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By G Tranell, E Pastor-Vallés, A Vallejo-Olivares, J B. Pettersen

Metals are essential for the sustainability transition and decarbonisation of society. Yet, it will be paramount to produce them sustainably and minimise the affiliated resource and energy use and the associated emissions. In the circular economy, the metallurgical industry should recycle existing material stocks, and improve its utilisation of wastes, residues and side streams. This increases the complexity of processes, as they become both (often multi-fraction) waste treatment as well as material production processes and brings complexity to the assessment of environmental benefits. Assessing the environmental impact of technological developments frequently is supported by life cycle assessment (LCA). While the method is well documented, its implementation involves several methodological choices that deserve reasoning and analysis, such as how to define the product when former wastes are turned into new products, the selection of impact methodology when converting emissions to environmental indicators, the definition of system boundaries and co-product allocation and the interpretation of sensitivity and uncertainty in final outcomes. In this exploratory study, we investigate how the variation of LCA set-up affects the environmental burden of the system. We consider a metallurgical process where a mix of hard-to-recycle aluminium-containing streams is used to produce aluminium cast alloys in a rotary furnace. Remelting with salt-fluxes allows recovering metals from partly oxidised/contaminated streams, such as dross, bottom ash and industrial shavings, but at the expense of generating significant amounts of salt-slag/salt-cake hazardous waste. The study considers different system alternatives such as landfilling the salt-slag residues versus valourising them into salts, aluminium concentrates, ammonium sulfate and non-metallic-compounds to be used by the metallurgical, construction or chemical industries. Practical recommendations are outlined to facilitate the implementation of LCA in assessing the potential benefits of the circular economy in the metallurgical sector.

Aug 21, 2024

By P. Mageau-Béland, È. -M. Proulx, M. -C. Patoine

Over the past six decades, Hatch has helped several industrial processing facilities in debottlenecking their operations, allowing them to produce more with the same equipment, to reduce and even eliminate expenditure investments, or to increase the return value of their expansion projects. These successes result from the application of a proven analysis approach that can be applied to any industrial facility. A five-stage methodology is discussed and demonstrated with a specific example of a nickel concentrator optimization study. The first stage is an observation stage which allows to meet key actors at the plant, develop mutual understanding of problems, understand operating philosophy, and efficiently collect large amounts of operating and maintenance data. Following is a data compilation stage during which data is analyzed over a representative time period to identify parameters that significantly affect the production, to evaluate data reliability and to define the focus of the upcoming analysis. Quantitative metrics are defined using statistical tools such as pivot tables, histograms, percentiles and MDR (Maximum demonstrated production rate during 3 to 7 consecutive days). Then, the production bottlenecks are identified by a thorough analysis of the facility’s control philosophy, process throughput, equipment capacity, availability, downtime causes, and interaction between components of each circuit. Understanding the maintenance practices and frequency of planned shutdown is also critical to this analysis. Opportunities for improvement are identified in collaboration with the operation, maintenance and engineering teams, ranked as a function of their impact on the bottlenecks and prioritized. The final and most critical stage involves engagement with the plant stakeholders, namely the operators and the maintenance staff members, to present the results of the analysis and obtain their participation in the implementation of the solutions. The benefits of the case study translated into: 10% production capacity gain, improved maintenance planning and avoidance of several million dollars of investment.

Jan 1, 2016

By L. J. Kane

Chemical processes using coal often require economical removal of dust from high-temperature gases. Laboratory-scale investigations by the Federal Bureau of Mines have shown that an aluminum silicate fiber is suitable for filtering dust from gases at 1,800° F. The effects of the bulk density of the filter, rate of gas-flow, concentration of dust in the filter, fiber diameter, depth of filter, and concentration of dust in the feed gas on removal efficiency, pressure drop, and capacity of the filter to hold dust were studied. The laboratory filters were difficult to construct because the fibers were longer than the tube diameter. This caused irregular distribution of fiber that permitted dust-laden gases to leak through channels developed in the filter. Leaks also formed between the filter and the tube wall, but this was minimized by improved filter design. However, edge leaks and leaks through channels in the filter probably would be insignificant in properly constructed filters of industrial size. As the concentration of dust in the filter increased, the efficiency of the low-density filters decreased, contrary to expectations, probably because a higher percentage of the dust passed through channels that developed in the filter. The efficiency of high-density filters, however, increased with the concentration of dust in the filter. Results indicate that loosely packed filters would have a longer life than tightly packed filters at the expense of efficiency. As regeneration or replacement of stationary filters is difficult and expensive, loose filters would be best for filtering gases containing much dust. Gases containing little dust may be cleaned with tightly packed filters to obtain higher efficiency. For either type of filter, precleaning with cyclone separators or other means is advisable.

Jan 1, 1960

By Samuel Filgueiras Rodrigues, Clodualdo Aranas Jr., Gedeon Silva Reis, Eden Santos Silva, Fulvio Siciliano

When austenite is deformed above the Ae3 temperature, partial amount of it transforms dynamically into ferrite by a displacive mechanism. After unloading, it retransforms back into the stable austenite by a diffusional process. This influences the rolling load which decreases under isothermal condition or does not increase with decreasing temperature as rapidly as expected under cooling. Plate rolling simulations under isothermal and continuous cooling conditions were carried out on a 0.09 wt.% Nb X-70 steel. Pass strains of 0.2 were employed together with interpass times of 10 s, and 30 s for the cooling conditions and 0.3 with interval of 10 s at 900 °C for the isothermal experiments; strain rate of 1 s-1 was used during the simulations. The mean-flow-stress (MFS`s) behavior of both conditions indicates that dynamic transformation and dynamic recrystallization were taking place during straining. The critical strains for the initiation of dynamic transformation fell around 0.06 while the critical strain for DRX was 0.12. It has been shown that ferrite is formed due to the applied deformation of roughing passes and increases its volume fraction throughout the finishing rolling stage. Under cooling conditions, the ferrite formation is also favored as the temperature approaches the Ae3 line. Such ferrite forms when the driving force for dynamic transformation is higher than the total free energy barrier preventing its formation. This obstacle consists of the free energy difference between austenite and ferrite as well as the lattice dilatation work and shear accommodation work. The addition of Nb retards the retransformation of the ferrite into austenite. Moreover, holding times after rolling increases the amount of austenite available for microstructure control on subsequent stages. The dynamic transformation (DT) mechanism can be used to design improved rolling schedules

Oct 1, 2019

By M. El Ganaoui, P. Bontoux

"A computational model to investigate solid/liquid phase change transitions for binary alloy under directional solidification is presented. Conservation equations are developed by using an homogeneous formulation. A second order accuracy method of time and space based on finite volume approximation has been evaluated by comparing results to spectral solution for time-dependent solutal convection developping in a melted alloy. For extended model to solid/liquid interface effects time amplification of solutal perturbation injected near the interface is described before considering solutal convection is melt.IntroductionThe enthalpy method gives a front fixing approach for energy equation without introducing coordinate transformation. The interfare position is recovered a posteriori [1]. A number of authors have extended this approach so as to include the convection phenomena within the two phase 'mushy region' [2, 3, 4, 5, 6].We have developed a time-dependent enthalpy-porosity formulation for directional solidification [4, 6, 8]. The interaction between solid and liquid phases is modelised by a Darcien type force in the phase change area. The behaviour of the melt is similar with the flow of an incompressible fluid in a porous medium. This force is proportional to the relative phase velocity. It corresponds to a damping force depending on the anisotropic permeability of the 'mushy zone'. The permeability depends on the liquid fraction and on the size of·solidification microstructures. An informative discussion of a new slant on the general approach of continuum mechanics needed to analyze the formation of mushy zone is given in [12]. The method is extended to the presence of species diffusion: the solutal Stefan condition which expresses the solute incorporation or rejection across the interface is accounted implicitly in a species equation valid in all the domain [14, 15]."

Jan 1, 2001

By A. Golabchi

Building Information Modeling (BIM) is an increasingly popular method for generating and managing facility information during the life cycle of a building, ranging from facility conceptualization, through design, construction and its operational life. Organizations involved in Facility Management (FM) have the opportunity to use BIM as a knowledge repository to document evolving facility information and to support decisions made by the facility managers during the operational life of a facility. This paper demonstrates the potential of using BIM to develop algorithms that automate decision making for FM applications. The potential of utilizing BIM as an analysis tool is demonstrated through the scenario of HVAC (Heating, Ventilation, and Air Conditioning) system failure in an operating facility. In case of a typical HVAC malfunction today, facility occupants record complaints in a ticketing database maintained by the FM organization. Upon receiving notification of HVAC system failure, facility inspectors visit the location to confirm the reported failure. Upon confirmation, facility managers review building plans and specifications to develop a detailed plan of action to repair any HVAC components suspected of damage. Based on the plan of action, inspectors visit the facility to inspect and, in case of damage, repair the appropriate HVAC system components. These FM practices ? as currently implemented across the industry ? are labor intensive, time consuming, and often rely on unreliable and outdated information. To address these shortcomings, the authors propose an alternative methodology of HVAC fault detection in operational buildings. The authors implement an algorithm that leverages complaint ticket data and automates BIM to determine potentially damaged HVAC system components. Based on the list of HVAC components suspected of damage, the algorithm develops a plan of action for the facility inspectors. Finally, the authors discuss the advantages of the proposed method as well as the challenges of implementing automated BIM-enabled decision making processes in the FM industry.

Aug 1, 2013

By Ian James McDonald

Each year, approximately 400 million tons of blast furnace slag is produced worldwide with a tapping temperature of around 1,500°C. It is normally used as a substitute for cement clinker or as an aggregate material in road construction. Currently, the slag is granulated in wet-granulation plants using large volumes of water and to date, it has not been possible to utilise the remnant heat energy of the molten slag, which amounts to approximately 1.8 GJ of energy per ton. However, in an R&D project currently underway led by Primetals Technolgies and industrial partners, a new dry atomising technology is being investigated to use air to cool molten slag and recover the lost heat energy. The resultant pelletised slag fulfils the same criteria as wet-granulated slag for use in the cement industry. Phase 1 of the project has now been completed where a technical plant was set up at the University of Leoben in 2012. A series of dry-slag granulation campaigns were carried out using remelted blast furnace slag. The elevated offgas temperatures and the quality of the slag product as verified by the FEhS Building Material Institute have shown the process suitability as an industrial application and the decision was taken to escalate the project from large laboratory scale to a full size pilot plant. The phase 2 development of this plant is now underway and is scheduled for installation at the site of an industrial partner in early 2016 where full slag flow will be fed directly to the plant from Blast Furnace ‘slag runners. This paper will show the development path taken to date and the planned route to our goal in 2016 of being the first to industrialise the ‘game changing’ process of dry Slag Granulation with Heat Recovery from the slag.

Aug 16, 2017

By R. L. Grayson, T. Simonyi, R. A. Andrel

"The purpose or this paper is to disclose analytical, statistical, and observational results relating to mineralogy and trace elements in respirable dust samples collected from two different mines in West Virginia. Samples were taken from longwall panels, and the panels operated in different coal seams, one located in the northern part or the state and the other in the southern region. Mining conditions and equipment arrangements on the panels will be described along with dust control techniques used. Results from sample analyses are summarized with emphasis on relationships between mineralogy, trace elements and mineral particle size to worker locations. Correlations are made between micro x-ray diffraction and energy dispersive x-ray analyses for sample mineralogy.IntroductionThrough the work of many researchers worldwide, the health of coal miners in modern societies is now protected from harmful exposure to respirable coal mine dust. A vast amount of research culminated in the exposure-response model of Jacobsen, et al, (l) which has been used to establish the 2 mg/m3 exposure limit in the United States. According to the model exposure to respirable dust for 35 years at this level or less could prevent the occurrence of a clinically significant case of coal workers' pneumoconiosis (CWP) in a miner. The exposure limit, of course, must be adjusted whenever greather than five percent free silica exists in the respirable dust.The Jacobsen model was built around a mean mass concentration exposure, which generally showed the highest correlation with both incidence and progression of CWP. As Morgan, et al noted, however, the quantity of respirable dust inhaled is not the only significant factor. 2) They noted that although mass of respirable dust correlates highe.st with the incidence of CWP, it is not a causal factor. Admittedly, the insidious processes causing the disease occur at the lund cell-dust particle level."

Mar 1, 1989

By Deming Wang, R. A. Overfelt

"This paper presents a computer-aided heat transfer simulation method to predict the thermal characteristics of an alloy sample in a special furnace for directional solidification. A two-dimensional transient heat transfer by conduction combined with radiation is developed to calculate the energy exchange between a directional solidification furnace and the sample. Finite difference equations with control volumes are used to calculate the transient heat transfer. A special boundary control volume is used to combine heat conduction and radiation in the transient heat transfer. Heat radiation effects on the surfaces of the special control volumes with a changeable view factor during directional solidification processing are also represented. The simulation results are verified by measurable experimental data. Using the computer simulation model, many thermal properties of the directional solidified castings can be obtained, such as temperature distribution, solidification velocity, the shapes and positions of the liquid/solid interface and thermal gradient at the interfaces. These are very important to analyze microstructure of casting alloys, avoid casting defects and control casting quality. 1 IntroductionIn directional solidification (DS) processing of castings, the temperature distribution, the interface between liquid and solid zone, thermal gradient in the mushy (pasty) zone and solidification rates are very important factors to analyze the microstructure and the casting quality. These variables affect the orientation and size of dendrites, shapes of grains, solute segregation and deleterious casting defects, such as microporosity, freckles and segregation channels. In order to avoid the casting defects, the temperature distribution and thermal gradients of castings during directional solidification must be strictly controlled. However, the structure of furnaces used for directional solidification is often complex. Heat transfer and temperature distribution within a casting not only depend on furnace temperature but also on the thermal properties of the casting alloy, crucibles, retorts etc. A more accurate heat transfer analysis."

Jan 1, 2001

By J. M. Clark

(Wilkes-Barre Meeting, June, 1911.) For some years past, those interested in the development of the increasingly important mining industry of Canada, have urged the adoption by the Dominion Parliament of a federal mining-law, which would have the force and stability of statutory enactment. At present, placer-mining in the Yukon Territory, is governed by the Yukon Placer Mining Act. All other mining under federal jurisdiction is governed by 'Orders in Council and Ministerial Regulations. In the earlier stages of development, it is perhaps a matter of necessity that these important matters should be so dealt with; but it is now felt that the time has come when mining-rights in the extensive regions under federal control should be put on a permanent basis, -and that any changes required from time to time should be made only after full and open discussion in Parliament. A short sketch will suffice to indicate how vast and varied the interests affected really are. When the Dominion of Canada was constituted by the Imperial Statute known as the British North America Act of 1867 (which came into force by proclamation on July 1 of that year), it comprised only the present Provinces of Ontario, Quebec, Nova Scotia, and New Brunswick; but provision was made for the inclusion of Newfoundland, Prince Edward Island, British Columbia, Rupert's Land, and the North West Territories. Subsequently Rupert's Land and the North West Territories were acquired, the 'Crown Colonies of British Columbia and * SECRETARY'S NOTE.-Mr. Clark, an eminent Canadian lawyer, and joint author of the treatise on "The Law of Mines in Canada," has been requested by the Do¬minion Government to prepare a Federal mining-law, and presents this paper, by invitation of the Council, in order to obtain, if possible, useful suggestions from members of the Institute.-R. W. R.

Apr 1, 1911

By William Petruk

Many gold operations lose gold during processing because some ore characteristics which affect recoveries have not been determined, and consequently the plant could not be designed to account for them. The ore characteristics can be determined with mineralogical techniques by analyzing the plant feed, final tailings and mill products. The plant feed and/or final tailings are commonly analyzed first as a separate project. Mill products are analyzed only if the process employs a minerals separation circuit to produce a concentrate (e.g. secondary flotation circuit to concentrate gold-bearing arsenopyrite), and if assays and materials balances indicate a recovery problem in the minerals separation circuit. Many ores have been evaluated at CANMET on a confidential cost-recovery basis by custom-designing a work plan which was dependent upon the problem and on the characteristics of the ore. The reasons for gold losses have been identified in most cases, and suggestions for modifying flowsheets have been proposed. The methods used in performing the analyses are described in this paper, and non-confidential results from in-house projects are provided as examples of the benefits of such analyses. The analytical methodology involves a combination of the following procedures: -producing heavy mineral concentrates and identifying the gold minerals in the concentrates; -determining quantities of invisible gold in gold-bearing sulphides, sulpharsenides, etc. by SIMS; -determining quantities and liberation characteristics of all gold minerals and gold-bearing minerals in the sample; -finding and identifying gold minerals in silicates; -extensive grinding and cyanidation to determine the ultimate amount of cyanidable gold; -determining impact of clay minerals and graphite; -performing a mineral balance for the gold in each sample; -performing a materials balance to determine the distribution of the gold minerals, gold-bearing minerals, and other minerals throughout the flowsheet, and; -interpreting the results.

Jan 1, 1995

By Tugba Cebeci, Bahjat Khoshaba, Bern Klein, Libin Tong, Andrew Bamber

"Sensor-based sorting technologies have potential to pre-concentrate low grade subeconomic ores through discarding the barren waste particles. However, the inability of sensors to accurately discriminate ore from waste is a barrier to prevent their wide applications. The present study focuses on the development of more intelligent sensing systems by using correlation and regression analysis of X-ray fluorescence (XRF) sensor responses on the copper ore samples obtained from Chile. The responses obtained through XRF scanning were reported both in the form of counts and the grades of elements. Linear and multiple linear correlation analyses were made between the XRF counts and the copper grades obtained through chemical analysis. Both the heterogeneity of the ore particles and the matrix effect in the XRF measurement are discussed in the study.INTRODUCTIONSorting can not only discard waste rocks away from the concentrator but also recover metal bearing ore particles that would be lost to the waste dump. The benefits of ore sorting include reduced energy consumption, water and reagent usage in the downstream operations (Bamber, 2008; Gunson, Klein, Veiga, & Dunbar, 2012; Kleine & Wotruba, 2010; Knapp, Neubert, Schropp, & Wotruba, 2014; Kobzev, 2014; Lessard, de Bakker, & McHugh, 2014; Mazhary & Klein, 2015; Robben, Wotruba, Robben, von Ketelhodt, & Kowalzcyk, 2013). X-ray fluorescence belongs to sensor-based sorting technologies and Xrays are a high energy-high frequency form of electromagnetic radiation inhabiting the region between the ultraviolet radiation and gamma rays (Shackley, 2011). Recent XRF sorting studies on low grade copper ores were carried out at MineSense Technologies Ltd. aimed at increasing the capacity related to improving the understanding of ore heterogeneity as the basis for developing semi-bulk or bulk sorting systems (MineSense Technologies Ltd., 2016)."

Jan 1, 2016

By M. S. Diederichs, G. Walton

"Developments in understanding the brittle fracture of rock over the past two decades ultimately led to the acceptance of a cohesion-weakening-friction-strengthening model as an appropriate strategy for the modelling of spalling using a continuum approach. This strength model has been used to replicate observed failure depths and geometries for a number of case studies in the literature, most notably the AECL Underground Research Laboratory in Manitoba. One thing which these case studies typically ignore, however, is the influence of rock dilatancy on the evolution of brittle failure. Physically, this phenomenon is the volumetric expansion of the rock due to fracture opening; numerically, this phenomenon is captured by the flow rule, which is often characterized by the dilation angle, ?. Accurately modelling rock dilatancy in conjunction with strength evolution is necessary both to predict the magnitude and distribution of ground displacements, as well as the exact depth and shape of the fracturing zone. Both of these factors can have significant implications for support design. This paper is focussed on presenting some of the recent developments in this field in the context of a number of numerical modelling case studies. Initially, a new model for the dilatancy of brittle rock is presented, as well as some representative data and model parameters for different rock types. Next, several case studies of highly stressed tunnels and shafts are presented. The results of continuum numerical models are presented to demonstrate the ability of the back analyses to match observed in-situ measurements and obtained. The predictive capabilities of the material model are also highlighted for cases where sufficient “a priori” information (such as laboratory compression testing data) are available. The issues of model nonuniqueness and strain-localization/bifurcation are also addressed."

Jan 1, 2015

By G. C. Lindeque

"A downward trend in tyre life on haul trucks at an open pit iron ore mine prompted an investigation into the current tyre management strategy in order to improve tyre life. ‘Best practice’ was compared to the current tyre management strategy at the mine to determine aspects that could be improved. Aspects that showed significant room for improvement included employee tyre awareness, tyre pressure maintenance, and road conditions. For each of these aspects a plausible alternative was suggested.A new tyre management strategy was formulated as a step-by-step guide on how to implement the proposed changes. Each step introduces new initiatives but at the same time builds on the previous step’s success. A sensitivity analyses was performed to determine the impact of the proposed changes, with the variables being the reduction in the percentage of premature tyre failure, and the reduction of the site wear rate.The ‘most likely’ scenario showed an increase in tyre life of 41% for the Komatsu 730 trucks and 105% for the CAT 777 trucks if the entire tyre management model is implemented. This would result in a possible annual saving related to tyre usage of R9.2 million. OverviewThe study focused on the tyre life on the main haul fleet at an open pit iron ore mine. The haul fleet consisted of 17 Komatsu 730 (180 t) haul trucks and 12 CAT 777 (90 t) haul trucks.The haulage operation consists entirely of tyre-based haul trucks. Five per cent of the total mining budget is related to tyre costs. Since 2012 there has been a steady decrease in tyre life as measured in operating hours (Figure 1) due to the high percentage of tyres that fail prematurely. In 2014 a total of 41% of all tyres failed prematurely and 61% were classified as ‘worn out’."

Jan 1, 2016

By Yan Yang

The Jinfeng gold mine is one of the three gold mines that Eldorado Gold has in China and it is the second largest gold mine in China. The mine is located in a relatively remote and mountainous area in the southwestern Guizhou province. The orebody is similar to the Carlin type deposit in Nevada. The mill throughput was designed to treat 3,600 tones per day. The ore comes from open pit mining and underground mining, and is fed to one-stage jaw crushing. The crushed ore is stockpiled, reclaimed and then fed to the SABC grinding circuit. After classification with hydrocylones, the ore is floated, and the resultant concentrate is oxidized biologically in a process known as BIOX®. The oxidized concentrate is then washed in a CCD circuit and finally leached with cyanide in a CIL circuit for gold extraction. Jinfeng produces about 180,000 oz of gold per year. This paper introduces operations and modifications of SABC circuit over the past three years, and then describes some technical characteristic of the SAG mill and other circuits in the processing plant. Major modifications and improvements on the SABC circuit are described in the paper, including: 1. Impacts of grinding ball and mill liner with respect to material selection, quality, hardness, manufacturing methods, and interactions between mill liner and grinding ball. 2. Effect of milling operation parameters on milling efficiency. 3. Impacts of SAG mill scats and modifications of grate size to improve mill throughput. 4. Design and construction of a pebble crushing system, and recycle the crushed scats to the SAG mill to improve mill throughput. With the above-mentioned modifications, 20% increase over the design in mill throughput has been realized over the past three years, and operating cost has been significantly reduced. However, some issues still remain, and thus process modifications and technical innovations are still needed.

Jan 1, 2012

By E A. Agorhom, M Beyuo, C Owusu, I Quaicoe

Understanding the mineralogy and liberation of gold particles in an ore is key to the development and optimisation of gold processing operations, being cyanidation or gravity separation. This can be achieved through basic historic geological information, gold deportment studies, chemical speciation and metallurgical test works. The present study assessed the nature of the occurrence of gold particles (mineralogical composition, liberation, associations and surface chemistry) and its effect on the process route (cyanidation and gravity separation) of a typical paleo placer gold ore deposit within the Tarkwaian Rock system. The investigative approach used involved chemical assay, quantitative X-ray diffraction (QXRD) and quantitative evaluation of minerals using scanning electron microscopy (QEMSCAN). The ore samples (A, B, C, D, E, F) used were obtained from six active pits of a gold mine working on this orebody. The results of the mineralogical analysis revealed that the ore is highly oxidised and comprised quartz (>80 per cent) and Muscovite mica (>6 per cent) as the major mineral phases in all the samples. Trace amounts of hematite, kaolinite and todorokite were also identified in all the samples. The chemical analysis showed presence of gold (Au) in all the samples with samples B (3.62 g/t) and C (3.96 g/t) containing the highest concentrations. Trace amounts of copper (Cu), iron (Fe), sulfur (S), aluminium (Al), arsenic (As) were also detected in all the ores. The QEMSCAN mineralogical liberation and gold association results revealed that the gold grains were relatively coarser in all samples (P80 > 80 µm Au in size) except F (P80 < 32 µm Au in size). Gold grains were highly liberated especially in sample B with the majority of the locked gold grains forming complex associations. All the samples responded well to cyanidation and gravity separation except samples C and F, respectively.

Aug 24, 2022

By Pekka Hanniala

The Outokumpu Flash Smelting process today is the most feasible method for copper matte smelting. The economic feasibility of the process has always been one of the main decision making criteria in smelter projects. Thus, today about 50 % of the world primary copper production utilizes Outokumpu Flash Smelting Technology. However, in the future, environmental criteria will have stronger and stronger impact on decision making. Flash Smelting technology offers the best pollution control features of any process. today. It is foreseen that, in the near future, the global trend will be that all the smelters must decrease their emissions at an accelerating rate, compelling the smelters to make increasingly larger investments on environmental protection. In most of smelters ?today, Peirce-Smith converting and transfer of the molten material in ladles are the number one pollution source. The key today for copper converting and minimizing emissions is the Kennecott-Outokumpu Flash Converting process, which has proven to be the most effective converting method in terms of pollution control and, production efficiency including capital and operational costs. Outokumpu Flash Smelting technology is applicable also for small to medium scale smelters but the most interesting area is the upper capacity limit for smelting in one line, which has not yet been reached. We predict that by the year 2000 to 2005, there will be at least one smelter which produces 500,000 tonnes of Cu per year based on one Flash Smelting and Flash. Converting unit. The current state-of-the-art of the Outokumpu Flash Smelting - Flash Converting process is presented in this paper as well as some new options for copper production to be utilized in the near future but which are available already today.

Jan 1, 1998

By G Balog, T Ormerod, D Sidea

Carrapateena is a copper-gold sub level caving operation located in the Gawler Craton, South Australia. One of Australia’s largest undeveloped copper deposits, the project will be a 4.25 Mtpa underground operation, with an estimated mine life of 20 years (OZ Minerals, 2017). First concentrate production was achieved in December 2019, within the Iron Ore Copper Gold (IOCG) hematite breccia complex. The Carrapateena orebody is overlain by 500 m of barren sediments of the Stuart Shelf, which hosts two aquifers. The cover sequence is dominated by shales, quartzites and sandstones in order of thickness. The cover sequence presented challenges to the mine ventilation system as a result of highly variable rock strengths. On this basis, the site developed the first vent rise, Vent Rise 5 (VR5), earlier than required as a means to test the empirical stability assessment. Assessment for VR5 was completed in 2017, with the mine yet to develop through much of the cover sequence. Due to the geotechnical data available at the time, it was anticipated that break out would occur within the vent rise walls as a function of the low strength Woomera shales. VR5 was developed to 4.5 mᴓ in late 2018. The timing of the VR5 development enabled the site technical team to calibrate empirical stability factors for the assessment of future vent rises. At the time of writing, four additional vent rises have been successfully developed to a diameter of 5.5 m. No significant overbreak has been observed within any of the vent rises. This paper is intended for geotechnical practitioners designing large-diameter vent rises in geological environments similar to the Stuart Shelf where a similar approach to vent rise design may be warranted.

Mar 15, 2021

By R Castroviejo, E Pirard, L PTrez-Barnuevo

Process mineralogy provides the mineralogical information required by geometallurgists to address the inherent variation of geological data. The successful beneficiation of ores mostly depends on the ability of mineral processing to be efficiently adapted to the ore characteristics, liberation being one of the most relevant mineralogical parameters. The liberation characteristics of ores are intimately related to mineral texture. Therefore, the characterisation of liberation necessarily requires the identification and quantification of those textural features with a major bearing on mineral liberation. From this point of view, grain size, bonding between mineral grains and intergrowth types are considered the most influential textural attributes. While the quantification of grain size is a usual output of automated current technologies, information about grain boundaries and intergrowth types is usually descriptive and difficult to quantify to be included in the geometallurgical model.Aiming at the systematic and quantitative analysis of the intergrowth type within mineral particles, a new methodology based on digital image analysis has been developed. In this work, the ability of this methodology to achieve a more complete characterisation of liberation is explored by the analysis of chalcopyrite in the rougher concentrate of the Kansanshi copper-gold mine (Zambia). Results obtained show that the method provides valuable textural information to achieve a better understanding of mineral behaviour during concentration processes. The potential of this method is enhanced by the fact that it provides data unavailable using current technologies. This opens up new perspectives to the quantitative analysis of mineral processing performance based on textural attributes.CITATION:PTrez-Barnuevo, L, Castroviejo, R and Pirard, E, 2013. New perspectives on quantitative textural analysis, in Proceedings The Second AusIMM International Geometallurgy Conference (GeoMet) 2013 , pp 191-198 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 29, 2013

By J. H. Wiggins

"The tests described below were conducted by the Bureau of Mines at a lease in Oklahoma on installations designed to decrease evaporation losses of crude oil Pram storage tanks. Use of the lease was granted by the Oklahoma Producing and Refining Corporation of America. Tankage was obtained through the courtesy of the Parkensburg Pig and Reel Co. The purpose of the installations and tests was to demonstrate the value of making crude-oil storage tanks gas-tight, rather than to determine the amount of evaporation in any one type of tank. None of the tanks used were absolutely gas-tight, but one of them was very nearly so. They comprised a tank of the ordinary open type with an 18-inch manhole, a tank with a ""4-inch vent"", a tank with a ""smaller vent"", and a tank which had only ""pin holes"" through which air and vapor could pass freely. On the last two tanks any excess pressure was taken care of by an automatic differential pressure regulator.The results obtained in these tests indicate that tight tankage will soon pay for itself. They will not, however, serve as a basis on which a producer can compute the actual number of days necessary for tight tankage to pay out, because the oil used was exceptionally volatile. It is probable that the average evaporation loss in the Mid-Continent field is at least one-half as great as that shown by these tests, and if this is true, the saving that would be effected by providing tight tankage on the lease will undoubtedly justify the expense. The installation of evaporation-proof tanks on the lease has been delayed by the failure of production managers to realize, first, that their evaporation losses are enormous, and, second, that they can practically eliminate these losses by a simple and inexpensive installation."

Apr 1, 1921