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By G. J. Desroches, E. Ozberk, M. J. Collins, B. D. Krysa, I. M. Masters

The zinc refinery of Hudson Bay Mining and Smelting Co., Ltd. went through a major modernization in 1993, when the roaster and the calcine and fume leach circuits were replaced by a new Sherritt zinc pressure leach plant. The HBMS plant, in Flin Ron, Manitoba, represents the first commercial application of the Sherritt two-stage zinc pressure leach process, with /00% of the zinc concentrate feed processed in autoclaves. The process design of the new plant required definition of the deportments of elements such as antimony, arsenic, chlorine, cobalt, fluorine, germanium, magnesium, manganese, selenium, tellurium and thallium. This paper describes the deportment of these elements in the commercial zinc plant during the first nine months of pressure leach operation, and compares these results with operations prior to the introduction of pressure leaching, and with the results of tests carried out in the She"itt laboratory during the process development phase.

Jan 1, 1995

By Alan B. Morrow, William A. Poe

"Minerals processing operations are constantly challenged with improving production rates, yields, energy efficiency and process stability. Advanced Process Control has proven to be an effective tool for improving operations by capturing the full process capabilities consistently. However, the velocity of applying the technology as well as the sustainment of these significant benefits has been hampered by the usability of the software and adaptability of the applications.Some of the new technology developments that improve the usability and adaptability of advanced process control include:• modern and intuitive user interfaces,• customizable models to support unique process behavior,• fast and flexible OPC connection tools,• automated model building,• integration with first principles dynamic models and• improved performance monitoring.This paper will briefly discuss the new technology developments that have improved the usability and adaptability of advanced process control and how this can affect minerals processing operations.In today’s environment, Minerals Processing plant managers continuously face new challenges and requirements including:• higher energy efficiency,• increased run lengths,• reduced product quality variability,• reduced emissions,• higher availability, and• lower operating costsOperating a unit to meet these challenges in real time is not easy for operators and conventional process control systems. However, innovatively using existing technologies in Minerals Processing plants can improve operations on a minute by minute basis and reap significant benefits.Advanced Process Control (APC) can extract the maximum performance benefits from existing equipment while respecting plant operating constraints. Expensive capital projects to upgrade equipment are not always necessary. Advanced Process Control can deliver significant economic benefits by maintaining the plant at its most profitable point as conditions change."

Jan 1, 2016

By W. Evans, T. Steis

"Sulphide ores under certain circumstances will react with explosives to generate an autocatalytic chemical reaction. This reaction is exothermic and results in the production of large volumes of poisonous gases and creates an unsafe, unstable condition with the possibility of a low energy deflagration or even a detonation of the loaded hole. This paper outlines the conditions that need to exist for such a reaction to take place and the precautions necessary to minimize or eliminate the problem in areas of reactive ore. A special case study involving a northern Ontario mine will be detailed.IntroductionOne of North America's leading underground gold producer's processes over 6500 tonnes of ore per day from an orebody containing high concentrations of sulphides. After six years of problem free operation, the mine experienced two serious reactions in two months between the sulphides and AMEX II, the ammonium nitrate and fuel oil explosive it uses."

Jan 1, 1995

By John W. Korczak

The use of geological and grade block models has been standard practice in mine design for many years now, with a wide range of software available for creation and analysis. Although geotechnical parameters are of vital importance to mine planning there is very little in the way of commercially available systems for integrating geotechnical data into the mine planning and design process. Sirovision is a new technology developed by the CSIRO (Commonwealth Scientific and Industrial Research Organization) in Australia for automated, safe and accurate 3D mapping of geological and geotechnical features. Datamine has integrated this capability into its product range so that Sirovision has become an integral part of the day-to-day mapping, mine geology and geological / geotechnical modeling in both open pit and underground mine environments. This is the first integrated underground application of Sirovision from Datamine collaboration with Xstrata Nickel at the Nickel Rim South Project. This paper discusses the role of Sirovision in collecting the raw data required for geological and geotechnical analysis and the interpretation in a quick, safe, auditable and reproducible manner.

May 1, 2009

By G. W. Poling

"Construction, equipping and planned operation of a new laboratory for engineering-teaching and research in coal and mineral processing is described. This facility will provide approximately 1860 m2 (20,000 ft. 2 ) of laboratory space with nearly half devoted to a new venture in coal preparation. Two high-bay, overhead crane-accessed areas will accommodate major unit operations for each of the ""coal"" and ""mineral"" laboratories. COAL PREPARATION FACILITIES:The coal facility provides three main functional areas:(1) Sample preparation (drying, blending, crushing, screening) and sink-float washability testing.(2) Unit operations U1igh-bay, serviced by crane).(3) Analytical laboratories.(l) Sample Preparation and Sink-Float TestingBreaking or comminution of coal will be accomplished using a rolls crusher, a hammer mill, a jaw crusher, or a pulverizer. Capacity to prepare coal at rates of up to approximately 4 tph will be provided by some of these units. Large diameter (~0.5m) baths of heavy organic liquids will be available for sink-float washability tests on coal samples of several kg. Particle sizes of up to 25 mm can be tested in these baths. Smaller scale washability tests on finer samples will be accelerated by centrifuges."

Jan 1, 1980

By Vern Evans

Saskatchewan has historically been recognized for farming, but in 1943 while drilling for oil, potash was discovered. The initial attempt to gain access to the potash beds was unsuccessful, however, subsequent attempts were successful and today there are ten operating potash mines in Saskatchewan. In this paper we will provide a brief overview of the historical and current Potash industry in Saskatchewan.

May 1, 2011

By Greg Collins

BUCKO EXPLORATION HISTORY ??1964-Discovery ??1970?s -114 holes totaling 34,000 metres drilled -vertical shaft excavated to a depth of 300 metres (1000 Level) plus 800 metres of underground development -Exploration program cancelled due to Falconbridge economic issues ??1990?S-19 holes drilled totaling 9,600 metres ??2000 -13 hole 4,600 metre exploration program by Nuinsco Res.

May 1, 2006

By B. McFadzean, J. Taguta

In order to recover minerals by flotation, the sub-processes of collector adsorption onto the valuable minerals followed by bubble-particle attachment should occur efficiently. This paper investigates both of these sub-processes for various thiol collectors and their mixtures onto base metal sulfide minerals. The aim of the work was to investigate whether there is a correlation between the strength of the collector interaction with the mineral and the subsequent bubble-particle attachment. The collector-mineral affinity was measured experimentally using an isothermal titration calorimeter in order to determine the molar enthalpy of adsorption for each collector-mineral system. The bubble-particle attachment was measured using a microflotation device which essentially determines the hydrophobicity of the mineral. Sodium ethyl xanthate (SEX) and sodium diethyl dithiocarbamate (DTC) and mixtures thereof were used as collectors with either single minerals or binary mixtures of pyrite and chalcopyrite, respectively. The adsorption enthalpies of the collectors were interpreted with reference to the chemical structure of the collector molecule and showed that the greater the positive inductive effect of the collector, which may be qualitatively related to their pKa, the greater their affinity for the mineral surface. In the microflotation studies, recoveries were strongly related to the alkyl chain length but there was no correlation between the enthalpies of adsorption and the flotation recoveries. When mixtures of collectors were used there was clear evidence of synergistic effects and in the case of DTC/xanthate mixtures it is possible that this synergism is related to a DTC promoted oxidation of xanthate to dixanthogen. When mixtures of pyrite and chalcopyrite were used the flotation recovery and enthalpy of adsorption of SEX onto the individual pyrite particles in the mixture increased substantially compared to the case of pyrite alone. Mechanisms are proposed to interpret these important observations.

Jan 1, 2016

By L. A. M. Castro

As Canadian mines progress to greater depths, magnitudes of induced stresses increase, becoming high enough to cause rock mass damage and failure during excavation. In addition, depending on the orientation of key geological structures in relation to the in-situ stresses, induced shear loading can be developed on these structures, creating the potential for: a) remobilization of existing geological structures, b) formation of new seismically active structural zones, created through rock mass damage and coalescence along such structural zones, and/or c) interaction between existing and newly created structures. Numerical analyses were carried out to investigate four possible factors that might cause fault slip on controlling structures, namely: (a) unclamping, (b) day-lighting, (c) stress rotation and (d) pillar shear. Application to an underground mine in the Sudbury Basin allowed verification of these factors and the proposal of two alternative mine planning methods to limit fault slip on key structures: (1) pillar clamping and (2) stope sequencing.

May 1, 2009

By Rene Klymowsky, Norbert Patzelt, Egbert Burchardt, Johann Knecht

"The challenge of ""ore bodies getting steadily harder and lower in grade"" was brought to light during the first oil crisis in the 70's. Shortly afterwards, HPGRs appeared on the scene with the promise of saving energy. This combined with developments in wear protection for the rolls ushered in a period of trade-off studies that considered the HPGR as an option to improve project economics or to even make projects feasible at all.Since then, applications of HPGRs at Cerro Verde (Freeport), PTFI Grasberg (Freeport), Mogalakwena (Anglo Platinum), Tarkwa (Goldfields), Boddington (Newmont), Penasquito (Goldcorp), and others have contributed to the creation of a formidable basket of operating experience. Collected through years of successful operation, this information has been used to validate design criteria, scale-up factors and establishing a clearer picture of what ""to do"" and what ""not to do"".This paper compares results from various mining operations using HPGRs in their processing plants. Some of the lessons learnt in different operating environments are reviewed in order to support proper implementation and operation of HPGR's. Some of the development programs that have been initiated to improve wear life of the tyres and to reduce overall operating costs are reviewed. It is timely to summarize today’s experience and analyse its implications for existing and new operations"

Jan 1, 2012

By S. Esfahani, M. Barati, K. Danaei

"Substituting Portland cement with slag cement is one of the most economically attractive uses of slags. For this application, high cooling rates are required to form an amorphous structure. However, this is counteracted by the need to use small coolant flowrate to allow recovery of slag thermal energy as high quality heat to the coolant fluid. Therefore, a relationship between cooling rate of slag and its structure is essential to recover the heat effectively while making an amorphous slag.A modified Single Hot Thermocouple Technique (SHTT) was employed to investigate the crystallization behavior of slags by plotting their TTT (Time-Temperature, Transformation) diagrams. Seven different slag compositions containing CaO, SiO2, Al2O3, MgO were prepared at varying basicity (CaO/SiO2 =0.5-1.4).The results indicate that with increasing basicity, the TTT curves of glassy to crystalline transformation shift to the left which means higher crystallization tendency. This agrees with the fact that with the increase of basicity, the Si-O bonds are weakened, which in turn facilitates the re-ordering and crystallization of the silicate structure."

Jan 1, 2014

By P. Condori, G. Rech, J. Winnett

"Palabora Mining Copper has a unique ore body composition which unlike other copper ore bodies has three main components in significant proportions; these are copper bearing ore, magnetite and dolerite. The high content of dolerite, a hard barren material, creates a high proportion of pebbles which normally are recycled back to the mill. This action increases the mill bearing pressure and power progressively until corrective actions are taken.A logical action to solve the pebbles generation would be to incorporate a pebble crusher. This in fact was done however two fundamental issues were encountered; the high content of magnetite and existence of a cyclone classification section. Due to the high content of magnetite, metal detectors have not been able to work efficiently to separate tramp metal which causes damage to the pebble crushers. The existence of cyclones in the circuit had a detrimental effect on the final product when the pebbles crusher was online producing coarse sandy material.Due to the difficulties in treating pebbles via conventional procedures and the unique Palabora ore composition and characteristics, sorting technology was investigated at laboratory and pilot scale. It was found that a combination of optical and electromagnetic sorting could efficiently separate dolerite from the copper bearing and magnetite ores.This paper reports the findings of the laboratory and pilot scale work performed and discusses the additional benefits to the circuit."

Jan 1, 2012

By R. K. Jonas

Many leading copper and other mineral processors have rapidly adopted advanced controls in last 5-10 years. Almost 600 multivariable predictive controls have been installed in mineral processing, and almost 50% of those are in copper concentrator plants. In most cases, mineral processors rely on 3rd party support to implement these advanced technologies. One challenge facing advanced control user is the selection providers and services for these technologies. The trend has been towards the use of multivariable predictive control and use of technology provider’s services. This paper will discuss status of advanced control, and the merging trends in the mining industry. A review will be presented of how advanced control is being applied in the mining industry over the last decade, and how user challenges are being overcome. Next the emerging uses of multivariable predictive control (such as multi/inter-unit optimization), focusing on the latest trends in concentrator plants. Finally, a review will be made of emerging technology advances in the that can be advantageous to mineral processors. INTRODUCTION Review of advanced control in mineral processing Advanced controls are serving an increasing role to improve processing plant operations and profitability. As advanced control is being installed into more mining processing plants such as copper concentrators, many of these plants are concerned about the selection technologies and vendors to support the installation and maintenance of these controls. In a study by Jonas and Craw (2011), they found that most new users have not had prior experience with advanced controls. It is the author’s experience of almost 30 years in advanced controls that most mineral processers considering advanced controls can benefit from better understanding of the technologies and their support requirements.

Jan 1, 2019

By I. M. R. Duarte, J. A. Rodrigues-Carvalho, F. R. S. Rosa, A. B. Pinho

"This paper aims to contribute to the knowledge of the mechanical properties of the shales and greywackes which constitute the flysch-type deposits of the Baixo Alentejo Flysch Group, in the south of Portugal. These formations are flysch-type deposits constituted by sequences of usually thick greywacke beds alternating with thin shale beds, which include sometimes intercalations of conglomerate beds. All the sedimentation of these flysch formations was controlled by tectonics. At the same time, should have occurred along with the first Hercynian deformation phase, a low-grade metamorphic event (chlorite zone), that affected these flysch deposits. This study highlights the influence of anisotropy and heterogeneity of these flysch rocks on their physical and mechanical characteristics. The anisotropy verified in some physical properties and on mechanical properties, due to the foliation makes difficult the sample preparation for the laboratory tests. Besides, it induces a scattering of the properties values measured, as for example, the strength and the deformability. The heterogeneity is related to the main features of these geological formations, which are constituted mostly by thinly stratified greywackes and shale beds, which sometimes may affect the results of the laboratory tests making them less representative. The study is made by using both shales and greywackes that constitute these flysch-type deposits in order to evaluate their geotechnical properties, mainly of the shales. Samples of these two rock materials, are tested accordingly a laboratory testing programme, which includes which included mineralogical analysis (X-ray diffraction), physical tests (bulk density, porosity, and void index) and mechanical tests (uniaxial compression, and deformability tests). INTRODUCTIONOne of the factors that most influence the geomechanical behavior of rocks, as well as rock masses is the anisotropy. The word anisotropy comes from two Greek words ""anisos"" (meaning uneven) and ""tropos"" (meaning direction). A body or material is considered to be anisotropic, where the same property has different values depending in which direction it is measured, therefore, an anisotropic material is one whose magnitude of the properties depends on the direction in which these are studied or measured. Otherwise, it is about an isotropic material. However, the fully isotropic materials are quite rare in nature."

Jan 1, 2015

By F. Cheuk, E. Krause, V. G. Papangelakis, G. A. Moldoveanu, S. Abendschein

Systematic studies have been conducted at the University of Toronto in order to evaluate lanthanide extraction from clay minerals from different geographical regions. It was found that rare earth elements (REE) are easily recovered into an aqueous solution via an ion exchange mechanism by leaching with electrolyte solutions containing monovalent cations under ambient conditions. In this study we assessed extraction levels of individual REEs as a function of initial clay composition and leaching conditions. It was found that, in spite of variations in clay origin, all clays consistently reached peak REE extraction levels with fast kinetics. However, terminal extractions were clay-specific. The feasibility of using seawater as a leaching solution and potential synergies with ammonium sulphate as a lixiviant was also investigated. Seawater was found to be inferior to using ammonium sulphate, and provided no observable synergy in leaching performance when used together. The aqueous phase trapped in leached clays was shown to contain significant amounts of REE, as demonstrated in clay washing tests. Techniques to improve the REE concentration in leachate through process variations were investigated. However, it was found that most techniques capable of increasing REE concentrations in the resultant leachate also resulted in reduced REE extraction.

Jan 1, 2014

By M. Lahtinen, B. Saxén, M. Latva-Kokko

The conventional jarosite precipitation process with neutralization by zinc calcine is widely utilized in the zinc industry. However, it has a significant drawback of causing losses of valuable metals like zinc, lead and silver to the jarosite. This comes mainly from the content of these metals in the calcine used for neutralization. As the zinc plants today want to maximize metal recoveries and minimize the amount of residues, this matter has become more and more relevant for zinc producers. Outotec developed and patented in early 2000 an improved version of the jarosite precipitation process in which the need for neutralization can be minimized, thus the metal losses to the jarosite also can be minimized. At the same time, the iron content of the jarosite increases and the amount of produced jarosite is smaller. The main feature of this process is to start the precipitation from ferrous iron after having reduced all the iron by zinc concentrate in a separate step before jarosite precipitation. Iron is then oxidised back to the ferric form simultaneously with jarosite precipitation. By this method, the formation of sulphuric acid is only half that compared to the conventional method and the need for calcine for neutralization can be avoided. High mixing and oxygen dispersion capability are needed in this jarosite precipitation process. Such capabilities are found in the Outotec OKTOP® reactor series. High performance reactors are not only needed to generate high quality precipitates, but also to maximize oxygen utilization; i.e., to minimize operation costs. Outotec’s latest development in this area is the OKTOP® plant product in which not only the reactors, but also all the accessories are designed, manufactured and delivered by Outotec. One responsible supplier ensures efficient and fast delivery and can provide mechanical and performance guarantees for the entire plant unit.

Jan 1, 2016

By R. A. McIvor, R. S. Rafuse

"INCO Limited purchased a custom designed mobile hoist rope winder/tensioner in 1988 from TimberLand Equipment Limited to handle Large hoist ropes and serve as an emergency hoist. This paper describes the operation of the winder/tensioner and some of the different applications that the machine has been used to handle large loads.IntroductionINCO Limited operates 24 mine hoists in the Ontario Division and has approximately 50 miles of mine hoist rope hanging in the shaft plus an equal amount on spare reels. The mine hoist ropes range in size from )( inch to 2.305 inches in diameter with the majority being 1 3/4 inches and above. Prior to the procurement of a new high powered winder/tensioner in 1988, the mine hoist ropes were handled with a variety of methods and equipment using hydraulic or pneumatic powered reel winders. The largest such reel winder has a pull rating of 8000 Ibs and travels approximately 40 ft/min. Head ropes for the tower mounted friction hoists were installed and removed using a magazine on the hoist drum to wind and unwind the rope because the loads were greater than the capacity of the existing machinery. It was recognized that a large high capacity machine would improve the productivity for handling the larger hoist ropes and a feasibility study was undertaken to determine the parameters for such a machine."

Jan 1, 1995

By Ian S. Thompson

"Exploration properties form a continuum from grass roots to those with favourable geology, geochemical and/or geophysical anomalies, mineralization, showings (prospects), and finally to those with defined mineral deposits. Often properties exhibit a composite of these categories.The most problematic to value are properties or deposits that are not economically exploitable at the time of the valuation, due to a lack of exploration, insufficient grade or tonnage, poor mining conditions, or the imposition of socioeconomic, environmental, or legal constraints.Various acceptable methods of valuing the range of all such mineral properties or deposits are reviewed. Some inappropriate methods are also discussed.BIOGRAPHYIan S. Thompson is President and Principal of Derry, Michener, Booth & Wahl Consultants Ltd. (DMBW), an independent consulting practice, specializing in exploration, ore reserve estimations, engineering and valuations of mineral properties.Mr. Thompson is a graduate in Honours Geological Sciences from the University of Toronto with over 35 years Canadian and International experience in mineral exploration and development, including the discovery of base metal. gold and uranium deposits.DMBW is affiliated with DMBW, Inc. in Colorado, and works with independent engineering and financial groups in North America, Europe, Australia and Africa.Mr. Thompson is a national member of CIM; the Associations of Professional Engineers of Ontario and British Columbia; The Geological Association of Canada; The Society of Economic Geologists; The Prospectors and Developers Association of Canada and the BC and Yukon Chamber of Mines.INTRODUCTIONThis paper is presented in response to the request of the Mineral Economics Society of the Canadian Institute of Mining and Metallurgy for a Review of Approaches to Valuation of Mineral Properties, as recommended by the TSE/OSC Mining Standards Task Force.Exploration properties with undeveloped mineral resources range from grassroots acreage without exploration history, to those containing mineralization (or a mineral resource) that is insufficiently explored, to well explored deposits which lack either continuity, or sufficient grade/tonnage, or have poor mineability or metallurgy, such that they are not currently exploitable at the time of the valuation. This does not imply that they do not have value."

Jan 1, 2003

By Patrick R. Taylor, T. A. R. Putra

A review of various methods to treat high arsenic copper concentrates through pyrometallurgical processing is presented. Examples are drawn from various past and current operations and research. Various aspects of the engineering alternatives for treatment methods are discussed. Some of the methods discussed include: controlled oxidation roasting, adaptation of some smelter technology to accept higher amounts of arsenic, complete oxidation with arsenic fixation; sulfation roasting; acid baking, soda ash roasting, and others methods. Other topics include: a short discussion of other problematic impurities; the effects of arsenic on copper electro-refining and product purity; and methods for the ultimate disposal, or marketing, of the arsenic. The latest work being done at the Colorado School of Mines on soda ash roasting is also presented.

Jan 1, 2014

By Alireza Sarafi, Alijan Aftabi

"A hydrocyclic system used for mineral separation at the laboratory scale results in the separation of more than 90% of micas. The system functions only by water and might offer advantages where other methods of mica separation are not available. INTRODUCTIONVarious methods for the separation of micas, wollastonite, and garnet, e.g., screening, flotation, magnetic separation, and heavy liquids, are well known (e.g., Spence, 1929; Bates,I960; Gillson et al., 1960; Benjamin, 1971; Connor and Kolhnar, 1991; Collings and Andrews, 1991). However, where these methods are not available, the separation of micas by a hydrocyclic system developed by Sarafi and Aftabi (1991) may prove to be economic. This note is a brief description of the hydrocyclic system. Minerals and MethodFor testing the recovery of mica and other minerals from different rocks (garnet-mica schist, skarn, and pegmatite), standard minerals were tested first, and then rock samples. Pure mineral standards were prepared from coarse-grained samples of pegmatite, mica schist and skarn; the grain size of the minerals separated was more than I cm. The Hydrocyclic System and Mineral SeparationThe hydrocyclic system is shown schematically in Figure 1. In the first step in mineral separation, mineral and rock samples were crushed, milled, and then sieved to minus 250 plus 125 microns. Approximately 10 gm to 25 gm of the sample were inserted in decanter Dt • The motor pwnps, M1 and M2, were then turned on and the water valve rl was opened. At this time, water was flowing turbulently (30 em3/sec. to 50 em3/sec.) and minerals were separated according to their crystallographic nature, density and!or habit. The fInal separation was done by exit valves r2, r3 and r4, while the motor pwnps were still operating. After each experiment, the rt , r2' r3 and r4 valves were closed and the motor pumps were turned off. Following this, minerals in each decanter and the mter were collected, dried and weighed. The whole time of the experiment was optimized to be about 10 minutes, but varied from 3 to 15 minutes for micas and garnets. respectively."

Jan 1, 1994