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By D. A. Fenton

The reliability of large diameter, high horsepower ball mill is paramount when large production and minimum downtime is required. The 17 ft. x 56 ft. double compartment ball mill at St. Lawrence Cement Company has the first gearless drive built in North America and has the world's largest hydrodynamic bearings currently built and running. The machine has seen three years operation and has met its specifications. The mill was designed by Aerofall Mills Limited and the gearless drive built and designed by the Canadian General Electric Company. This paper discusses the operation of the first North American installation of a gearless drive ball mill from the mechanical, electrical and process aspects.

Jan 1, 1977

By C. Coles, J. A. I. Young, W. A. Wyeth, D. A. Fenton, G. W. Herzog

The reliability of large diameter, high horsepower ball mills is paramount when large production and minimum downtime is required. The 518 x 1706 mm (17 x 56 ft) double compartment ball mill at St. Lawrence Cement Co. has the fist gearless drive built in North America and has the world's largest hydrodynamic bearings currently built and running. The machine has seen three years operation and has met its specifications. The mill wm designed by Aerofall Mills Ltd. and the gearless drive built and designed by the Canadian General Electric Co. The paper discusses the operation of the machine from the mechanical, electrical and process aspects.

Jan 1, 1980

By Joël P. T. Kapusta, Romeo U. Pagador, Noparut Wachgama, Chumnoom Khuankla

"Thai Copper Industries (TCI) is a custom copper smelter and refinery in Rayong, Thailand, with an annual capacity of 165,000 tons of cathodes. It employs the El Teniente Technology as the primary smelting reactor to produce white metal from copper concentrates. The white metal is further treated in Hoboken Siphon Converters to produce blister copper then refined in anode furnaces before being cast into anodes for electro-refining in the on-site tankhouse.Thai Copper Industries is the first copper smelter to install and successfully operate on a commercial scale with the Air Liquide Shrouded Injection (ALSI™) Technology in the Hokoben converters with sonic injection of oxygen enriched air and nitrogen for cooling of the injector tip areas. Following commissioning and the establishment of operating practices, the performance of the Hoboken converters with ALSI™ Technology produced outstanding results. The unique combination of an El Teniente and Hoboken siphon converters, both of which are bath smelting operations, offers very high blowing and oxygen efficiencies. As a consequence, reverts recycling was accelerated with minimal build up on the mouth, end-plates or even below the siphon that is typical in Hoboken converters.These outstanding results in the Hoboken Siphon Converters with ALSI™ Technology helped the TCI Plant reach a production of about 75% of its capacity within four months despite the fact that the TCI staff is quite young and its converter know-how and experience are not yet fully developed."

Jan 1, 2009

By Per-Lennart Nystedt

"The Boliden Lead Kaldo Plant for the treatment of lead bearing flue-dust from the Copper Smelter and the Slag Fuming Plant has been in operation at the Ronnskar Works of Boliden Metall since the middle of 1976. At the present stage, the plant can treat lead-bearing dust of different kinds and compositions. The process allows good separation of arsenic and halogens from lead.The flue dust from the Copper Smelter and the Slag Fuming Plant is very complex and, apart from lead, also contains zinc, copper, tin, bismuth, cadmium, antimony, arsenic, sulphur, silver, chlorine and fluorine. The metallurgical process has been developed by Boliden Metall and has been tested on a pilot scale at the Foundation for Metallurgical Research (MEFOS) in Lulea, Sweden.The pelletized dust is smelted in the converter, where the heat is generated by an oil oxygen burner. The second step consists of reduction with coke. A lead bullion and slag are obtained. The slag, transported in liquid form, is treated in the Slag Fuming Plant for the recovery of zinc. The third step is the elimination of arsenic from the bullion. This is achieved by treating the lead with iron (turnings or pellets). The result is a crude lead and speiss. The lead contains silver, tin, antimony and bismuth, and is suitable for the final refining stages in normal plant equipment for refined lead.For process control, we use the rapid analysis centre, which is pneumatically and electronically linked to 'all major plant sections and allows for a quick turn-around between delivery of the sample and feedback of results. All three steps in the process are performed in the same converter.Since the starting up of the plant, the original process has been subjected to some modifications. Initial problems related to equipment, maintenance and environment have been solved step by step. Examples are quoted. Recent operating particulars are presented."

Jan 1, 1980

By K. R. Barrett

The cupellation of dore/lead bullion to recover precious metals is one of the oldest metallurgical processes known to man. In recent times this has been carried out in small reverberatory furnaces but the process suffers from a number of disadvantages. A new process has been developed at the Northfleet refinery of Britannia Refined Metals Ltd, which gives much improved performance. The process depends upon the injection of oxygen through a nitrogen shrouded lance at the bottom of the furnace. The lance is consumable and of unique design. Reaction rates are high giving short process time; fuel consumption is low; oxygen efficiency is high and dore recirculation is low. The new process has resulted in substantially lower operation costs.

Jan 1, 1989

By Martin Brueggemann

In 1993, the El Paso Smelter began operation of the first commercial CONTOP copper smelting furnace. The CONTOP process was chosen for the plant modernization due to its low capital cost and the ease that it could be incorporated into a 100 year old existing smelter. After four years of operation, CONTOP has proved itself to be a reliable copper smelting technology. This paper will discuss a brief start-up history, current operation, and future modifications and improvements.

Jan 1, 1998

By The Mill Staff

"IntroductionCOMMENCEMENT of operations at the new No. 7 shaft and 10,000-ton mill at Creighton mine was a major step in the programme of conversion to all-underground mining by the International Nickel Company of Canada, Limited. Planned ten years ago, the orderly transition has been greatly speeded-up to offset the heavy drain on production imposed by World War II and also to meet the increased demand for nickel caused by the current international situation. Development of new mining methods, and process changes in the reduction plants, have made possible the economic recovery and utilization of ore of lower grade than formerly used and of varying metallurgical characteristics. By 1953, when the Company's open-pit mining operations are scheduled for completion, the hoisting capacity of its five underground mines in the Sudbury district will have been increased to 13,000,000 tons per year, compared with 5,700,000 tons of underground ore hoisted in 1950.Two types of ore occur at Creighton. One is a breccia and stringer type that contains a high percent-age of massive sulphides and is located in sheets along shears and in large and small pockets on the underside of the main norite mass; the other type, forming the main part of the ore zone, is mineralized norite that occurs as a •sheet up to 400 feet thick overlying tl1e breccia ore. In both types of ore the minerals of economic interest are pentlandite, which is intimately associated with pyrrhotite, and chalcopyrite. Early mining was confined to the breccia ore; this ore was mined by open stoping methods. The hanging-wall was later allowed to cave, with the result that the old stopes are now filled with caved low-grade ore."

Jan 1, 1952

By A. M. Martinez, L. Melis, R. C. Peláez, L. G. Garcia

Orovalle Minerals S. L. operates a copper/gold mine in the Asturias region of northern Spain, with the operation dating back to December 1997. The feed to the El Valle mill, consisting of oxide/sulphide (skarn) mineralization, is highly variable, even on a shift by shift basis and presents challenges to the mill operating staff on a daily basis. The mineralogical characteristics of the ore are quite complex with copper present as native copper and sulphides as well as copper minerals with deleterious elements. Gold is present as native gold and electrum. The mill circuit includes SAG/ball mill grinding, gravity recovery of native copper and gold, flotation of copper concentrate, carbon-in-leach gold recovery and SO2/air cyanide destruction. The paper will provide a description of the different unit operations and present operating data of the mill operation.

Jan 1, 2019

By Dan Urich

This paper covers the construction and operation of the Grate-Kiln system at the Humboldt Mine. The mine concentrator and pellet plant are located approximately 14 miles West of Ishpeming, Michigan, on the Marquette iron Range. Production of pellets began in mid-July, 1960.

Jan 1, 1962

By Suswnu Makino

Sumitomo Metal Mining developed a new nickel refining process ( Matte Chlorine Leach Electrowinning process) based on chlorine leach and electrowinning technologies. After the pilot plant study, the commercial plant with design capacity of 24,000 tonnes per year was constructed and has been successfully operated since August, 1992. During the practice of the past three years, great deals of improvement have been achieved. Through these operations the MCLE process has been demonstrated to be one of the most superior processes in the world with nickel recovery, productivity, cathode quality and working environment. Today the refinery product capacity is increased to 30,000 tonnes per year. This paper describes the equipments and operation of the Sumitomo MCLE process.

Jan 1, 1996

By Z. Jun, L. Kerning

Jinlong copper smelter and refinery, originally designed for 100,000tpa primary copper and started up in 1997, has been expanding its capacity on the basis of operational optimization and by modifying its facilities. Currently it is producing 210,000tpa primary copper, and the new phase of expansion project with a target capacity of 350,000tpa primary copper is ongoing. This paper reviews problems and improvements made with operation and equipment in the past years. Recent plant operation is briefly described. The expansion projects completed are summarized and the ongoing expansion project is present.

Jan 1, 2007

By Jason Palmer

"Water in mining is the commodity that has driven the mining industry for decades. Often used frivolously, modern economic and social pressures are forcing change to use less water and to improve the quality of water and effluents. Used in many processes, water is ultimately consumed in tailings disposal and technologies which can increase the recovery of water are constantly being developed. Filtration and thickening are often seen as competing technologies for water recovery however new cases are developing that show significant advantages can be achieved by combining the two technologies to develop the most effective solution. Supported by case studies this paper investigates the merits of each of the technologies and which strategies of combining the two produce the best outcomes.INTRODUCTIONMineral processing applications generally require water for the processing of ores, whether utilising physical or chemical methods. Water is first added in the milling stage and additional water added as required throughout the circuit. Water losses from the circuit are principally associated with the tailings stream. Optimised water recovery is necessary both because it is a scarce commodity and to minimise the environmental impact.Water recovery is usually accomplished through a sedimentation or filtration processes. Water can be removed from the tailings impoundment by evaporation but this does not improve the mine’s water consumption. The water recovery methodology also determines the water quality; increasing water recovery concentrates solutes in the process water and may create recirculating loads of fine solids."

Jan 1, 2016

By H. B. Charmbury

The acid mine drainage problem in Pennsylvania is of continuing and growing interest to the coal mining industry, the state government and the citizenry at large. Approximately one-third of the total volume of mine drainage presently polluting the streams of the Commonwealth originates from active coal operations and two-thirds come from ?abandoned mine discharges.? For this reason the Pennsylvania Department of Mines and Mineral Industries has mounted a significant research and action program seeking solutions to this two-fold problem. The Coal Research Board of the Department has sponsored a wide variety of research projects in an effort to study the treatment of acidic and highly ferruginous mine waters. A review of the published literature on the treatment of mine waters indicated that many laboratory and theoretical studies had been undertaken on various aspects of the coal mine drainage problem, but little applied, developmental, or engineering study had been undertaken. In January of 1964 the Board commenced a rigorous program using state and industry funds in an effort to find a ?least cost? solution or solutions to this vexing problem.

Jan 1, 1967

By O. Tiitu

Drying is a unit process that has numerous applications in metallurgical process industry. Kumera Technology Center is a worldwide equipment and process supplier, who has expertise on both direct and indirect drying. In a conventional direct heated dryer, the required energy is obtained from combustion of fossil fuels emitting a considerable amount of off-gases. However, thermal energy can be already available in some metallurgical plants such as modem copper smelters where steam is produced by waste heat boilers of flash smelting furnaces. The total volume of off-gases, and especially the amount of harmful gases, released into atmosphere can be remarkably reduced when using steam as an indirect energy source for drying. Kumera Technology Center has developed a new type of steam dryer for drying of, for example, abrasive copper concentrate with silica sand. In the development of the new dryer, Kumera's approach has been to combine the best properties of both the existing steam dryers and the rotating drum dryers. In the design, special attention has been paid to overcoming the reported problems of excessive wear and clogging of steam tubes and to reducing the required maintenance operations. The Kumera Steam Dryer, having a patented flexible steam tube arrangement inside the rotating shell, has a high effective heating area - drum volume ratio without leading to problems with build-up and clogging. It can also be easily scaled up so that a single dryer can dry all of the feed for a large flash furnace. In this paper, we will present the operational and maintenance experiences from two years operation of the first full-scale Kumera Steam Dryer at Norddeutsche Affinerie Aktiengesellschaft in Hamburg, Germany. We will also provide an overview of the future developments with respect to construction and scale up as a response to market demands.

Jan 1, 2002

By R. R. Montigny

A brief description is given of the history, location and geology of the Granisle Copper Limited operation on Copper I land in Babine Lake. Detailed information is given with regard to pit design, planning, drilling, blasting, excavation and haulage. Equipment maintenance and mining costs are also presented.

Jan 1, 1971

By Rob van Opbergen, Edo Engel

The highly dynamic economic climate of recent years has tightened the operating envelope for steel producers world-wide. Steel producers continue to experience immense pressure to respond quickly to changing circumstances and the focus has shifted towards efficiency improvement and maximizing flexibility in operations. The ability to safely stop, restart and ramp-up production facilities has become essential. Establishing this level of flexibility, without sacrificing efficiency, requires sound process control, fit-for-purpose process management practices and solid know-how and experience regarding special situations in blast furnace ironmaking operations. The same business environment that demands this increased flexibility has made it increasingly difficult for steel producers to sustain sufficient knowledge about these situations. While many experienced, senior operational staff have retired, a new generation of ironmaking specialists has acquired its hands-on experience over more recent decades, during which these process situations have been much less frequent than before. Over the past 10-15 years, the requirement in the industry for external operational support during e.g. blast furnace blow–downs, salamander tapping and restarts after planned and especially unplanned stops, has become increasingly frequent. This article presents a number of these cases from a process management perspective as well as with regard to project organization and optimized cooperation between internal and external teams of experts.

Oct 1, 2019

By H Weitz

Bateman Engineering provided process technology and engineering design to China Yunnan Metallurgical Company (CYMCO) for a 30 MW DC furnace for the production of high-grade titanium dioxide slag.Following the successful commissioning of the furnace during the latter part of 2009 and the first quarter of 2010, a period of adverse circumstances resulted in having to operate the furnace without feed and at a low power input for a period of time. When normal feed resumed, a layer of solid material was detected on the slag-iron interface during sounding measurements. The condition of the iron was also significantly altered. The iron temperature was much higher than the design value, but the carbon content had decreased to such an extent that a large amount of iron solidified in the furnace, which made iron tapping very challenging. The slag temperature was increased in order to melt the solidified iron. However, severe sidewall damage resulted, which finally led to a burn-through. A number of samples were taken from the slag that remained in the furnace. These samples were analysed to determine the chemistry and phase profile throughout the slag bath. The mechanisms of formation of the high melting-temperature phase on the slag-iron interface are discussed, as well as procedures that can be applied to prevent a recurrence of this phenomenon. Some recommendations are made for instances when furnace feeding is interrupted for an indeterminate period.

Oct 5, 2011

By S Grönstrand, C. Perez, A. B. Yañez, F. Coddou, P. Morales, H. Elgueta

"The TankCell® 300 forced air flotation cell designed and built by Outotec, with active volume of over 300 m3, was installed at Codelco’s Chuquicamata concentrator in September 2008. After that, a program was conducted, where the new cell was tested against the plant’s existing flotation cells of type TankCell® 160, with an active volume of over 160 cubic meters.Testing program was exhaustive and detailed. Grade-recovery curves for each setup were reported, along with recoveries by particle size. Secondly, operational characteristics like air feed and froth height setpoints, and power consumption are compared side-by-side. As the third topic, gas dispersion characterization included velocity mapping, holdup, bubble size and bubble surface area flux operating range. The fourth area of interest was the retention time distribution (RTD) of the 300 and 160 m3 cells in comparison. A detailed campaign using radioactive tracer tests was conducted to clarify this.All of the investigations mentioned above are reported in separate papers for more detail. The aim of this paper is to collect the key findings, and present them in real terms, always referring to operability and metallurgy of the cells. It is destined for people designing new plants and to those improving and expanding existing ones. The most frequently heard question is: will the new large cells operate at same efficiency as the smaller ones. In short, the answer is: NO. They operate at improved efficiency!INTRODUCTIONIn the last two decades of minerals processing, there have been three dominant trends of development in the flotation technology: equipment scale-up, cell characterization and circuit modeling. Equipment scale-up has been rapid in the past two decades. In the year 1990, the largest flotation cell in use was 50 cubic meters of size. This year, 300 cubic meters is the largest installed cell. Characterization of flotation equipment and circuits is a very popular subject nowadays and has helped many operations to improve their recoveries through better control strategies, for example by using optimized air feed and level control profiles (Gorain, 2005), (Doucet, Gomez, Finch, 2006), or through better maintenance (Coleman, Urtubia, Alexander, 2006). Characterization work is closely linked to circuit modeling. The aim is to produce sufficient amount of data to allow reliable model building. These models are then used to design new circuits and to improve existing ones. So in summary, these three lines of development have slightly different aims – from capital and operational cost to performance optimization. Ultimately, they converge in the same end result – maximizing the profitability of the operation. Following chapters will summarize the extensive test work and scientific studies at Codelco Chuquicamata. The aim was to compare a TankCell® 300 cell, with nominal volume of 300 m3, against two TankCell® 160 machines, with 160 m3 volume in each. The work should yield answers to questions: does the larger cell produce similar results – is the scale-up successful?"

Jan 1, 2010

By Frank Cook

As in other areas of the country, surface coal mine productivity in the Central Coal Province--primarily Illinois, Indiana, and west Kentucky--has declined steadily since 1969 (figure 1). Productivity, as measured in tons of clean coal produced per man-shift, dropped 35 percent during the period 1969-1975. Unwelcome at any time, this phenomenon is particularly untimely now, when increased coal production is a national goal. The U.S. Bureau of Mines has been working with the coal industry to develop new operating methods and equipment to enable increased productivity and improved reclamation performance in surface coal mining. Several projects have involved identification and evaluation of existing overburden handling and reclamation practices, and development of means to improve operational procedures. Some results of one of those projects, as they apply to the Central Coal Province, are summarized in this paper.

Jan 1, 1977

By Justin S. Johnsen

As OEM sensors and interfaces have grown in number, the available data from equipment in the mining environment has continued to multiply. This equates to an increased visibility of operating performance, mechanical and electrical health, and predictive monitoring that can directly improve maintenance reliability and scheduling. With increased visibility, where should a reliability engineer begin to look to directly impact Capacity Assurance? More specifically, what source will provide inputs to the Failure Modes Effects Analysis (FMEA)? Results from these analyses must be documented, and they must contribute to the overall mission of the mining company; these results must reduce costs and increase profits. Through detailed data capturing, documenting, and analysis, Modular Mining Systems? Time Tracking application, used in the MineCare® maintenance management solution, can drive decisions and provide direct impact to engineering projects for continuous improvement in the mine maintenance organization.

Nov 1, 2011