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By W. K. Rankin

Achieving continued economic growth with social equity within the natural limits of the Earth's eco-systems is the major issue facing the world today. The material and energy needs of the world cannot be met with the current ways of addressing this issue. The need for metals, an important class of materials, will continue into the future because their unique properties make substitution by other materials impossible in many applications and this need will continue to be met from primary metal production and recycling. However, the recycling rate will increase and the usage pattern of metals will change to reflect the environmental impact of their production and use. Pyrometallurgy has an important role in meeting the metal needs of the future since some metals can only be produced pyrometallurgically; the energy required to produce some metals pyrometallurgically is significantly less than by other methods; most metals are most efficiently recycled pyrometallurgically; and the release of harmful and toxic elements into the biosphere can sometimes best be controlled through pyrometallurgical processing. The development of strategies for pyrometallurgical processing for the future lies in the recognition that sustainable development calls for large step improvements in value delivered per unit of environmental impact over the entire supply chain. Pyrometallurgists can respond to this challenge by contributing to reducing the environmental impact of meeting metal needs using three broad strategies: "end-of-pipe" approaches to convert emissions into benign materials for storage or disposal; flowsheet redesign to limit or eliminate emission production; and improved recycling technologies. A number of examples are discussed to illustrate how the sustainability driver is already influencing the technological development of pyrometallurgical processes, and how these will develop further as the sustainability driver strengthens.

Jan 1, 2003

Achieving continued economic growth with social equity within the natural limits of the Earth's 'eco-systems is the major issue facing the world today. The material and energy needs of the world cannot be met with the current ways of addressing this issue. The need for metals, an important class of materials, will continue into the future because their unique properties make substitution by other materials impossible in many applications and this need will continue to be met from primary metal production and recycling. However, the recycling rate will increase and the usage pattern of metals will change to reflect the environmental impact of their production and use. Pyrometallurgy has an important role in meeting the metal needs of the future since some metals can only be produced pyrometallurgically; the energy required to produce some metals pyrometallurgically is significantly less than by other methods; most metals are most efficiently recycled pyrometallurgically; and the release of harmful and toxic elements into the biosphere can sometimes best be controlled through pyrometallurgical processing. The development of strategies for pyrometallurgical processing for the future lies in the recognition that sustainable development calls for large step improvements in value delivered per unit of environmental impact over the entire supply chain. Pyrometallurgists can respond to this challenge by contributing to reducing the environmental impact of meeting metal needs using three broad strategies: "end-of-pipe" approaches to convert emissions into benign materials for storage or disposal; flowsheet redesign to limit or eliminate emission production; and improved recycling technologies. A number of examples are discussed to illustrate how the sustainability driver is already influencing the technological development of pyrometallurgical processes, and how these will develop further as the sustainability driver strengthens.

Jan 1, 2003

By D J. Williams

Tailings management is typically constrained by many factors that are taken as given. These include the tailings production rate that must be accommodated, the desire to deliver the tailings cheaply and easily as a slurry using centrifugal pumps, and a tailings footprint limited by the desire to minimise capital costs leading to a rapid tailings rate of rise and a low settled density. Other constraints include wall raises being delayed due to limited capital, inadequate tailings water and rainfall run-off management, and the net present value (NPV) approach to capital expenditure that puts off expenditure at the expense of performance. All of these constraints result in the tailings occupying much more volume than is necessary, being difficult to rehabilitate, and not being capable of supporting a beneficial post-mining land use or function. Ultimately, such constrained tailings storage facilities will assume very large dimensions, but each will typically be developed as a series of smaller storages that are filled rapidly and added to progressively. The optimal stage to efficiently recover process water is in the process plant, but this is limited by the desire to use centrifugal pumps rather than the more costly positive displacement pumps, which also require greater management of tailings deposition. Process water can also be recovered from the tailings storage facility (TSF) decant. Tailings water that is not recovered from the plant or the decant will be lost to entrainment within the tailings, seepage to the foundation or through the wall, or evaporation. However, tailings water is not always suitable for reuse in the plant, particularly when it becomes contaminated by the processing, and it may simply be stored on the TSF. This will exacerbate the seepage of contaminated water to the environment, and will limit the densification of the tailings that would otherwise occur due to desiccation of the tailings on exposure. If a larger tailings footprint were developed early, cycling of tailings deposition in thin lifts between a number of cells could occur, maintaining the dormant cells dry to enhance desiccation and densification, and ultimate rehabilitation. The end result would be a much reduced stored volume of tailings, the potential for upstream raising, and ease of rehabilitation to a high level. The higher initial capital cost would be overtaken by reduced ongoing capital, operating and closure costs.CITATION:Williams, D J, ?2014. An alternative whole-of-life approach to tailings management, in Proceedings Life-of-Mine 2014 , pp 285–298 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 16, 2014

By T. N. Williamson

Most U.S. coal production is bituminous coal. Some 90% of current production comes from a geographical area enclosed in a circle with a 300 mile radius and its center at about Huntington, West Virginia. There are important underground coal production areas in the western parts of the United States as well. Most U.S. coal production comes from fairly level seams, many of which pitch rather uniformly only a few feet per mile. Usually there will be several overlying seams of varying thicknesses, separated by several tens of feet. Fig. 1. 1. Seams have minor local undulations but these? are small enough not to be a major consideration in a horizontal drilling research program.

Jan 1, 1970

By C. F. Cockrell, H. E. Shafer, J. W. Leonard

A significant technological development is discussed for the processing of certain power plant flyashes that are a problem because they contain a high water-soluble mineral content and yield inferior flyash-based brick. This development is based on the addition of hydrochloric acid to the flyash-bottom ash-sodium silicate blends used for the production of flyash-based structures. Favorable changes are evi-dent in sodium silicate consumption, where about half the amount used for making brick from normal flyash is required, processing costs, and strength and appearance of the resulting freshly formed green and fired structural products. In some high cost in-stances (above the $30 or less per thousand brick estimated for normal flyash), hydrochloric acid additions can replace or reduce other costly additives normally required for problem flyashes. This results in savings of as much as $9 per thousand brick. These developments offer promising possibilities for utilizing problem flyashes as well as flyashes which may come into contact with water soluble sulfur as a result of the eventual application of certain experimental air pollution control processes. Much of the research datal-6 accrued through work by the Coal Research Bureau of West Virginia University for the Department of Interior's Office of Coal Research on converting waste power coal ash to valuable brick and other structural products, can be categorized as follows: (1) general ash-to-brick tech- nology; (2) specific ash-to-brick optimization; (3) pilot plant progress; (4) production cost estimates. A summary of the progress on bench-scale experiments indicates that coal ash can yield two types of brick. An acceptable brick is obtained by mixing 73.6% fly-ash, 23.5% bottom ash and 2.9% sodium silicate solution (dry basis). Depending on the flyash and bottom ash used, optimum brick can be manufactured by mixing 72-77% flyash, 20-25% bottom ash and 2.3-3.0% sodium silicate (dry basis) with Na2O : SiO2 ratio varied according to the composition of the flyash used. These blends are thoroughly mixed and mechanically formed into green brick shapes at pressures ranging from 1000 to the more usual 3000 lb per sq in. The green shapes then are dried and fired at temperatures ranging from 1975-2150°F using clay brick cycles that are shorter than standard. Other findings reported to date indicate that when making optimum brick, it is necessary to carefully control the top size of the moisture-releasing bottom ash so that it falls between 8 and 30 mesh, depending on the flyash used. Moreover, the chemical composition of bottom ash and flyash have been found to be of little significance with the exception of a few problem flyashes which are the subject of this paper. Finally, the pilot plant, which was previously reported under construction, is now in operation. This will indicate, among other things, the cost of brick production, which was earlier estimated for non-problem flyashes at $30 or less per thousand brick. The foregoing bench-scale technology is applicable to all the initially tested ashes as well as to the majority of ashes examined during the course of research. However, a few of the ashes yield green and fired products that may be structurally inferior or unacceptable, necessitating excessive and diverse reagent addition, and/or may be coated with unsightly surface deposits. These problem ashes generally originate in certain areas of Illinois, western Ken-

Jan 1, 1969

By Steve Kral

"The Rapid Excavation & Tunneling Conference (RETC) is a world-renowned event that attracts some of the best minds in the global underground construction and tunneling industry. The experts gather at this conference to impart new technologies, discuss challenges to their projects and learn about new technologies that have become available to them.The 2015 RETC will be held June 7-10 at the Sheraton New Orleans, in New Orleans, LA. This biennial conference, of which SME is a sponsor, is expected to attract about 1,400 attendees from around the world. These professionals represent all parts of the global tunneling and underground construction industries - contractors, engineers, owners, consultants and equipment suppliers.More than 110 technical papers in 21 sessions will be presented over two-and-a-half days. Paid attendees will receive a proceedings volume of the conference. The proceedings will also be available from SME. In addition to the technical programming, the accompanying exhibit will include 155 exhibitors occupying 175 booths, providing RETC attendees the opportunity to get a look at the latest in equipment and service technology. Three short courses will be held on the Sunday preceding the start of the show. And there will be plenty of opportunities for attendees to meet and chat during several social activities that are scheduled throughout the conference."

Jan 1, 2014

By Edward H. Robie

THE registration badges gave out, there were not enough programs, the Pioneer Hotel's rooms were insufficient, and some hundred applicants for banquet tickets had to be turned down at the Institute's Regional Meeting in Tucson, Nov. 1-5. Minor inconveniences these, however, occasioned by the fact that, optimistic as they are in Arizona, about half again as many partook of the week's activities as were expected. For this, the local program committee can be blamed-both the technical and social features were too attractive in quantity and quality. Seriously speaking, though, the Institute has probably never had a more successful Regional Meeting than this one. It being the first that has been held in Arizona in 22 years, no effort was spared to make it the distinctive gathering that it was.

Jan 1, 1938

By R. Craig McClung

Contrary to other sulfide minerals, where recovery is principally liberation controlled, the recovery of molybdenite is more complex. It is this complexity that initiated a geometallurgical investigation of molybdenites from Bingham Canyon. The aim of this investigation was to determine the effect mineralogy and/or mineralogical attributes have on recovery. All samples were analyzed using normal mineralogical techniques. The results reveal the presence of two distinctly different types of molybdenite. These have been identified as the two polytypes of molybdenite: i.e. hexagonal (2H); and rhombohedral (3R). The 2H-polytype occurs as textbook-shaped particles in quartz-molybdenite veins that are located in the current pit bottom. The 3R-polytype occurs as disseminated, “ball”-shaped particles with a dull or frosted appearance and are concentrated along the margins of the current pit. Concerning their metallurgical behavior, each type exhibits unique metallurgical properties that are consistent with those reported in the published literature. The 2H-polytype is easily ground and kinetically “faster” floating with surface attributes that are amenable to higher rates of recovery. This results in the production of a high quality concentrate under normal operating conditions. The 3R-polytype, by comparison, is difficult to grind and kinetically “slower” floating with surface attributes that are less amenable to recovery. Therefore, in deposits with higher concentrations of the 3R-polytype, modifications to the normal operating parameters may be necessary to improve recovery. This investigation highlights the necessity for understanding the mineralogical characteristics of any economic mineral(s), as these will have a direct impact on recovery.

By Herbert H. Kellogg

A model of the ISF is described. which reproduces with accuracy the "normal" operation of three industrial furnaces. The model, written in Fortran, is based on detailed heat and material balances, and the concept that the ascending gases reach equilibrium with zinc oxide and with the water-gas shift reaction. "Solution loss" of carbon in the lower shaft, and partial reoxidation of zinc vapor in the upper shaft are also essential features. For prediction of furnace behavior under altered operating conditions (blast rate, temperature, moisture content, oxygen enrichment, or injection of oil or coal through the tuyeres) the model modifies the heat loss, temperature of slag and bullion, amount of reoxidation in the upper shaft and the condenser efficiency to reflect the altered operating parameters. Model predictions for such operating conditions are in reasonable agreement with plant experience.

Jan 1, 1990

By D Connelly

As the resources sector becomes tougher with rising costs and cyclical metal prices, mining companies need to continue to reduce their costs and do more with less. Many new resource projects fail to come in under or on budget based on Feasibility Studies. Particularly, capital expenditure (CAPEX) proves difficult to achieve for resource projects. A number of resource projects have failed because of aggressive plant CAPEX cost cutting resulting in projects with no surge capacity and are unable to achieve design throughput. In addition, the plants are not operable because of the omissions. In recent times many businesses have also experienced the "costs" of simply implementing aggressive operating "cost cutting” measures as a strategy for solving business performance problems. This paper looks at technology driven, employment related, luxury cuts, department cuts and restructuring cuts. In the past companies used an incremental approach based on the use of past budget information as an integral part of the budget construction process going forward. The use of performance reports and Management Information Systems (MIS) is examined along with the role of continuous improvement in achieving sensible cost cutting.

Aug 8, 2011

By D. R. Nagaraj, Raymond Farinato

Water constitutes one of the most valuable resources employed in mineral recovery and processing. Identifying potential problems encountered in mineral processing in waters unusable for drinking or agriculture (including seawater and even hypersaline waters), understanding chemical factor interactions, and optimization of flotation reagents will greatly expand our ability to create more sustainable beneficiation technologies. The current paucity of our knowledgebase regarding high salinity effects on flotation clearly signals a need for a significant research effort. We report here results of a study designed to probe effects of pulp chemistry on metallurgical performance in the flotation of Cu and Cu-Mo ores in saline waters. The results clearly demonstrate that pH (more correctly dosage of pH modifier to target a pH set point) has the most significant effect on Mo recovery when using seawater. This is linked to the formation/precipitation of Mg(OH)2 when pH = 10.3 (in seawater). The type of pH modifier used, NaOH or Ca(OH)2, had no impact on Cu or Mo recovery, indicating that Ca2+ ions were not involved in any reduction in Mo recovery in the pH range of 9-11. Our results in tap water spiked with either Ca2+ or Mg2+ ions in the same pH range (controlled by NaOH), confirmed that Ca2+ ions had no effect on Cu or Mo recovery, but that addition of Mg2+ ions had a severe adverse effect on Mo recovery at pH = 9.5, and to a lesser extent on Cu recovery. The onset of Mg(OH)2 precipitation occurred at a higher pH, and the adverse impact of Mg(OH)2 on Cu recovery (and perhaps Mo recovery as well) was less, in sea water than in tap water spiked with Mg2+. These effects are attributed to the mitigating role of the high electrolyte concentration, notably NaCl.

Jan 1, 2014

By T. Bruce, R. C. A. Minnitt

Mining operations are generally reluctant to install high-cost sampling systems at operations that have been functioning for many years. The principal objection to installing appropriate equipment to extract correct and representative samples in process flows is the time and costs involved. The Theory of Sampling (TOS) provides a structured framework for identifying and quantifying the errors and bias associated with any sampling event, but this may be insufficient to initiate substantial investment in correctly designed sampling equipment. Financial losses arising from substandard sampling installations are usually disregarded because the value-add from a good quality sampling solution is invisible, but the cost is quite obvious. Depending on the needs, a less-than-perfect or fit-for-purpose sampling solution may be acceptable, provided the magnitude of sampling errors is understood and the assay results are interpreted accordingly. Categorical levels of acceptable accuracy and precision can be established depending on the sampling position in the mining value chain and the nature of the decisions to be made. The objective benefits of proposed fit-for-purpose sampling solutions should be presented to relevant decision-makers in such a way that adverse subjective decisions are countered so that appropriate solutions are implemented. Practical examples of the benefits from motivating the implementation of fit for purpose sampling solutions at sampling facilities around the world are provided.

Jul 2, 2022

By W. E. Wells

This report describes experimental investigations made in the batchwise retorting of Colorado oil shale. Three heat-carrying mediums were used -hot shale gas, superheated steam, and hot flue gas. Using hot Shale gas for retorting, the several variables studied were retort-inlet-gas temperature, gas velocity through the shale bed, shale particle size, and grade of shale. In studying the effect of any one of these variables on oil yield, as and operability, the other variables were maintained essentially constant. Oil yields decreased with increasing in-let-gas temperature and increasing shale-particle size, and oil yield increased with increasing grade of Shale up to 50 gallons of oil per ton of shale, beyond which the process was inoperable because of swelling and caking of the shale during retorting. Changes in gas velocity had little effect on oil yield. Gas yield increased with increasing inlet-gas temperature, gas velocity, particle size, and shale grade. Oil yields of 100 percent of Fischer assay and from 1,600 to 1,800 cubic feet of 300-B.t.u. gas per ton of shale were obtained. Two runs only were made using superheated steam. Oil yields averaged 97 percent of Fischer assay, and gas yields averaged 4,00o cubic feet per ton of shale. Retorting with a hot flue gas produced from combustion in the shale bed, as in the N-T-U process, gave excellent yields using closely sized shale with recycling of flue gas. An excess of fine shale in the charge resulted in channeling and low oil yields. Using no recycle gas, good yields were obtained that tended to decrease with increasing air rate, and the retorting rate increased with increasing air rate over the range studied. Coking was not found serious with 30-gallon shale at the air rates used.

Jan 1, 1952

By N. L. Piret

In copper smelting minimization of solid waste generation is receiving increased attention with more stringent environmental legislation and lower disposal space availability. Copper smelting slags generally being valorizable, solid waste generation is attributed to the presence in the feed of unvalorizable impurities which do not report to the slag and to the unavoidable formation of contaminated dilute acid solutions which need neutralization. As to unvalorizable impurities, solid waste minimization is achieved by rejecting them in the highest possible concentration. Dilute acid is mainly due to the formation of SO3 in the smelter gases and to the discard of decopperized bleed-off electrolyte. Its generation is substantially lowered by preventing SO3 formation, by converting the dilute acid to a valorizable product, e.g., by thermal decomposition for H2S04 recovery or by precipitation as chemical gypsum, and by suitable treatment of the bleed-off electrolyte for impurity removal. Industrial processes are evaluated and alternatives are discussed.

Jan 1, 1994

By Irina Chernyshova, Erik Larsen, Hanumantha Rao Kota, Vladislav Slabov, Garima Jain

The separation of fine mineral particles, especially using environmentally friendly approaches, is one of the main problems in the processing of low-grade ores and the re-processing of mining tailings. This work assesses the potential of biosurfactants as collectors in the flotation of ultrafine (smaller than 20 μm) particles of hematite and malachite. As biosurfactants, we test acetylated acidic (ac-ASL) and lactonic sophorolipids (ac-LSL). In addition, n-dodecyl-β-D-maltoside (DDM) is used as a model non-ionic alkyl disaccharide surfactant, and sodium oleate (NaOl) is used as a reference. The biosurfactants are characterized using surface tension and foam analysis. The interaction of the minerals with the surfactants is characterized using zeta potential, solubility, and single-mineral flotation. The collecting properties of the surfactants are compared for the ultrafine (− 20 μm) and coarser (38–90 μm) particle size in the two-mineral flotation of hematite and malachite against quartz. The ultrafine particle size improves the grade in the oleate flotation of hematite, as well as the grades in the DDM flotation of hematite and malachite, which is explained by the weak interactions of the metal oxides with fatty acids and DDM. At the same time, the flotation with ac-LSL and ac-ASL is highly tolerant to the ultrafine particle size. These results indicate that biosurfactants are an interesting alternative to conventional petroleum-based surfactants in the flotation of Fe and Cu oxides. Moreover, a proper selection of surfactants can help combat the problem of fines.

Feb 23, 2023

By M. Y. Wong

Electronic detonators have been used on a trial basis for over a decade, and found more recent application in production blasting as well. The relative merits of these detonators and their applicability are outlined through examples from actual blasting operations. They offer unprecedented flexibility in the design of mass blasts and in control of vibration and blast-induced damage. However, the drive towards replacing the pyrotechnic detonators by electronic ones in general could prove to be counter productive without a re-examination of prevailing blasting practices. In fact, such an approach tends to blur the tremendous potential of the electronic detonators in redefining many standard blast designs and practices.

Jan 1, 2004

By P. R., Bradley

THE Juneau gold belt is divided into ore-bands of poor definition. The most easterly workings on the , belt, those of the Alaska Gastineau Co., disclosed three separate bands: the Footwall or Ground-hog band, 70 ft. wide; the Perseverance band on which the recent mining was done, also 70 ft. wide; and the No. 2 band, 100 ft. wide. These bands, aggregating 240 ft., are found over a width of 2000 ft. Going toward the west into the adjoining Alaska Juneau ground, four bands have been found which have a total 'right-angle thickness of 755 ft. These bands are convergent in their westerly trend and terminate on the plane of Silver Bow fault. The four bands have better definition at the fault plane than at the eastern boundary line where they enter the property. -Along the property line, the width of the bands and intervening country is 1600 ft., and at the Silver Bow fault this width is reduced to 1300 ft. The distance from the eastern property line to Silver Bow fault is 2400 ft. The bands are slate or slate with metagabbro intrusions, together with gold-bearing quartz masses, stringers, and gash veins. The bands themselves are not all ore, but all commercial .ore is found within the bands. They have no uniform width either in horizontal or vertical section. The ore has no hard and fast boundary except where cut by faults, and profitable mining ceases on a vague and

Jan 1, 1929

By Prasad S. Mulukutla

INTRODUCTION The use of specialty chemicals In mining Is an Important consideration In determining the economic efficiency of a floatation plant. The plant metallurgist would like to maximize the recovery of valuable minerals while maintaining an acceptable grade product. The direct cost of the reagents, while significant, Is only a part of their economic effect. Reagents determine the flotation rates and the selectivity of the mineral separation. In flotation practice, mineral selectivity can be achieved through the addition of various reagents that can control the wettablllty of a particular mineral In the flotation pulp. The reagents which will generally optimize the flotation process are commonly classified Into three distinctive categories: collectors frothers and modifiers. Large tonnages of metal sulphide concentrates which are the source of most of the common base metals are produced economically by fairly standard flotation techniques. The advent of modern technology coupled with the necessity of processing finely disseminated and complex ores of low grade has Increased the need for utilization of non traditional and high selective chemicals reagents for the economic recovery of metals and raw materials. Mining operations in developing countries continue to progress at a rapid growth as many countries mine and process both metallic and nonmetallic ores. The total mine production of base metals, precious metals, Iron ores and coal In developing countries In Africa, Asia and South America has been much higher as compared to the western world production In terms of tonnage and dollar value. Global capital Investments In mining during 1991-95 Is $ 55.1 billion and It Is anticipated that the development of new and specialty reagents may be concentrated In the processing of aluminum , copper, precious metals and Industrial minerals with special reference to potash, phosphates, kaolin and silica sands.(1) The challenge for the design and development of new specialty chemicals Is dependent on Its cost performance and environmental acceptability. Information on the theory and application on the development of mining chemicals has been reviewed In several conference proceedlngs,(2-4) publications(5) and also discussed by several Individual authors.(1,6-10) These publications serve as a comprehensive reference source on the reagents used In several flotation processes. This paper discusses the present trend in the use of specialty mining chemicals In diversified mining operations on several mineral systems with particular reference to sulfide ore systems. The necessity to expose these specialty chemicals through aggressive marketing techniques In mining operations In many developing countries Is also presented. SPECIALTY CHEMICALS Specialty mining chemicals, like other specialty chemicals, share common business characteristics that transcend geographic boundaries. They are manufactured 1n a few selected areas, generally expensive relative to commodity chemicals, shipped and compete globally and usually require specialized knowledge for proper use. Specialty mining chemicals are relative newcomers to chemical markets. The vast majority of mining chemicals are derived from products that are less than two decades old. Traditional collectors and frothers have been available for a considerably longer time. The emphasis on adding value to existing products and byproducts Is responsible for several characteristic features of the mining chemicals business. Most raw materials for these chemicals are related to oil and gas byproducts, chemical refineries, pulp and paper mills and all chemical manufacturers. Until the last several years these operations were located In Industrialized countries, while a significant number of mining chemical users were In developing countries. Therefore International trade In mining chemicals developed through agencies or agents in each particular country.

Jan 1, 1993

By Jeanie Wills, Theresa Nyabeze, Samantha Espley, Donna Beneteau

This presentation reports survey findings that aim to modernize the definition and understanding of the term 'mining.' The survey, conducted via LinkedIn in Winter 2024, garnered responses from a diverse group of individuals, including current or former employees of mining or exploration companies, mining consulting firms, service providers, supplier firms, as well as students and retirees with industry experience. The data, ethically approved by the University of Saskatchewan, offers valuable insights into satisfaction levels within the mining sector and suggests an expansion of the identifying characteristics of definitions of mining. This marks the third CIM gaining insights paper by Beneteau, Espley, and Nyabeze, following previous works on 'Career Satisfaction for Women in Mining' (2010) and 'Mentorship Initiatives in the Canadian Mining Industry' (2018*)."

Oct 1, 2024

By L. Galarza

"INTRODUCTION Beneficiation of ores and minerals in a concentrator plant requires a significant amount of water [1] for the grinding and particle separation processes; most of it ends up being recirculated for reuse, slurry pumps are used after crushing and grinding feeding the ore to a classifier to separate fine-grained material (less than 5 mm) from coarse-grained material requiring further grinding. The lower ore grades [2] in the past couple of decades have demanded an increase on power size and efficiency of process machines to maintain a competitive plant throughput; Hydro-cyclone feed pumps to control both under and over milling or grinding are not the exception; Fig. 1 shows a conventional drive train [3] comprising an (1) asynchronous motor (also known as squirrel cage induction motor = SCIM), a high speed coupling (2), a gear reducer (3) and a low speed coupling (4) attached to the shaft of the pump (5), to accommodate the motor rated speed (typically 1800 rpm) to the process requirements (in the range of 250 rpm to 350 rpm), requiring additional components related to the gearbox: instrumentation, maintenance, disposable lubricants and filters, spare parts, thus reduces the overall system efficiency ultimately reflected into CAPEX and OPEX.WHY VARIABLE SPEED DRIVES FOR CYCLONE FEED PUMPS Hydrocyclones or commonly referred as “cyclones” are one of the most important devices in the minerals industry [4]; almost universally used in close-circuit grinding because of their high capacity and relative efficiency, the evolution of Power Electronics made affordable the use of Medium Voltage - Variable Frequency Converters (VFC) for Cyclone Feed pumps in combination with induction motors larger than 500hp (373kW) to gain multiple benefits: - Soft start with minimum electrical utility disturbance = inrush current mitigation - Full Torque available at zero speed for overload startup with pulp solidification after long still stand periods, superior to any other reduced voltage starting method. - Optimum and constant pump speed (independent of the electrical network or load condition), compared to across the line SCIM operation - Flexible Motor Voltage and Speed regardless of the power distribution Voltage and Frequency - Improved Power Factor (close to unitary), over the entire operating speed range"

Jan 1, 2015