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By A. Blackmore, A. Lamoureux, J. Woloshyn

This paper provides an overview of recent applications of Computational Fluid Dynamics (CFD) to combustion related fugitive emissions problems. The aim is to illustrate the capabilities and discuss the present limitations in this field. Examples include design of retrofitted NOx reduction technology in a kiln and in a boiler, and the prediction of pollutants such as SO2 and metallurgical dust emanating from a copper flash smelting furnace. It is demonstrated that CFD is an effective tool for reducing technical risk in design, for identifying the root-cause problems and testing solutions, and for concurrently assessing emissions reduction and process impact. In addition, the value of CFD for demonstrating due diligence for regulatory compliance is discussed.

Jan 1, 2015

By M. Mohammadijoo, J. B. Wiskel, D. G. Ivey, S. Kenny, H. Henein

Cold-wire tandem submerged arc welding (CWTSAW) has recently been developed as a novel welding technique to replace the conventional tandem submerged arc welding (TSAW) process and improve the productivity of pipeline manufacturing. The process involves two electrodes with arcs and one electrically cold electrode. Since heat-input of the welding process is a key factor affecting the properties of the weld metal (WM) and the heat-affected zone (HAZ), and the additional cold-wire affects the heat introduced to the weldment, it is of interest to investigate property and geometry changes in the WM and HAZ when a cold-wire is added to the welding process. In the current research, the CWTSAW process is investigated and optimized by correlating the main welding parameters with the micro-hardness of the WM and HAZ and the geometry of the weld, i.e., the bead width (BW), penetration depth (PD), reinforcement area (RA) and coarse grained heat-affected zone (CGHAZ) area. Three statistical and mathematical methods are employed to optimize the CWTSAW process in terms of the mechanical properties and WM and HAZ geometry of a typical microalloyed steel used for pipeline manufacturing.

Jan 1, 2015

By George J. Cymerman

Since 1978, Syncrude Canada Ltd. has been expanding steadily its oil sand mining and processing capacity while reducing unit energy requirements. At the current rate of ~180 M tonne/year oil sand, the originally adopted Karl Clark?s 80°C version of the Hot Water process would require some 53 PJ (53 x 1015 Joule) heat. If this amount of heat were to be derived from burning natural gas it would cost $369 M/y (at $7/GJ). Fortunately, effective recovery of waste heat from the upgrading operations at the Mildred Lake site obviated the need for water heating with natural gas. The oil sand hydrotransport technology, first utilized commercially in the mid-nineties at Syncrude?s North Mine, reduced slurry temperature from ~80°C to ~50°C, cutting the unit heat requirement from 293 MJ/tonne to 183 MJ/t. However, in the new 100 Mt/year Aurora Mine even a 50°C process temperature would still require 18 PJ of heat energy per year. Only limited quantity of 65°C water could be imported from Mildred Lake site and some waste heat would be available from Gas Turbine Generators. A new, Low Energy Extraction (LEE) process was developed to minimize heat requirements by further reducing process temperatures to 25°C in the slurry pipeline and 35°C in the Primary Separation Vessels (PSV). Unfortunately, when applied to certain ore facies in Aurora, the LEE process yielded disappointing bitumen recoveries, necessitating an increase in slurry temperatures from 25°C to 35°C in the pipeline and from 35°C to 42°C in Primary Separation. In 2004, an Optimized Low Energy process (OLE) was developed and piloted at Syncrude Research using a 2000 kg/hour pilot plant. In the OLE process, most available heat is applied up-front to produce 45°C pipeline slurry at a density of 1.58 kg/l. Once the pipeline conditioning process is completed, the slurry is flooded with cold (10°C) water, resulting in PSV temperature of 34°C. The overall heat and water requirements are the same, or slightly lower, compared to those of the LEE process ? but without the penalty in bitumen recovery. Processing 100 Mt oil sand at 34°C (96 MJ/t), rather than at 50°C (183 MJ/t), will save $61 M/y (@ $7/GJ) and reduce green house gas emissions by ~47 %. The OLE process is currently being implemented at the Syncrude Aurora Mine.

May 1, 2006

By Iain Sommerville, Hugh Mountford, Dawid D. Smith, Claude Dube, Brett Hixson

JW Aluminum use lean and Six Sigma techniques to continuously improve their target of reliable, repeatable and reproducible (3R) manufacturing. Six Sigma’s second stage gate, known as "Measure" involves identification and qualifying appropriate measuring systems. Metal quality (inclusions) are known in the industry to be an important element in 3R casting. The measurement of inclusions at JW Aluminum historically depended on outside vendors. In order to establish real time inclusion measurement ability within JW Aluminum, inclusion measurement systems in the marketplace were investigated. The qualification of a MetalVision MV20/20 ultrasonic inclusion analyzer are discussed as well as the subsequent application of the system in melting and casting improvement projects.

Jan 1, 2015

By R. R. Culbert

Several thousand parts per billion of uranium are present in some alkaline lake and ground waters of the Okanagan region, British Columbia. To a major extent the uranium content of these highly anomalous waters is controlled by their levels of dissolved bicarbonate. In lakes, dissolved bicarbonate and the organic content of the sediment largely control the partitioning of uranium between sediment and water. This relationship is found to a lesser extent in alkaline creeks, and transported geochemical anomalies in soils appear where uranium-bearing alkaline ground waters have encountered organic materials. There is a possibility that young, near-surface deposits (with very low radioactivity) are forming from these uraniferous waters.

Jan 1, 1978

By K. Karan

Oxygen reduction reaction in PEM fuel cell cathodes involves participation of three reactants - oxygen, hydrogen ions, and electrons. Electrochemical reaction in the catalyst layer is, therefore, influenced by how these species are transported to the reaction site. The two-phase boundary locations at which percolating networks of ionically conducting electrolyte and electronically conducting Pt/C meet are feasible reaction sites. The electrolyte phase also provides pathway for the transport of dissolved oxygen. Most of the 3-D models describe the catalyst layer as an ultra-thin layer, thereby, losing useful information on the distribution of electrochemical reaction rate. In this paper, we extend our previous work on 2-D cross-the-channel modeling of PEMFC cathode based on agglomerate catalyst layer. In particular, we take a closer look at the influence of proton conductivity on the reaction rate distribution in the catalyst layer. As well, we re-examine the role of anisotropic transport coefficient of the porous transport layer (PTL), commonly known as the gas diffusion layer, on the current density distribution under the channel and the rib of the flow-field plates. Results from both a 2¬D and a 3-D models will be presented.

Jan 1, 2005

By J. P. Weiler

The increasing use of high-pressure die-cast magnesium alloys in the automobile industry requires a better understanding of the mechanical properties, the microstructure, and particularly, the relationship between these two. The goal of this study is to first understand the microstructural features which control the mechanical properties observed from an AM6OB magnesium alloy, and second, to be able to predict the local mechanical properties based on microstructural features encountered in different areas of the die-cast component. The two main tools used in this study are spherical indentation testing, used on local areas of the die-cast magnesium alloy AM6OB to detect changes in microstructure and mechanical properties, and X-ray tomography, used to non-destructively investigate the internal porosity in a sample. The results from these tests are then used to predict the local mechanical properties such as the yield stress, the strain-hardening characteristics, and the fracture properties of the AM6OB component.

Jan 1, 2006

By Subrata Dutta

Sindesar Khurd Mine is situated in Rajasthan, India, and operated by Hindustan Zinc Ltd, under Vedanta Group. The base metal mine is high in reserves of Lead, Zinc and silver and has been producing since 2007 with initial production of 0.3 mtpa. Recently the mine has gained prominence as a base metal underground mine in introduction of latest mining techniques and achieving high production at lowest costs. The promising Lead-Zinc reserves of Sindesar Khurd Mine (SKM) and high-tech exploration adopted by Hindustan Zinc Ltd (HZL), (Vedanta Group), raising the reserves and resources from a meager 9 Mt (1997) to 81 Mt (2012), has prompted HZL management to ramp up the mine production from 0.3 mtpa (2006-07) to 2 mtpa by 2013-14 with ambitious plans to reach 3.5mtpa subsequently (presently largest underground metal mine in India). The complete trackless system underground mine, recently equipped with latest leaky feeder communication system (unique in India), utilize modern drilling, mucking and hauling equipment aided with various utility/service vehicles. Excavation optimization and quality recovery maximization from the open and post filled stoping methods, continual expert analysis and feedback from International consultants like AMC (Australia) and SRK (UK), and involvement of renowned bodies in management excellence, have lead the mine towards highest productivity and lowest mine operating cost, earning the mine a prominent place in the global base metal industry. The paper deals with how the various challenges in mine planning and designing, mine development, operator skill, equipment introduction and maintenance, expertise availability, provide training and exposure to officials, prompt and effective communication/service, control of ground vibrations, maintain ventilation standards etc are faced in attaining high operational excellence and thus attain a record mine output/man shift (OMS) of 14 ton/man shift with targets to reach 20 ton/man /shift. Scientific designing using 2D/3D numerical mine-modeling techniques, faster stope sequencing with introduction of paste filling ( first time in India),latest leaky feeder communication system, control ground vibration to stringent standards using electronic delay system, faster raising techniques using raise borers to enhance development and ventilation, cavity scanners to monitor large stope voids, fast shaft sinking at 100 m/month(Chinese expertise) and maintaining adequate ventilation with close software monitoring are some of the highlights discussed in the paper towards achieving the targets.

Aug 1, 2013

By T. D. Chatwin

While new jobs and taxes are major incentives for support of mining, stakeholders must also be assured that current jobs, resources and environment will be protected. Mining companies can help achieve stakeholder support by frankly addressing Acid Rock Drainage CARD) issues. To prevent ARD, miners must begin early in the mine life-cycle to develop an ARD management plan and integrate it into the mining operation. As this proactive preventative program is initiated, mining companies also need to engage and collaborate with stakeholders to insure that their expectations and needs are met. Stakeholder engagement is enhanced as mining companies emphasizes the value of clean and available water for current and future generations.

Jan 1, 2011

By Jennifer Abols

In July of 2013, Lundin Mining acquired the 2,000 tpd Eagle nickel and copper project from Rio Tinto. The project had been put on hold earlier in the year and construction was approximately 50% complete. Lundin immediately accelerated project activities and by September of 2014 the project was constructed, commissioned and ramping up. The newly commissioned facilities went on to reach design throughput, recovery and product quality targets by the end of the year. This was accomplished ahead of schedule and below budget despite numerous obstacles including the worst winter on record in the past 50 years for the area. What led to the success of the project, and in particular the commissioning phase of the project? This paper takes a high level look back and provides an overview of the methodology used, key issues encountered and lessons learned to answer this question.

Jan 1, 2015

By J. B. Hinzer, J. D. Harvey

"Noranda's Lyon Lake property in the Sturgeon Lake area of Northwestern Ontario was staked by Mattagami Lake Mines Limited in May 1969 to cover airborne Input anomalies. Subsequent ground geophysical and diamond drilling programs resulted in the disco very of the Boundary Extension, Lake and Creek ore zones. As of December 31, 1978, ore reserves were estimated at 3,945,000 tons assaying 6.53 per cent Zn, 1.24 per cent Cu, 0.63 per cent Pb, 3.42 oz/ton Ag and 0.010 oz/ton Au.These deposits are hosted within the South Sturgeon Lake volcanic pile of Archean age, which consists of several cycles of basic intermediate and felsic volcanic materials overlain by a sedimentary iron formation and built upon a plutonic base (Franklin , ' 1975). The top 50 m of the second felsic cycle, according to mine terminolo gy, contains the mineralization within Quartzphenocryst- bearing felsic lapilli tuff and underlying thin discontinuous graphitic sediments and altered coarse pyroclastics. The basal andesitic member of the overlying cycle forms the hanging wall to the ore deposits.Although there is no alteration pipe below the deposits, the coarse footwall rocks are permeated by chlorite, garnet, carbonate, iron sulphide and magnetitie-bearing veins intensifying from west to east.Immediate host rocks are alkali depleted and MnO, FeO, Zn and Cu enriched compared to Goodwin's (1972) average Archean rhyolites. Bedded pyrite-pyrrhotite-chalcopyrite lenses with sphalerite-rich tops are underlain by weakly developed stringer mineralization.Traversing eastward from the Lake Zone to the Creek Zone and toward the Sturgeon Lake Mine deposit, more rapid facies changes, more pronounced chloritic and carbonate alteration, the presence ofgarnets, greater MnO, FeO, CaO and Ag abundances, and increasing Zn/Cu and MnO/FeO ratios are apparent."

Jan 1, 1981

By R. Poulin, M. R. Samis

Real options valuation is an alternative net present value framework that is able to incorporate both management flexibility and dynamic project risks. In this paper, management is considering the development of a satellite low-grade zone while operations in a developed high-grade zone continue. If the lowgrade zone is developed prior to high-grade zone exhaustion, mine capacity must be expanded before additional production from the low-grade zone can be processed. This expansion can be avoided only if low-grade zone development is delayed until the high-grade zone is exhausted. The real option model presented here allows the development and capacity expansion decisions to be reconsidered on a discrete half-year basis. It delineates price regions, for given levels of high-grade zone reserves, in which it is optimal to develop the low-grade zone, defer low-grade zone development and abandon the mine irrevocably.

Jan 1, 2006

By John Loui Porathur

Highwall Mining has been recently introduced in India. The first Continuous Highwall Mining extraction in India started operating at Ramagundem Opencast Project-II (OC-II) of Singareni Collieries Company Ltd. (SCCL) in December 2010. A new hybrid empirical and numerical modelling approach has been devised to design web pillars for the initial Highwall Mining sites in India, considering the complex geology, such as existence of thick seams and multiple seams in close proximity. This paper gives the scientific elucidation of a comprehensive design methodology adopted for the above mentioned Indian Highwall Mining sites. The design technology includes web pillar design for multiple seams using hybrid empirical and numerical methods, slope stability assessment, ground movement monitoring, and recommendations for conducting blasting operations in the vicinity of Highwall Mining extractions.

Aug 1, 2013

By H. G. Wang

The production process of a coal mine can often be interrupted by all kinds of events scheduled or unscheduled and thus often needs gas drainage for a temporary or long-term sealed area. Gas drainage has a relatively high risk, therefore attention must be paid to its design to keep the process safe. Based on the conservation laws of mass and constituents, and under the conditions of the allowable gas concentration limit in the return air route, the relationship between gas concentration and gas drainage flow rate as a function of time during the drainage process is discussed in detail to build a mathematical model of gas drainage from a sealed area. With respect to the gas drainage process, two different conditions need to be considered: one with a methane free fresh air supply, the other with a low gas concentration. This paper presents the derived mathematical models for these situations and then shows that they can be incorporated into one model with some modification. This combined model can be employed to determine the optimum gas drainage flow rate with the shortest drainage time. The application is coded using the C# programming language within the .NET framework. Finally, the application program developed by the author is used to validate the mathematical model through an example of gas drainage with varying rate.

Aug 1, 2013

By J. Donovan

Underhand cut and fill mining is being planned for selected areas at the David Bell Mine where high ground stresses have resulted in particularly challenging mining conditions. In order to test the placement and performance of a variety of underhand cut and fill paste mats three different designs have been installed and extensively instrumented along the A-Zone 9C ore sill. The sill is approximately 87m long, 4.0m high, and 5.0m average width. The sill was broken into 3 sections each of which will contain one of the sill mat designs. The underhand sill will be mined 3.75mW x 4.0mH, allowing for some overbreak while minimizing the risk of the back span exceeding the design limit of 4.0mW. Each test sill mat includes pre and post-support and includes 0.5m (18?) broken muck mat placed along the sill floor. Upon developing beneath these mats quantitative and qualitative measures will be used to determine which design is the most suitable for application in underhand mining at David Bell.

May 1, 2007

By Seungyeol Lee

Currently, a new construction method using a robotic system is widely spreading in construction sites. This study is related to the design of glazing robot?s teach pendant which can improve convenience of handling and hence improve the productivity through the efficient interaction between an operator and a robot while doing glazing works, e.g., curtain wall installing. The suitability of selection and arrangement of control switches was assessed according to mechanical motions of a glazing robot, and design guidelines for improving convenience and productivity were drawn up through questionnaires carried out by site operators. To verify the proposed design guidelines, working time comparison of the proposed teach pendant and the existing teach pendant was executed.

Aug 1, 2013

By S P. Giambra

The 50,000-ton-per-day Concentrator and Crushing Plant, complete with its related water supply, tailings disposal and concentrate handling systems, was started up in a five-month period, with the entire plant obtaining its design capacity six months after the first mill became operational. Individual mill lines, with their spiral circuits, achieved design capacities within a week after the first treatment of ore through each mill. Construction and start-up proceeded together in many areas of the plant, and considerable organization and cooperation between the Owner, the Engineer and the Contractors permitted a smooth transition from construction to operation. PLANT DESCRIPTION THE Carol Lake Plant of the Iron Ore Company of Canada l1as been well described in various technical magazines. The purpose of this paper is to present a brief outline of the start-up of the con-centration complex. This start-up was accomplished in a period of five months, with the plant producing one million tons of concentrate and achieving its design-rated tonnage less than six months after the first ore was treated.

Jan 1, 1963

By D. Sanguinetti, A. Consigny, M. Nodwell

"Alkali precipitation of dissolved metals is an inexpensive but non-selective means of treating mine wastewater. Alternatively, sulphide precipitation can treat to below parts-per-million concentrations while selectively recovering valuable metals. While technically feasible, sulphide treatment of dilute waste streams increases the size and cost of the plant relative to the metals loading. Ion exchange has been applied at two separate sites to pre-concentrate nickel containing wastewater prior to recovery in smaller and more cost effective sulphide precipitation circuits. The result is a dual-circuit system that can maintain high selectivity and reduce overall facility cost while meeting strict effluent regulations.INTRODUCTIONAlkali precipitation using lime is the most common method of treating mining effluents for dissolved metals removal. This method is generally sufficient for waste streams containing mixed metals of little value, and for meeting modest metal concentration limits in the final effluent. Due to the non-selective nature of the lime process, the produced metal hydroxide sludge is of little value. All metals are removed together in a sludge product which cannot be re-processed for further value recovery.By contrast, sulphide precipitation can be used to selectively remove and recover valuable base metals (such as copper, zinc, nickel and cobalt), since the sulphide will preferentially target these metals without reacting with less valuable metals (such as iron and aluminum). The low solubility of the metal sulphide solids also supports the removal of base metals to lower concentrations than can be achieved with alkali precipitation in addition to other benefits discussed more fully in a prior paper (Bratty, Lawrence, Kratochvil & Marchant, 2006). The corollary to this solubility feature is that sulphide precipitation can function on influent streams containing low (< 10 mg/L) metals concentrations to meet very low parts-perbillion final effluent concentrations. Reagent overdosing is also minimized when compared to alkali precipitation."

Jan 1, 2012

By L. I. Kiss, S. Perron, D. Toulouse, S. Poncsák, A. Perron

Bubbles play an important role in many industrial processes. In a Hall-Heroult cell, used for aluminum production, bubbles contribute to induce flow in the cell. The induced flow is important for the thermal balance of the cell as well as for the distribution and dissolution of the alumina. The existence of the bubble layer does not have advantages only. It increases the voltage of the cell and causes deformation along the cryolite-molten aluminum interface. The role of the anode inclination in the behaviour of the bubble layer as well as in the hydrodynamics of the bath is not clearly understood. In this work, the effect of the anode inclination angle on the bubble driven flow is studied in an industrial scale air-water model. The inclination angle is varied up to 5° from the horizontal. The instantaneous flow field is captured by Particle Image Velocimetry (PIV) system. The mean velocity fields were calculated by ensembleaveraging the instantaneous velocity fields measured at different time. The existence of the counter-flow in the interpolar space and the vortex in the side channel has been confirmed. Furthermore it has been observed that the effect of anode slope on the velocity field is weak.

Jan 1, 2006

By J. G. Whellock, J. W. Matousek

"In spite of their importance to the economics of many metallurgical projects, the values and technical aspects of precious metals losses in smelting operations are relatively undeveloped subjects. This paper attempts to provide a condensed overview of precious metals losses in pyrometallurgy, using some of the limited production and experimental data available. It is intended for three general groups of metallurgists - operators attempting to improve recoveries, cost-accounting engineers making estimates of metal losses in new or modified smelting plants, and research engineers and students.Distribution coefficients of precious metals, the ratios of metal or matte assays to slag assays, are convenient means of comparing smelting processes and the tendencies of the different metals to enter the slag. For silver in lead blast furnaces this ratio is approximately 250;for gold and the platinum group metals in submerged-arc, electric furnaces it is 900. The ratio for gold and PGMs in converters varies with the degree of oxidation of the charge. The over-all cycle-average for industrial installations is tentatively estimated to be 35.IntroductionThe magnitude of precious metal s losses in pyrometallurgical operation s is difficult to assess. The primary producers are generally reluctant to discuss the subject. The by-product producers (the large sulphide smelters o f copper , nickel, and lead) might be more willing to disclose information, but these have precious metals in their feeds in such dilute quantities that accurate accounting is extremely difficult. It is not until numerous processing steps have been taken t hat the precious metals become sufficiently concentrated to permit acceptably accurate sampling and analytical procedures to be followed. Thus, knowledge of the precious metals contents o f the intermediate mattes and slags may simply be unavailable."

Jan 1, 1990