analysis (MLA), require extended measurement times to analyse statistically representative numbers of particles at these size ranges. This work investigates the use of 3D X-ray microtomography to fill this quantification gap at these size ranges (1 mm to 9 mm). In-house image processing algorithms are used to estimate the mineral/metal content in each particle. Particle grade distributions, as well as density distributions, are thus produced without a minimum mass requirement and with each scan providing information about tens to hundreds of particles at a time. Mineralogical data from MLA analysis, of finer size ranges, is used to inform X-ray microtomography, so a simpler 3D mineral map can be obtained using the image intensity. Chemical assay information of the scanned samples is used to validate and correct the mineral phase segmentation.

Aug 24, 2022

By P. R. Warner

This paper reviews the development of certain aspects of the electrical specifications of Anglo American?s suite of specifications for gearless mill drives (?GMDs?). These specifications are based on experiences in both Anglo American?s and others? operations, benchmarking against large hydro generators, the advice of industry and university experts, and continuous close co-operation with OEMs. To achieve a step change in availability additional final testing and electrical protection have been implemented, insulation requirements have been specified for machines to be operated at high altitude and clean area and access control systems have been developed.

Jan 1, 2012

By G. Hamel

The LCL&L process (Low Caustic Leaching & Liming) is a patented hydrometallurgical route developed by Rio Tinto Alcan (RTA) to economically process spent pot lining (SPL) generated by aluminum cells. The three resulting end-products (carbonaceous, fluorinated and caustic liquor) are inert and have valorization possibilities. An industrial size pilot plant located in Saguenay (Quebec) was inaugurated in mid-2008 to demonstrate and optimize the technology. This paper describes characteristics of the LCL&L process and the experience acquired by RTA since the plant's start-up, including ramp-up capacity and technology challenges that were overcome. Possible end-products valorization methods are also presented. The carbonaceous end-product can be separated into carbon and brick rich fractions and used as either alternative fuel, reducing agents, or as raw material for third party processes. The development of a conversion process for the fluorinated end-product would allow its reuse as a substitute to fluorspar mineral for aluminum fluoride production. Finally concentrated caustic liquor is already valorized at the nearby RTA Vaudreuil alumina refinery.

Jan 1, 2011

By J Zhang, L Klemettinen, A Jokilaakso, J Biswas, J Partinen, H O’Brien, A Klemettinen

Waste lithium-ion batteries (LIBs) are important secondary sources of many valuable materials, including Critical Raw Materials (CRMs) defined by the European Union (EU): lithium, cobalt, manganese, and graphite. Additionally, LIBs typically contain nickel and copper, which are classified as Strategic Raw Materials for EU since 2023. In recent years, great effort has been made to develop efficient recycling processes for waste LIBs. Pyrometallurgical processes have been essential in industrial production of metals for many decades. These technologies are relatively mature, with high adaptability for different raw materials. Pyrometallurgical treatment in LIB recycling typically involves the use of smelting processes, in which waste batteries are heated above their melting points and metals are separated through a reduction reaction in the liquid phase. Through this recycling route, cobalt, copper, and nickel can be efficiently recovered in the form of a metal alloy, whereas lithium and manganese are lost in the slag phase. The goal of this work was to increase the recoveries of valuable battery metals through a combination of hydro- and pyrometallurgical unit operations. First, industrial Li-ion battery scrap underwent a selective sulfation roasting stage, where the aim was to transform LiCoO2 and Mn-oxides into Li, Co and Mn sulfates. After roasting, the battery scrap was leached in distilled water with a solid to liquid ratio of 100 g/L at 60°C and recovered 95 per cent of Li, 61 per cent of Mn and 35 per cent of Co. After leaching, the solid leach residue was mixed with industrial Ni-slag and biochar, followed by reduction at 1350°C in argon atmosphere. The high-temperature smelting experiments were conducted as a function of time (5–60 mins) to investigate the reduction behaviour of battery metals. The results show that Co and Ni from the slag and leach residue can be efficiently recovered in the slag cleaning stage.

Jun 19, 2024

Economic and technical reasons forced the mining industry all over the world to increase the unit size of mineral processing equipment. in large flotation cells, this development leads to problems in areas of air dispersion and keeping solids in suspension. Outokumpu, an operating mining company, designed and developed a mixing mechanism for large flotation cells at its own concentrators and also studied problems related to tank design. Ideal conditions for flotation can only be achieved if the flow pattern created by the mixing mechanism fits well into the tank configuration and the risk of short circuiting is minimized. In large deep flotation cells, four different zones can be found which improve the behaviour of large cells when compared to small cells. Selectivity is increased and in some cases final concentrate grades can be produced from the rougher cell. The largest units have also been used as final cleaners in some installations. When modernizing old plants by installing fewer larger flotation cells, immediate and substantial savings in power consumption are achieved. Additional power savings are made in pumping costs because of simpler circuit design and decreased circulating loads

Jan 1, 1978

By I. Govender

Positron-Emission-Particle-Tracking (PEPT) has enabled the non-invasive observation of charge and slurry transport in model mills under operational conditions. We use high quality PEPT data to infer that the charge motion can be effectively described by a non-Newtonian granular fluid. An improved theory for slurry transport, including inertial effects, is presented.

Jan 1, 2012

By S. Khan, M. Auret

Due to the modernisation of mines, traditional training methods may be supplemented to support the upskilling of supervisors in mines. A project was initiated by the SAMERDI SATCAP programme to demonstrate the “art of possibility” through a modern training methodology. Two exemplar digital supervisory leadership development modules for underground gold and platinum-group metal conventional and modernising mines, were developed for potential uptake by the mining industry. These exemplar modules were exhibited on a digital platform, towards leading and driving mining modernisation. The research adopted a mixed method approach that included a literature review, a review of an existing supervisory leadership development programme, data gathering, a pilot study, and stakeholder validation workshops. The research supported the development of exemplar digitised modules. The two digitised modules were showcased to the industry for potential adoption. Training slides, a facilitator guide, and a training video were developed for ease of use by industry. The training modules are generic and not specific to a particular mine. They may be used by multi-commodity mines, including gold and platinum-group metals, as ‘stand-alone’ modules. They are customisable, through consultation with relevant service providers for specific working environments. The findings indicated that both the traditional classroom training and the new digitised online learning solution offer advantages for supervisory leadership development. Digital learning is not a new concept for supervisors at mines and modern training methods are well-supported by supervisors in the industry. A ‘modernised’ training solution may consider a ‘blended’ learning approach that combines traditional training with digital methods.

Jun 27, 2025

By G F. Brent, R D. Hart, C Carr, F Felipe

In underground operations, where copper, gold and other metals are mined, the open stopes can be backfilled to stabilise surrounding workings. This fill may consist of tailings from the processing plant, usually mixed in slurry with a binder such as ordinary Portland cement (OPC). Extensive use is made of tailings in OPC-based paste fill, cemented hydraulic fill or cemented aggregate fill applications. A large underground operation such as the Mount Isa Copper Operations utilises over three million tonnes of backfill per annum. Geopolymers offer an alternative binder system with significant environmental advantages over OPC. Geopolymers are formed by polymerisation of aluminosilicate precursors in an alkali medium. They generally form products with superior strength characteristics as well as increased resistance to degradation, particularly under acidic conditions. Geopolymers have lower carbon dioxide emissions associated with their manufacture than OPC and offer further potential advantages, such as the use of less water and more waste materials. The application of geopolymers to weak material systems such as mine backfill has not been widely studied. The aims of this investigation were to assess a range of Australian mine process wastes for suitability as feedstocks in fill applications and to construct a range of these cemented minefills using a geopolymer binder. The physicochemical characteristics of each of the wastes are discussed as well as how they ultimately contribute to the geopolymer cement through direct replacement of OPC. Results from various tests on the candidate geopolymer fill formulations are presented and the potential of such fill formulations to replace OPC in mine backfilling operations is highlighted. The significant potential contribution to reducing greenhouse gas emissions from the use of geopolymer-based mine backfill across the industry is noted. Conversion of a single mine, such as the Mount Isa Copper Operations, is shown to match the reductions in greenhouse gas emissions due to the current total installed photovoltaic electricity generation capacity of Australia. A similar examination of wastes available to a gold mine could potentially yield new binders for use in established or new fill systems.

Jan 1, 2007

By Bryan M. Maybee

The scheduling of underground mining activities is a complex task, in particular because of the requirement to satisfy a large number of constraints. A Schedule Optimization Tool (SOT) for underground mine planning is described, and its use for investigating strategic decisions is illustrated by means of a case study. The main components of SOT include: a genetic algorithm, which searches for optimal schedules; guidance, the application of heuristic rules to guide the genetic algorithm; and sliding, which implements just-in-time development. For the case study, SOT is employed to generate schedules at various ore capacities, accounting for the appropriate financials in each schedule evaluation. The case study finds that preliminary scheduling performed before invoking SOT, intended to provide a good starting point for the search, does not ultimately lead to higher value schedules. Two key uses for SOT are identified. A mine planner can save time by using SOT to produce high-value scheduling alternatives. This process ensures a broader investigation of the value that the deposit can yield. Also, SOT can be used to validate strategic and tactical decisions, by scheduling under alternative scenarios. Both uses produce high value schedules conforming to all imposed resource constraints.

May 1, 2009

By Peter Fullagar, Adel Vatandoost, Steve Walters, Toni Kojovic

"Traditional comminution tests are a vital component in every mine plant design. Comminution behavior governs both the cost of equipment and its operating efficiency. Most comminution tests are conducted off site on a limited number of samples, owing to the high costs and long lead times involved. Therefore a strong incentive exists to find alternative means for efficiently characterizing comminution behavior for a truly representative suite of samples. The potential for inferring comminution behavior from drill core is investigated in this paper. Our approach involves development of small scale comminution tests on the one hand, and measurement of a wide range of core attributes on the other. Our focus is the relationship between petrophysical properties and comminution behavior.Petrophysical properties of archival diamond drill core from the Ernest Henry Mine (Queensland, Australia) have been measured using a Geotek multi-sensor petrophysical core logger. We have investigated the relationship between the petrophysical properties and the corresponding small scale A*b and estimated Bond mill work index test results for 2m composites of the core. Core samples were petrophysically classified by means of cluster analysis. Comminution behaviour was then modeled for each cluster via multiple regression. The results suggest that prediction of the comminution behavior on the basis of petrophysics is viable at Ernest Henry.INTRODUCTIONMineral processing is the most important downstream operation for mining engineers and metallurgists since most mined materials are subjected to some type of comminution or beneficiation operation (SME, 1992). Comminution or size reduction is typically the first stage of processing. Size reduction steps (crushing and grinding) in any plant consume large amounts of energy, normally more than 50% of total energy (Weiss, 1985). Therefore, it is desirable to obtain laboratory results to design the size reduction equipment appropriately. One of the main factors that control the selection of hard-rock crushing equipment and the design of a crushing circuit is the mechanical character of the ore(s). Work index, density, abrasivity, compressive strength and clay content are essential parameters for ore characterisation (SME, 1992)."

Jan 1, 2009

By S. J. Frank

Ferroalloy furnaces are well known to be extremely difficult to control from a metallurgical perspective. Mostly metallurgical control is still reactive in nature, causing a significant amount of reworking and product blending to achieve a proper product specification. Despite numerous efforts towards the model based control of primary smelting operations, actual metallurgical feed forward control seems to remain elusive. One of the key reasons in the failure to model these metallurgical reactors well, is that fundamentally orientated pyrometallurgists, statisticians, data miners and control engineers very often have diverging ideas how to model these systems. Furthermore, metallurgists have often come to rely on their ability to develop empirical regression models of furnace behaviour, as they have lost their faith in the ability of thermochemical and metallurgical engineering fundamentals to accurately predict the outcomes from furnaces. This paper shows how good thermochemical modelling can be combined with proper technological and systems analysis, as well as a proper inventory model, to predict the alloy and slag chemistry with good accuracy one tap into the future, at a time horizon of typically around 4 to 6 hours. For this modelling approach, a number of tools will be used, such as data reconciliation, thermodynamic modelling using Fact Sage®, inventory and heel estimation, neural networks and statistical data exploration. Furthermore, systems identification theory will be combined with the approaches given above to develop a truly dynamic predictive model. This paper seeks to demonstrate the need for a hybrid approach, which incorporates plant data and readily accessible thermodynamic data to develop a proper dynamic model.

Jan 1, 2004

By G. A. Bezuidenhout, J. Davis, S. M. Bradshaw, J. P. T. Kapusta, D. K. Chibwe

"This research work forms part of an assessment to complement the feasibility of implementing high pressure sonic injection into relatively small (2.25 m I.D by 3.66 m I.L) Peirce-Smith converters (PSC) used at Lonmin Plc. Work has been carried out to characterize the fluid dynamics of three-phase (air, matte and slag) fluid flow in these converters using Computational Fluid Dynamics (CFD) simulations. The investigation has been done to study the flow pattern of the three phase system at high air pressure injection achieving sonic velocity at the tuyere exit into the converter. The 2-D and 3-D simulations of the three phase system were carried out using the volume of fluid (VOF) and realizable k -e turbulence models to account for the multiphase and turbulence nature of the flow, respectively. These models were implemented using the commercial CFD numerical code FLUENT. A detailed study of the flow pattern has been presented in the form of contour plots and the results obtained are useful for understanding plume extension and velocity distribution, shear wall stress distribution, and phase distribution characteristics in the system. The results provide a basis for further development of sonic injection technology into relatively small industrial Peirce-Smith converters with the ultimate objective of achieving lower energy consumption, improved process efficiency and increased throughput of the converting process. INTRODUCTIONPeirce-Smith converters (PSC) have been used in copper (Cu) and nickel (Ni) making smelters for more than a century for the purpose of removing iron (Fe) and sulphur (S) chemically associated with copper-nickel mattes through exothermic oxidation reactions. This process is commonly referred to as conversion. In principle, conversion is a submerged injection process, where typically air (or oxygen enriched air), at subsonic velocity (typically < 150 m/s), is laterally blown into liquid matte (Cu-Ni-Fe-S system). Oxygen preferentially reacts with Fe and S to produce iron oxide (FeO), which is slagged off, and sulphur dioxide (SO2), which reports to the process off gas."

Jan 1, 2012

By L. Holappa

Ferroalloy production is an energy-intensive industrial sector with significant CO2 emissions. In this paper the current situation in ferroalloy processes is discussed from the standpoint of global environmental issues, trends and development. Progress and data of ferroalloys production are frequently compared with the steel industry, which is a closely related sector and the main user of ferroalloys. Emission factors of processes and electricity production are examined as well as possibilities and future scenarios of how to diminish CO2 emissions. As a part of this study a questionnaire was submitted to experts in the field of ferroalloys worldwide to survey opinions on the ferroalloy industry today and in the near future (2020). Eighteen questions concerning raw materials, energy, environmental aspects, by-products and economic aspects were responded to by seventeen experts, the answers were analysed and conclusions were drawn. Keywords Ferroalloys, energy, CO2 emissions, electricity, sustainability, questionnaire.

Jan 1, 2010

By E. McCullough

"Fostering positive community relations is a principal tenet of sustainable development, but conflict can test even the strongest of relationships. While conflict surrounding resource development projects has the potential to be destructive, it may actually pose opportunities for partnership and collaboration when managed effectively. It is therefore not only important for mineral resource professionals to recognize the financial and social costs associated with legal disputes among project stakeholders, but also for them to prioritize resolving social conflict using alternative channels that allow for win-win outcomes. A variety of dispute prevention and resolution techniques do exist, but successful practice is not yet the norm. Here we review the sources and consequences of social conflict in the context of mining projects, and discuss typical and alternative approaches to conflict management in light of their respective benefits and drawbacks. We also suggest implementation of conflict resolution lessons into resource-related university curricula as a critical step in the continued shift of the mining industry towards sustainable development. INTRODUCTION Social conflict is a recurring phenomenon in the human experience and serves as a critical mechanism for change [1-5]. It occurs when two or more parties perceive that their needs and interests are in direct competition with each other and believe they cannot be reasonably accommodated. Conflict over mineral resource activities, particularly the distribution of benefit and risk, has become an omnipresent issue throughout the world [6-7]. Contrary to common perception, however, conflict can be a positive, transformative encounter in some instances [2, 8-11]. For this to be possible, society and its acting agents must reconsider how to address conflict. What if conflict were only a challenge to try something different? It is well-understood that the mineral industries must manage an increasingly significant volume of social conflict [12-13], which can be a costly externality impacting all of whom are involved. Conflict is commonly considered in a two-party sense, but this can deeply over-simplify the true number of stakeholders. Besides mining companies and community members, government policymakers and regulators, public interest groups, and judicial systems, to name a few, bear the social expenses of poorly-managed conflict [4, 6, 12, 14-22]. It is desirable for interested parties to participate actively in a constructive way to pursue their needs rather than contributing to adversarial relationships, operational problems, and legal costs [1, 4, 12]. Some mining companies are of course already working to develop more productive relationships with their stakeholders, but there is undoubtedly still a gap between ideal and common practices. This gap can inhibit collaboration and threaten the potential for mutually-beneficial resolutions to complex social issues [12]."

Jan 1, 2016

By Gabrielle Gaustad

For aluminum, substitution of primary with secondary resources decreases energy consumption; this energy advantage creates a strong economic incentive to recycle. Several authors have raised concerns that the current sinks for secondary materials may soon be saturated, impeding subsequent expansion of recycling. This work combines dynamic material flow analysis with optimal batch planning models to quantify the significance and drivers of these pending limits under several scenarios, and thereby explore potential opportunities to increase recycling. An aluminum recycling system case was developed that includes containers and packaging, automotive, and construction products and scraps. The impacts on aggregate scrap utilization and materials cost are explored in the context of changing alloy demand and lifetime. Insights drawn from this specific case study could be applied to multi-stakeholder, systemic models.

Jan 1, 2010

?Why TSM in Canada ?How it was developed ?Architecture and Goverance ?COI panel ?Performance indicators and how they work ?External Verification ?Reporting ?The national organization of the Canadian mining industry ?Mining, smelting and refining of base and precious metals ?Mining of iron ore, diamonds, uranium, oil sands, coal and industrial minerals ?Many associate members ?www.mining.ca

May 1, 2011

By Pierre Gratton, Gordon Peeling

The Mining Association of Canada launched the Towards Sustainable Mining initiative in 2004. TSM’s goal is to improve the mining industry’s performance by aligning its actions with the priorities and values of Canadians. The initiative currently includes performance indicators for four areas: tailings management, energy use and greenhouse gas management, external outreach and corporate crisis management planning. Over the past year, the association has been designing a performance assessment and verification system for these performance areas, as its members prepare to move to external verification of their performance in 2006. The presentation will describe the initiative and its evolution, as well as the challenges faced in developing a verification system applicable to an entire sector.

Jan 1, 2006

By G. R. Peeling

The Mining Association of Canada launched the Towards Sustainable Mining initiative in 2004. TSM&apos;s goal is to improve the mining industry&apos;s performance by aligning its actions with the priorities and values of Canadians. The initiative currently includes performance indicators for four areas: tailings management, energy use and greenhouse gas management, external outreach and corporate crisis management planning. Over the past year, the association has been designing a performance assessment and verification system for these performance areas, as its members prepare to move external verification of their performance in 2007. The initiative and its evolution, as well as the challenges faced in developing a verification system applicable to an entire sector will be examined.

Jan 1, 2007

About MAC ? The national organization of the Canadian mining industry ? Mining, smelting and refining of base and precious metals ? Mining of iron ore, diamonds, uranium, oil sands, coal and industrial minerals ? Many associate members ? www.mining.ca

Aug 1, 2013