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By J. Lui

At its Copper Cliff Smelter, bulk nickel and copper concentrate is processed in two Inca flash furnaces and Peirce Smith converters to produce Bessemer matte containing 0.6%Fe. After slow cooling and Matte Separation, Bessemer matte is converted into three main products using magnetic separation and flotation technology: (1) a nickel containing chalcocite concentrate (MK); (2) two types of copper containing nickel sulfide (ME and MR); (3) metallics (MYN). MK is further processed in the Inca top blowing bottom stirring MK Reactor to produce semi-blister copper containing ~4%Ni and ~3±1 %S. The semi-blister copper is then purified in the multi-purpose vessels (MPV) to produce blister copper by reducing Ni, Fe and S content through oxidation. High melting point NiO is formed inside the MPVs. The accumulation of solid NiO and other oxides requires periodic cleaning by adding reductant and furnace matte, a unique process called "washout" at Inca. For many years, the reductant used for the "washout" process has been 15%Si Ferro-silicon. With increasing cost and limited suppliers for 15%FeSi, alternative reductants were pursued. This paper summarizes the development and commercialization of new alternative reductants for MPV "washout".

Jan 1, 2007

By J. Suarez Condezo, E. Herrera Alarcon

The Ilo Smelter Modernization Project will require treating the slag from the Peirce Smith converters in Slag Cleaning Furnaces using pig iron technology. Currently the slags from the converters show variable magnetite contents. The copper contained in this slag is recovered in Reverberatory Furnaces, where the smelting rate was improved due to the high silica content of the converter slag. Preliminary industrial tests where developed to clean the slag from converters using pig iron. The results showed that the magnetite content has a significant influence in this process. This work describes the actions that are being implemented in the converter operation to control the magnetite content in the slag in order to maintain the high copper recovery of the smelter when the new facilities are commissioned. This task will demand a strong control of both the slag chemistry and converter practices in order to get the copper recovery considered as the design criteria (~97.4%).

Jan 1, 2007

Central to any business is its Asset Management Plan which encapsulates the business context and key organisational objectives such as profitability, safety and environmental standards. Life Cycle Planning (LCP) is a key component of an overall Asset Management Plan. A comprehensive approach to Life Cycle Planning forecasts the financial expenditure required to support the performance of the asset over the business life. It incorporates capital, maintenance and operational expenditure along with an estimation of economic life. Within its body the LCP provides the detail of the maintenance plan and method of its execution. Once optimised the LCP becomes the overarching plan executed through the application of several elements of the Asset Management Plan to ensure the return on investment from the assets is optimal. Each of the elements of the LCP is bound by a set of loops that provide information based on the analysis of outcomes. These loops drive the continuous improvement of performance and cost over the life of the asset. In this way we ensure that the LCP is a dynamic plan responsive to the changing business environment. The paper being presented today will describe the process undertaken and the outcomes derived when this approach was applied to a $600 M+ coal handling and preparation plant in QueenslandÆs Bowen Basin. It will also delve into the difficulties encountered from both technical and cultural aspects; the latter proving to be the most difficult to manage. It will describe the hurdles and barriers that hampered progress including the human influences and the natural desire to revert to what has been done in the past when things became a bit difficult. In the end the results are there to show that the upfront expenditure and investment in time was time and money well spent and the outcome has the operation well placed to manage the assets in a manner designed to deliver the optimal business outcome.

Jan 1, 2007

By A. Bezama

For over a decade European countries have addressed contaminated sites by developing technologies for managing both polluted soil and groundwater. This development has not only been driven by health and environmental aspects, but also because of economic pressures, as the remediation and redevelopment of derelict areas can be a meaningful alternative to undeveloped areas for the establishment of new industrial, recreational, housing and service locations. In most developing countries, however, the subject of contaminated sites is a new environmental issue that authorities have recently started to deal with. Among these countries, Chile has just started to prepare the country's legal context as well as to foster the formation of research and investigation groups that will deal with the exploration, investigation and management of contaminated sites. That requires a comprehensive technical, scientific and legal support in this stage. Goal of this article is to present the state-of-the-art technologies for site remediation currently applied in industrialized countries, in order to identify the most interesting approaches that can be implemented within the Chilean situation, especially considering the influence of the copper mining industry on the soil and groundwater quality of the environment surrounding their production facilities.

Jan 1, 2007

By W. Swidzinski

"Zelazny Most" post-flotation copper mine tailings pond is the only place to of storeing wastes for KGHM POLSKA MI EDZ S.A. The flotation tailings is are the main waste stream in copper mining in Poland. Sufficient storage capacity for tailings is crucial for , thus uninterrupted production of copper is crucially related to the possibility of storing wastes in the pond. The pond covers a Its over 14 km2 arca, almost 50 m high dams making this dame this construction one of the largest in the world. The risk assessment of potential damage due to un stable ility loss of dams or environmental contamination, as well as safely constructing damsincrease of dams within the design criteriaprocess, require quick access to a large amount of the monitoring data , which in vast amount have to be monitored, that needs to be analyzed and processed and reported, every day. This In the paper describes the numerical information system "SyZeM" , used for designated to the "Zelazny Most" pond, baseding on the Oracle database and Geographical Information System , to manage the graphical and descriptive data in coherent way., is presented. The main structure of the system, as well as the methodology of storing, processing and reporting the geological, geotechnical, hydrogeological, geophysical, chemical and survey data are shown. The aspects of Optimizing optimal and risk mitigation and safe management of copper wastes and risk mitigation with the help of "SyZeM" are discussed.

Jan 1, 2007

By C. A. Sosa-Blanco

Minera Sabinas in central Mexico treats a complex sulfide ore containing galena, chalcopyrite, sphalerite and argentite as valuable minerals, and in some cases important amounts of non-magnetic pyrrhotite. For high pyrrhotite ores, results obtained by selective flotation showed good grades and recoveries in the lead-copper circuit, but a commercial zinc concentrate could not be produced due to the high floatability of pyrrhotite. When this is the case, an alternative method was proposed to produce a bulk concentrate by flotation which is then leached to recover copper and zinc from liquor in a SX-EW circuit. Leaching was conducted in an autoclave in order to study the effect of temperature and pressure, but bioleaching tests were also conducted. Leaching lead-silver residues were treated by cyanidation in order to recover silver values. The results obtained by selective flotation and by bulk flotation with leaching of the bulk concentrate showed that the latter alternative increased zinc recovery by 30 % with similar recoveries of the other metals.

Jan 1, 2007

By S. Nikolic

"Calcium ferrite slags are currently used in a number of copper-converting processes. Despite the industrial importance of this system the phase equilibria have not been fully investigated. Characterization of this slag system is necessary to improve the control of process parameters, including fluxing and operating temperatures. Recently, a modified experimental method has been developed; this involves rapid quenching of slag samples equilibrated at high temperatures with the resulting phase assemblages analysed using electron probe microanalysis (EPMA). In the present study, experiments were completed under controlled temperatures and oxygen partial pressures using CO/C02 or H2/C02 gas mixtures. The investigated slags were supported during equilibration by a substrate of the primary phase. This technique removes the limitations arising from the use of crucibles and facilitates rapid quenching of the melt. Experiments were carried out at 1200°C and 1250°C (1473 Kand 1523 K) and in the composition range 0-40 wt.% Cu20, 0-25 wt. % CaO and 45-80 wt. % Fe203. Liquidus and solidus data are reported for the primary phase field of spinel between the oxygen partial pressures of 10-4.5 to 1 o- 6-5 atm. The analyzed compositions of liquids and solids are used to construct the phase diagram of ""Cu20"" -CaO-""F ez03"" system in equilibrium with metallic copper at fixed oxygen partial pressures."

Jan 1, 2007

By William M. Gleason

When SME’s 2006 Arizona Conference convened in December at the Hilton El Conquistador Resort in Tucson, AZ, there was considerable excitement among the 387 attendees. There was a noticeable buzz surrounding the progress of Phelps Dodge’s Safford copper mine in southern Arizona, one of the first new major copper mines to be permitted in more than 30 years in the United States. There were also plenty of good feelings about the mining industry in general. Commodity prices remained high and with no signs of a slowdown in the immediate future. Things were good in Arizona. But there were also cautionary tones at the conference and the Mining Foundation of the Southwest banquet that preceded it.

Jan 1, 2007

By H. E. Urtubia, C. W. Bailey

"BHP-Billiton’s Minera Escondida Limitada is one of the world’s largest copper producers. It treats a combined 88 million tons of copper ore per year through its two concentrators: Los Colorados and Laguna Seca. Over the past three years, metallurgical sampling has been performed at the Laguna Seca concentrator to calibrate both the JKSimMet and JKSimFloat grinding and flotation simulators. In the past, the calibrated simulators have been used to predict the effect of changes in operating conditions in the grinding and flotation circuits separately. To assist in the development of future processing options, predictions were required of the effect of changing grinding circuit conditions on flotation performance. This was achieved by using an integrated grinding and flotation simulation. The grinding circuit performance was predicted under different operating conditions (such as tonnage rate and product grind size) using JKSimMet, and these results were then used in JKSimFloat to predict the flotation performance for the new grinding circuit product. This combination of the simulators allows both the effects of residence time and grind size on flotation performance to be investigated.This paper presents the first combined grinding and simulation modelling and simulation case study using JKSimMet and JKSimFloat. The modelling and simulation methodologies for the grinding and flotation circuits are discussed along with the circuit simulations that were performed. The simulator predictions are presented in conjunction with independent laboratory results of the new operating conditions. The ability to predict flotation circuit performance based on changes in grinding circuit performance is also discussed. This methodology provides improved predictions of flotation circuit performance when grinding circuit changes (including grinding capacity increases) are made.INTRODUCTIONOver the past decade, the grinding and flotation research groups at the Julius Krutschnitt Minerals Research Centre - JKMRC (Brisbane, Australia), University of Cape Town (Cape Town, South Africa) and McGill University (Montreal, Canada) have been developing a methodology for optimising grinding and flotation plants using actual plant data together with semi-empirical sub-process models. The project is being conducted as part of the Australian Minerals Industry Research Association (AMIRA) P9 Project, titled “The Optimisation of Mineral Processes by Modelling and Simulation”. The project first commenced in 1962 and is currently in its “Nth” phase."

Jan 1, 2007

By J. J. Montoro

The influence of blasting on the excavators’ efficiency, defined as mucking rate (amount of rock mucked per unit time) and mean bucket load (amount of rock loaded in each bucket operation), is investigated. Rock characteristics, blasting parameters (drill pattern, explosive energy, and charging), and the excavator’s performance (truck loading time and number of buckets to fill a truck) were monitored in eleven blasts in an open pit iron ore mine. ANFO, ANFO/emulsion blend, and watergel were used in the blasts and the powder factor was varied between 0.98 and 1.45 kg/m3. The mean bucket load is mainly affected by the bucket size, which is independent of the blasting parameters. Besides the relation with the mean bucket load, the mucking rate was found to be positively correlated with the explosive energy, whereas no significant correlation with the rock properties was found. The analysis of the data, together with other published works, suggests a non-monotonic relation of the mucking rate with the powder factor, with a maximum mucking rate at a certain powder factor. This is especially true when the useful work of the explosive per unit rock volume is used rather than the classical mass powder factor and when only the amount of explosive above grade is considered.

Jan 1, 2007

By J. M. Menacho

As usually occurs in technological development, heap leaching knowledge has been built upon two parallel lanes, theory developed on fundamentals but relatively far from industrial applications, and operational know-how generated from empirical trial and error. As a contribution to close the gap between the above-mentioned lanes, the De Re Metallica process consulting group has been developing and applying fundamentalsbased modeling tools for industrial process design and process optimization of existing plants over the last ten years. As result, a library of models is now available with application to the whole production chain from blasting to electro winning. This presentation is centered in heap leaching and several real case studies are developed, showing how paradigms are broken when fundamentals are applied. Cu2007 - Volume IV (Book 1) The John E. Dutrizac International Symposium on Copper Hydrometallurgy Edited by P.A. Riveros, D.G. Dixon, D.B. Dreisinger, M.J. Collins Toronto, Canada,

Jan 1, 2007

By R. P. Goel, P. N. Chaudhary, R. K. Minj

The bulk of high carbon ferromanganese produced in India continue to have more than 0.35% phosphorus since they are produced by carbothermic reduction process. The low phosphorus manganese ores are depleting fast and ferromanganese manufacturers will have no option but to use medium and low grade ores having high phosphorus content resulting in high phosphorus in the product. A systematic study was taken up at NML to solve this problem. Initially, a thermodynamic analysis was carried out for which Ba-P-O ternary predominance diagrams were constructed at several temperatures to predict the most suitable conditions for selective removal of phosphorus from high carbon ferromanganese. These conditions required a usage of a flux having a high level of basicity, moderate oxygen potential as well as low melting temperature. The experimental results showed that it was possible to remove phosphorus from high carbon liquid ferromanganese from 0.56%to 0.18% using BaCO3 based fluxes at the rate of 16-wt% of the ferromanganese charged. However, the Mn loss varied in the range of 2-5%. The objective of the subsequent study carried out at the laboratory scale was to optimize the flux consumption as well as minimize the Mn loss with effective dephosphorization by using BaO based calcined pellets instead of BaCO3 based powders. It was felt that the handling of pellets under plant conditions would be easier and also eliminate the loss of flux as a dust, which occurs when powder is added. These pellets were forced towards the bottom of the melt for better efficiency. For this purpose, a plunging system was designed and fabricated in-house that helped in reducing the flux consumption to less than 5% and also improved the kinetics of the process. The desired results were achieved within 10 minutes of the addition of the flux. The know-how is ready for transfer to interested parties and authors are willing to conduct large scale trials with them.

Jan 1, 2007

By A. J. Rigby

Anode vessels are often relined with refractory every one to two years and a typical reline time can take between 16-20 days. Modem refractory designs using dense, corrosion resistant brick applied directly to the vessel shell in the high wear areas around and above the tuyeres and at the slagline can yield a lining life of up to 4-5 years before a complete reline is necessary. Installation methods using brick delivery on roller conveyors through an endwall access port and complete anchoring of the brick to allow for lining self-support can take days off the installation time. It is possible, therefore, to reduce the refractory relining period by 50% and increase lining life by 100% compared to typical anode repair schemes. Cu2007

Jan 1, 2007

By L. J. Friedman

The recovery of sulfur dioxide from metallurgical gases for the production of sulfuric acid has been the primary means of reducing sulfur dioxide emissions from nonferrous smelters. Sulfuric acid has been produced from gas originating from fluid bed roasters, electric furnaces, reverberatory furnaces, flash smelting furnaces, Pierce Smith and flash converters, sinter machines, etc. The gas from each of these sources has a unique set of variables that affect the design and operation of the sulfuric acid plant. In addition, the sulfuric acid plant itself has been evolving, with new equipment designs and materials. This paper will review each of the unit operations in the gas cleaning and contact sections of the metallurgical sulfuric acid plant, discussing various equipment designs, materials and the handling of gas stream variables and impurities. The paper updates to 2007 previous works on metallurgical sulfuric acid plants by the authors, and analyzes new equipment and systems, including: FRP or alloy quench systems, alloy converters, towers and pump tanks, heat recovery systems, high efficiency mist eliminators, tower packing, etc.

Jan 1, 2007

By D. D. Tannant, H. Ozturk

Thin spray-on liners are increasingly being used as rock support in underground mines. The adhesive strength between the liner and the rock surface is an important design parameter. Adhesion tests were conducted to assess the impact on adhesion of the presence of oil, water, and dust on a substrate, and the roughness and grain size of different substrates. Other factors such as curing time, loading rate, and liner thickness were also considered. Adhesion was measured using a pull test of a 33 mm diameter elevator bolt attached to an over-cored section of liner with strong epoxy. Most tests were performed using Tekflex liner material, although five other liner products were also tested. Adhesive strengths of about 2 MPa can be achieved with Tekflex under optimal conditions. Long-term creep tests showed that the adhesive strength could drop by at least 50% when the liner carries load for about a month. Where the rock surface is contaminated with dust or the rock is weak in tension, it may be difficult to reach adhesion strengths of 1 to 1.5 MPa. As the thickness of the liner increases, the adhesive strength to a substrate appears to decrease.

Jan 1, 2007

By B Menzel, M Wlasenko, J Phillips

Yandicoogina (Yandi) open pit mine is located in the eastern part of the Pilbara region of Western Australia. It hosts pisolitic iron-oxide mineralisation distributed within a meandering paleoriver channel. The deposit is characterised by clays occurring as lenses, accretions, desiccation joint infill and voids in the pisolite ore. The irregular shapes and highly erratic distribution of these clay pods represent a serious challenge for grade control at this mine.The current grade control approach used at the Yandi mine is based on sampling of production blastholes on a 6 m X 6 m spacing. Their good spatial coverage, tight spacing and low cost make blastholes a very convenient media for grade control and ore-waste definition. However the potential downside of this grade control approach is poor sample representivity. An alternative grade control approach is to drill and sample using reverse circulation (RC) holes distributed on a 25 m X 25 m grid. This approach has been tested in Yandi mine and compared with the blasthole sampling approach for sample representivity. The impact of increased drill spacing on mining block predictions has been studied using a conditional simulation technique. Blasthole and RC samples proved to be similarly biased, underestimating Al2O3 and SiO2 grades and overestimating Fe grades, when compared to full cone assays. These results show that using RC drilling for grade control at the Yandi open pit will not necessarily improve the representivity of the grade control samples. However, increasing the grade control spacing to 25 m X 25 m will lead to more than 12 per cent of the selective mining unit (SMU) sized blocks being misclassified. This is approximately a two-fold increase in the number of misclassified SMU blocks in comparison with 5 m X 5 m spacing.

Jan 1, 2007

By V. Ushakov, P. Bogdan

Daily production scheduling in a highly dynamic smelter environment has always been a great challenge for the operation management due to a significant amount of uncertainties. Planned and unexpected equipment failures, various energy outages, inaccuracies in flow and mass balancing, manpower availability conflicts and other constraints make the job of daily production planning exceptionally difficult. This paper discusses a general scheduling approach utilized by the production management of the Phelps Dodge Miami Smelter (the Smelter). It also describes logical assumptions and some practical software solutions that have been exploited by the Smelter managers to assist the front line supervisors in dealing with daily planning activities for several years.

Jan 1, 2007

By R. Bonifaz

The Chagres Smelter, part of the Anglo American plc group situated 80 Km north of Santiago in Chile, completed a series of operational improvement in 2005 resulting in an optimum capacity in its operational units. At present the Chagres Smelter has developed an operational strategy which seeks to reduce bottle-necks in the production process. In this way we have managed to lower operational cost, decrease energy consumption and maximize the capacity of the Acid, Oxygen, and Smelting, Converting, Refining and Casting units. A constant application of international benchmarks together with continuous staff improvement and the latest smelter technology have combined to place Chagres among the finest smelting works in the world. In response to environmental challenges, we have studying various options for investment suitable for a profitable business of benefits to both Anglo American and Chile as a whole. The most relevant technical indicators are the figures : Energy consumption less than 6,3 GJ/ton fine copper, Intensity of smelting rate in Flash Smelting unit of 6900 ton of copper concentrate/m2 settler of furnace area and be one of the top five smelter in direct cash cost .

Jan 1, 2007

The Argyle AK1 Pit has been operating and producing over 25 per cent of the worldÆs diamonds by volume for over 20 years. The mining boom in Western Australia is creating upward cost pressures to ArgyleÆs mining operation while the price received for its product remains flat in comparison to many other Western Australian commodities. This incongruity, which when combined with other circumstances such as the pit being close to the end of its mine life, a decline in head grades and a tightening in operational constraints caused by the pitÆs maturity, is causing the leadership team at the mine to utilise innovative strategies in order to ensure that the open pit continues to perform economically until its final closure in late 2010. The strategies that will be discussed in this paper are step change business improvement methods, localisation of the workforce, employment of Aboriginal people and the use of a clear and concise consultation process in order to provide certainty to a workforce working in a pit during boom times where pit closure is imminent.

Jan 1, 2007

By E. R. Bauer

Noise-induced hearing loss (NIHL) continues to be a concern of the mining industry. A new noise standard (30 CFR, Part 62) is aimed at reducing NIHL in mining through engineering and administrative noise controls. However, the difficulty and expense of implementing engineering controls can make administrative controls an attractive alternative for reducing worker noise exposure. Over the last three years, the National Institute for Occupational Safety and Health (NIOSH) has conducted worker noise exposure surveys in underground and surface coal mines and in coal preparation plants. The surveys revealed numerous possible administrative controls and an approach to implementation and analysis. The surveys have shown that worker dosimetry, time-motion studies and equipment noise profiling are important aspects of effectively utilizing administrative controls. A description of the approach for selecting, implementing and evaluating administrative controls and a list of possible administrative controls are reported.

Jan 1, 2007