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By C. Caballero, M. Rosales, C. León, A. Valencia, R. Fuentes, A. Moyano

Slopping is the formation of waves in the converter due to the gas injection by tuyeres. Those waves produce a premature wearing of the refractory lining of the reactor due to its great amplitude. The affected zones are the tuyere line (outlet gas from tuyeres) and the front of this line. In the present work, a theoretical and experimental study is made to develop a theory that determines the variables involved in slopping, characterizing the more important parameters of operation in the phenomenon of slopping. In addition, this theory will allow for determination of new technological alternatives of the blast injection permitting to depress the slopping phenomenon.

Jan 1, 2007

By P. C. Lightfoot, J. M. Duke, A. J. Naldrett

"The segregation of magmatic sulphides from mafic and ultramafic silicate magmas, in many circumstances, leaves the magma with a lower-than-normal Ni/MgO ratio, which is characteristic of both lavas erupted from the magma chamber and olivine crystallizing within it. Two end members of the segregation process are discussed; i) batch segregation and ii) fractional segregation.In the former, the critical factor is the magma/sulphide ratio. Computer modelling suggests that where this ratio has been less than 1000, the magma will be recognizable as anomalously low in Ni, due to sulphide segregation, and thus a good target for exploration. In fractional segregation, the critical factors are the proportion of sulphide to silicate being segregated and the degree of fractionation.Samples believed to represent the liquid portion of komatiitic lava f lows from a series of unmineralized sequences in the Abitibi greenstone belt, Canada. Belingwe belt, Zimbabwe, and Barberton Mountainland, South Africa coincide with the sulphide-free fractionation model. They are in marked contrast to samples from the ore-bearing districts of Kambalda and Scotia. Western Australia in which distinct Ni depletion, corresponding to fractionation of olivine plus sulphide in a ratio of between 100 and 200:1 is recognizable. Ni-depleted olivines also mark the sulphide-bearing Dumont intrusion of the Abitibi belt.The Moxie intrusion of northern Maine has distinctly Nidepleted olivines, as does the nearby and petrologically related Katahdin body. In both of these intrusions, the composition of the olivine allows reasonable predictions to be made of the Ni tenors of sulphide showings within them. At Katahdin, the Ni depletion is so widespread that little hope is help out for the presence of economic concentrations of sulphide. At Moxie. the olivine compositions suggest that the best chance of economic sulphides lies in the southern lobe of the intrusion.Ni-depleted olivines also characterize certain rock units within intrusions of the Insizwa complex, Transkei, Southern Africa. Many millions of tonnes of Ni have apparently been removed by sulphides from these rock units, many more than are contained within the single mineralized occurrence so far identified at Waterfall Gorge."

Jan 1, 1984

By C. S. Ha, H. S. Choi, D. Y. Shin

POSCO installed a new 100 ton oxygen bottom-blown converter in 2013 for the development of new steelmaking process named as PS-BOP which is reading POSCO-Saarstahl Basic Oxygen Process. This process was developed by the collaboration research between POSCO and Saarstahl AG in Germany that is based on substantial increase of CO post combustion in a converter by blowing hot air from the top of converter. The collaboration research has been finished successfully in November 2013 with 17% decrease in hot metal ratio (HMR) when hot air was blown from the top of the oxygen bottom-blown converter. After the collaboration research the converter has been tried to be operated as oxygen top and bottom-blown converter to reduce bottom wear and to decrease production cost with increased use of low cost Fe source by the help of increased CO post combustion. The presentation includes experience on the start up of oxygen bottom-blown converter, HMR reduction trials with hot air top blowing and transition from oxygen bottom-blown to top and bottom-blown converter operation.

Jan 1, 2015

The #3 Shaft at Brunswick Mine, Bathurst, New Brunswick, Canada, intersects a soft graphite zone just below the 3400 Level. Ground movement within this zone causes the concrete liner of the shaft to be deflected towards the shaft?s interior, affecting the steel framework of the conveyance. In some areas, the clearance between the cage and the liner has been reduced to less than 2 cm, which is a concern. An innovative surface-mounted extensometer was designed in 2008 to monitor potential movements of the shaft?s liner. Four such novel extensometers were installed in the shaft for the surveillance of a particularly critical 3.0m by 5.5m area. This article describes the approach taken to instrument the shaft, the principle of the new extensometer, as well as the performance of the instrumentation following its installation.

May 1, 2009

By Douglas W. Reeve, Hoc Nghia Tran, David Barham

"In kraft pulp mills, the spent pulping liquor is concentrated and used as fuel in the recovery boiler. Extensive deposits are formed in the upper section of the boiler due to the very high ash content of the fuel and the volatite nature of the ash. Deposits are composed of Na2S04, Na2C03 NaCI, some potassium salts and reduced sulphur compounds. Chloride and potassium salts are enriched in the deposits compared to the smelt due to their greater volatility.Severe corrosion of the superheater tubes in a recovery boiler has been traced to three factors: a non-uniform temperature profile in the flue gas, relatively high operating steam temperatures and high chIoride and potassium concentrations in the fireside deposits.The role of chIoride and potassium in superheater corrosion has been explained by increased Iiquid phase in deposits. Together with corrosion studies, this information has shown that kraft recovery boiler superheater corrosion due to the chloride and potassium enriched deposits can be avoided by proper boiler operation and by judicious superheater and furnace design.IntroductionThis investigation of recovery boiler superheater corrosion was initiated by the discovery of severe corrosion of the final stage superheater in a Canadian closed cycle kraft pulp mill(1,2). Metal wastage leading to tube failure was believed to be due to three major causes : the relatively high operating steam temperatures, the uneven distribution of flue gas temperature across the boiler which created a "" hot spot"" and the high chloride and potassium concentrations in the superheater fire side deposit. The mill responded to the problem by i) lowering the superheater steam temperature from 475°C to 380°C, ii) minimizing the chloride content in the spent pulping liquor, by controlling the NaCI input with recovered bleach plant effluent, and iii) changing metallurgy of a portion of the bottom section of the final stage superheater platens from ferritic steel T-22 (2.25% Cr, 1% Mo) to austenitic steel Incoloy 800H (21% Cr, 32% Ni, 46% Fe, 1.5% Mn, 1% Si, 0.6% Al) (Fig. 1). Details of the superheater corrosion experienced in the closed cycle mil! have been reported in previous papers(l ·2,) ."

Jan 1, 1984

By Gyeonghye Moon, Inhyeok Choi, Jyothi Rajesh Kumar, Jin-Young Lee

"This paper deals with the recovery of the tungsten and vanadium from spent SCR catalyst leach liquors by different hydrometallurgical methods. The first part consists of pressure leaching of spent SCR catalyst using caustic soda followed by metal recovery by liquid-liquid extraction. In a leaching process, the following experimental parameters were tested and optimized: NaOH, particle size of feedstock, temperature, and solid to liquid ratio. The optimum condition for leaching of tungsten and vanadium was under the following conditions: NaOH 3 mol/L, temperature 250°C, particle size <300 µm, and solid to liquid ratio 0.4. From these optimum conditions in this experiment, the dissolution efficiency of vanadium and tungsten was 91.5and 87%, respectively. Liquid-liquid extraction following commercial extractants were tested: TBP, Cyanex 272, D2EHPA, Aliquat 336, Primeme JM-T, Alamine 308, Alamine 304-1, and methyl-tri-octyl-ammonium chloride. The conditions for both valuable metal recoveries were optimized.INTRODUCTIONSelective Catalytic Reduction (SCR) catalyst has become the most effective to reduce nitrogen oxide (NOx) emissions from stationary segments such as power plants and waste incinerations around the world due to the reinforcing regulatory trend and emerging environmental issues (Forzatti, 2001; Spivey, 2002; Li et al., 2011).Currently, the most widely used SCR catalyst is V2O5-WO3/TiO2 system due to its great catalytic properties (Li et al., 2011; Marshneva et al., 1995; Marbergeret al., 2015). In general, the composition of the SCR catalyst used in the stationary application is 0.5 to 1 wt% of V2O5and 7 to 10 wt% of WO3(Marberger et al., 2015; Chen &Yang, 1992, Vuurman et al., 1991; Alemany et al., 1991). Currently spent SCR catalysts are treated as waste and disposed of in landfills. This causes a lot of waste of secondary resources of vanadium and tungsten. In terms of industrial value of vanadium and tungsten (Gupta &Mukherjee, 1990; Moskalyk &Alfantazi, 2003) and reduction of pollutant emissions, it should not be disregarded for their recovery for their material recycling from spent SCR catalyst. However, investigations for recovery of metal values from spent SCR catalyst has been rarely carried out."

Jan 1, 2017

By D. M. Maijer, S. M. Mohseni, A. B. Phillion

The microstructure evolution kinetics of aluminum alloy B206 during artificial aging has been investigated using non-isothermal calorimetry. A combination of differential-scanning calorimetry (DSC) and tensile tests have been utilized to develop an Avrami model to predict the precipitation kinetics as a function of the thermal processing parameters. The Avrami coefficients, found based on a Kissinger analysis, compare well against those reported in the literature for aluminum-copper alloys. The rapid precipitation kinetics predicted by the Avrami model at temperatures higher than 200°C were assessed through a qualitative comparison against hardness measurement results. In contrast to the continuous hardening observed at 150°C, the material softens with continuing heat treatment at 250°C resulting in an overaged state. This can be attributed to the rapid precipitation kinetics at this temperature, leading to the termination of the precipitation-hardening effects at early stages of artificial aging.

Jan 1, 2015

By P. W. Billwiller

Abstract The Britannia Mining and Smelting Company, Limited, have replaced diamond drills with percussion drills and tungsten: carbide bits for most of their blast hole drilling operations and have thereby reduced ore breaking costs. Two-inch Carset bits .are used, with one-inch hexagonal Atlas Chippewa alloy steel in 3-foot .and 6-foot lengths. Locally made couplings of Atlas SPS 245 alloy steel connect the rods. The machines used are 31½-inch automatic leyners with lugged or anvil block chucks. For drilling holes below the horizontal, the lugged machines with special adapter rods made from 114- inch solid round Atlas SPS 245 are required. These rods are lugged at one end and a water hole is drilled for six inches into the other end. Over this rod is placed a water swivel which permits the water or air to be sent directly into the steel. A decreased cost per foot, increased footage per shift, and the use of standard equipment and crews are some of the main advantages of tungsten carbide drilling over diamond drilling. Introduction Long-hole drilling with percussion drills and sectional steel was introduced in several American mines some twenty-five years ago. It did not prove very successful, however, because the rapid gauge loss in steel bits necessitated the use of very large starter bits. This in turn rapidly fatigued the straight carbon-steel then in use, made it difficult to maintain the couplings, and resulted in a slow drilling rate. The introduction of the tungsten carbide insert bit and alloy drill still has changed this picture and opened real possibilities for the application of percussion drills to blast-hole drilling. If this type of bit had been perfected ten years ago, much of the research work and experimenting done to apply diamond drills to ore breaking would have gone toward developing the application of the tungsten carbide bit to this problem.

Jan 1, 1950

By G. V. Lewis

"INTRODUCTORY REMARKS""I believe we need to communicate as much as possible with the industry. I don't think that we should be a body that just goes around doing dust surveys and writing nasty letters. We should get together on these problems and try and solve them as a group. I've only been with the Department a little over 12 months. I haven't visited all of your plants. I've visited most of the major open pits and I have had a chance to observe a lot of problems that you have encountered and a lot of the problems that you have brought up this morning. I thought the best thing I could do is perhaps mention a few of the approaches to the problems that my superior has suggested to me and we have discussed in the Department, and then perhaps go over a few of the evaluating problems and what we are trying to do with our dust surveys and perhaps ways and means of improving the present setup."""

Jan 1, 1976

By A. Blackmore, D. Baker, L. Human

"Mechanical mixing equipment is common in a wide variety of mining, metals and process applications, such as hydrometallurgical reactors, solvent extraction, digestors, and tanks for storage of slurry or hydrocarbons. Computational Fluid Dynamics (CFD) has been applied successfully to single-phase mechanical mixing problems for several decades and is established as a reliable design tool. As computational power and CFD codes have improved over the years, there have been significant advances in modelling capabilities including improved models of turbulence, interaction of rotating and stationary components, multiphase flows, and modelling of free surface interfaces, for example. This paper will provide an overview of the application of CFD to mechanical mixing problems. First, it will review the traditional single phase Multiple Reference Frame (MRF) approach and introduce a range of advanced modelling techniques. Three examples of the application of CFD to industrial mixing problems will be given. It will be demonstrated that CFD is an effective tool for reducing technical risk in design, for identifying the root-cause of mixing problems, and testing modifications to existing operations."

Jan 1, 2015

By B. Wasmund, M. Parravani, M. Jastrzebski, Z. Coull

"One of the main drivers of overall profitability of pyrometallurgical vessels is refractory lining campaign life. Increased economic pressure to improve vessel life requires innovative solutions to the problem of refractory cooling. Hatch has recently developed a high-intensity, waterless cooling system that bridges the performance gap between external shell cooling and internal water-cooled copper elements. External shell cooling has a limited effectiveness in protecting the refractory lining, because it is thermally insulated from the hotface of the lining by its thickness. This situation does not improve until the lining itself has become worn near the end of the campaign. The patented technology developed by Hatch overcomes this problem by positioning high-velocity air-cooling channels within the lining, closer to the hotface where the cooling benefits can be realized throughout the entire duration of the campaign. The current paper presents the development and application of Internal Air Cooling technology as well as results from the pilot campaign in an operating commercial vessel. Various adaptations for this novel, cost-effective and inherently safe system are also discussed."

Jan 1, 2015

By J. -M. Lalancette, D. Lemieux, C. Chouinard

"A gold bearing concentrate containing 107 g/T of gold, 9.3% copper and 706 ppm of mercury was processed at the demonstration scale for the extraction of gold and copper using a cyanide free process. The concentrate was generated through flotation to upgrade the gold and copper grade, but also showed contamination with mercury. This concentrate was submitted to the DST process demonstration plant. The concentrate was first oxidized using a fluidized bed to produce a calcine. The mercury was volatilized during the oxidation stage with an efficiency higher than 98%. The mercury was condensed and removed from the sulfuric acid using a thiosulphate process. Copper was extracted from the calcine as copper sulphate using diluted sulfuric acid. The solid remaining after acid leaching was submitted to the DST chlorination process for gold extraction. Under optimized conditions, a gold extraction of 97.3% was achieved in the chlorination reactor. Gold was recovered from the pregnant brine by precipitation on silica using a DST proprietary process.INTRODUCTION Dundee Sustainable Technologies Inc. (DST) offers proprietary metallurgical processes for the treatment of material from the mining industry. DST processes enable the extraction of precious metals and for the removal and stabilization of contaminants, such as arsenic, from ores and concentrates. DST provides environmentally-friendly, viable and efficient processes, capable of handling complex and refractory ores which cannot be processed with conventional approaches due to metallurgical issues or environmental considerations. Several mining jurisdictions around the world have banned or restricted the use of cyanide. DST has developed a closed loop chlorination process as an alternative to the conventional cyanidation process for the extraction of precious metals from minerals. The tailings from the process are inert from toxic substances such as cyanide and organic compounds, are sulphide depleted which means they do not generate acid, and thus, meet and/or exceed environmental norms. The process has demonstrated excellent gold recoveries within a fraction of the time needed for cyanidation to obtain similar results. Moreover, the closed loop process does not generate any liquid effluent and does not consume much water: it only requires a water make-up to compensate for moisture leaving with the tailings and by-products, and seawater may be used. The improved environmental footprint of the DST process has been certified by the Environment Technology Validation program (ETV) which provides an independent evaluation of the performance claims of innovative technologies."

Jan 1, 2017

By G. B. Harris, C. W. White

A study to investigate the recovery of base metals, notably copper, nickel, cobalt, zinc and manganese from iron-free concentrated chloride solutions using ion exchange was undertaken. In such solutions, apart from nickel and, to a lesser extent manganese, these metals are present predominantly as complex anions, and therefore conventional separation techniques based on cationic resins are not applicable. The results demonstrated that zinc, copper and cobalt can all be separately recovered leaving nickel and manganese behind. Specifically, zinc is a major nuisance element in nickel and cobalt processing, and the testwork showed that it can be preferentially removed prior to copper and cobalt. Selective resins for both copper and cobalt were identified, and it was demonstrated that the strength of the chloride background matrix has a significant effect on the efficiency of separation. An additional major advantage in such systems is that stripping can mostly be effected with water. Finally, some observations are made on the hurdles that must be overcome when attempting to introduce and commercialise new technologies.

Jan 1, 2015

By R. O. Suzuki, S. Natsui, R. Nashimoto, T. Kumagai, T. Kikuchi, H. Takai

A newly developed computational fluid dynamics model based on a multi-phase particle simulation is presented for predicting the entrainment behavior of liquid metal into slag due to rising single bubble. By comparing results calculated using this model against experimental data, it was found that the transient behavior of bubbles and the two immiscible liquids can be accurately estimated by this method. The rupturing of the thin water film surrounding the bubble was less reliably predicted, but this 3-dimensional unsteady numerical model still nevertheless provides valuable new information for directly predicting the change in the liquid-liquid interface over time. This model predicted the Young-Laplace pressure, and the interface shape was simulated with volume conservation using this model as opposed to the conventional particle method. This simulation model can calculate both of dispersed phase and continuous phase seamlessly.

Jan 1, 2015

By Cesar H. Oboni

The development of specific risk-based methodologies to guide and prioritize clearing decisions in countries contaminated by Unexploded Ordnance and Land Mines (generically defined as Explosive Remnants of War: ERW) either at country-wide scale or road-network-scale was used in an unexpected way when a large mining company asked Riskope (www.riskope.com) to develop a multi-modal transportation network risk assessment plan, which included ocean going vessels, ports, wharves, railroad, trucking and other modes of transportation. What had been a first-in-the-world attempt in the humanitarian landmine clearing industry turned out to be extremely useful and equally innovative in the extractive corporate world. Instead of a country contaminated by man-made hazards such as Explosive Remnants of War (ERW) we were now dealing with a very complex multi-modal transportation system afflicted by all sorts of potential hazards from quakes to climate change, sabotage to labour strikes, and vulnerable infrastructures to potential energy crises. Interestingly enough the method developed to deal with ERW risk based clearing was also capable of solving the transportation risk evaluation problem, after necessary customization. This paper shows how ?out of the box? thinking and industry cross dissemination can bring significant evolution and a competitive edge even to unexpected areas of the world-wide mining industry. The results of the logistic system risk assessment shed new light on the management of the system, changed the way insurance coverage was purchased, and led to significant potential cost reductions in a period of global recession.

May 1, 2010

By M. J. Fairweather, Keith Lee, Naseem Mian

"The initial metallurgical response of the lead flotation circuit at Cominco Alaska's Red Dog Mine was substantially below feasibility expectations. A program of diagnostic mineralogical analysis pointed the way to a number of process improvements, including simplification of the flow sheet and installation of a large flotation column as a lead cleaner. A diagnostic mineralogical analysis of the improved circuit shows that inadvertent activation of both sphalerite and pyrite has been substantially reduced, resulting in significant improvements in metallurgical performance. Directions for further improvements to the circuit performance are suggested by the recent analysis.IntroductionRed Dog is a high-grade, sedimentary exhalative (sedex) deposit with relatively simple mineralogy. The primary non-sulphide gangue minerals are quartz and barite, with minor barium carbonate (witherite). The iron sulphate minerals, siderotil, rosenite and copiapite occur variably throughout the deposit. Mineral texture is variable ranging from liberated sphalerite grains visible to the naked eye to intergrowths, particularly between sphalerite and galena, to less than ten microns. Both pyrite and marcasite are present. To date no enhanced reactivity of marcasite has been observed. For this discussion, ""pyrite"" will be used to refer to both iron sulphide minerals. In common with other sedex deposits, Red Dog contains organic and sulphur impurities."

Jan 1, 1997

By E. A. Lowe, A. F. Bellamy, J. W. Smith

"In the autumn of 1977 Bethlehem management initiated feasibility studies on recovery of by-product molybdenum from concentrate produced at the existing Highland Valley mining operation. Over the fall and winter months test work was carried forward concurrent with design, flowsheet, equipment specification and cost studies. The decision was made to go ahead with a 200 ton-per-day treatment plant. Construction started in early 1978 and progressed to an initial start-up stage in mid-June. Full operational status was reached in August 1978. Operational results through August 1979 are presented. INTRODUCTIONBethlehem Copper Corporation operates a 20,000 ton-per-day Open Pit Mine and Flotation Plant located in the Highland Valley, some 30 air miles Southwest of Kamloops and 20 miles Southeast of Ashcroft, B.C.Two open pits are worked; the Iona Pit with limited reserves of higher Mo content, and the lower grade, more extensive Jersey Pit. Upwards of 150 tons per day of bornite-chalcopyrite bulk concentrate is produced, ranging 0.25% to 1.5% in molybdenum grade depending on the area mined."

Jan 1, 1980

By T. Prietl

Metallurgical vessel linings are multilayered, consisting of refractory bodies, insulation materials, joints, and additional space to control for thermal expansion. A unique biaxial hot testing press (BHTP) was installed at the RHI Refractories Technology Center Leoben, Austria to enable the three-dimensional behaviour of complex vessel lining segments to be investigated under simulated service conditions. Using the BHTP, the heat up and thermo-mechanical behaviour of magnesia chromite brick lining segments with and without mortar filled joints were examined. The results obtained during the initial heat up provided validation of CFD modelling of the lining system. In addition, after the heat up and under steady state conditions, the lining behaviour during deformation-controlled compression and relaxation was examined. These analyses generated important data regarding the stiffness, joint compressibility, and brick damage of the lining segments after cyclic loading and unloading as well as the benefits of using mortar joints in the lining. These investigations were performed in collaboration with the Christian Doppler Laboratory for Secondary Metallurgy of Nonferrous Metals, University of Leoben, Austria. The BHTP has been operational since November 2004 and is providing information regarding the thermo-mechanical behaviour of different lining segments.

Jan 1, 2007

By G. McIsaac

"This paper discusses the formulation of a linear program with the objective of maximizing the cash flow of the long-term plan of an underground operation. A mine is split into eleven independent ore zones, each characterized by its reserves, required development, and mining method. Based on practical considerations, maximum rates are set for each zone’s development and production capacity. For the total mine plan, a minimum daily production rate is set along with a minimum feed grade to the mill. A maximum daily development capacity is set based on the equipment and labour available. Proven and probable ore is mined preferentially over possible ore in the early years of the plan. Also, the fixed cost of operating the mine is taken into consideration whenever mining activities take place.Once the linear program is solved, it can be critically reviewed, and unrealistic results can be identified. Some resource allocations constraints can then be changed in certain sectors, and new results can be analyzed. “Whatif” scenarios can also be examined, such as determining the impact of hiring a contractor to develop a given sector, or dropping an ore zone completely from the plan."

Jan 1, 2005

By G. McIsaac

This paper discusses the formulation of a linear program with the objective of maximizing the cash flow of the long-term plan of an underground operation. A mine is split into eleven independent ore zones, each characterized by its reserves, required development, and mining method. Based on practical considerations, maximum rates are set for each zone?s development and production capacity. For the total mine plan, a minimum daily production rate is set along with a minimum feed grade to the mill. A maximum daily development capacity is set based on the equipment and labour available. Proven and probable ore is mined preferentially over possible ore in the early years of the plan. Also, the fixed cost of operating the mine is taken into consideration whenever mining activities take place. Once the linear program is solved, it can be critically reviewed, and unrealistic results can be identified. Some resource allocations constraints can then be changed in certain sectors, and new results can be analyzed. ?Whatif? scenarios can also be examined, such as determining the impact of hiring a contractor to develop a given sector, or dropping an ore zone completely from the plan.

Sep 1, 2005