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Energy benchmarking is widely applied across industries to determine the potential to improve energy performance. Unlike the many technologies for which energy benchmarks and efficiency rating systems are already in maturity, benchmarking of mining processes is still in its infancy. Benchmarking energy usage in mining operations, where energy costs are high and represent a significant portion of overall operating expenses, is challenging due to the uniqueness of each mining operation. Mines vary in terms of geology, geographic setting, ore body geometry, mineralogy which impact the mining method, material handling, processing and waste management. In order to gauge the opportunity for reducing the energy intensity of individual operations and also to compare the energy performance of operations on a global scale, the deployment of new benchmarking methodologies, models and frameworks is necessary. As a step towards the establishment of an accurate framework for benchmarking the energy consumption of mining operations, comminution, one of the more energy intensive mining sub-processes, was selected as the focus of a new energy benchmarking method. The methodologies and processes used to onset fragmentation in a rock mass to the crushing or grinding of rock to a size that is suitable for economic extraction are predominantly dependent on the ore properties. For this reason, site specific factors, such as the size reduction requirements and ore hardness were included in an energy benchmark model so that the energy performance of comminution processes at different operations could be normalized and compared on a global scale. Single particle compression breakage has been identified by several prominent researchers in the field of comminution as the upper limit of energy utilization in size reduction processes. For this reason single particle compression breakage was proposed as the basis of a work index for ores to be used as an input for the benchmark model. Overall, the new method showed that the energy benchmark for mineral comminution can be normalized and subsequently compared for a range of mining operations once the ore hardness has been appropriately characterized.

Aug 1, 2013

By Atul Bhatnagar, M. P. Sinha, Md Zahid Ahmad, Pallav Garg, Sanjay Kumar Singh, Shashi Ranjan, An Ecolab Company Nalco Water

"Froth Flotation is undoubtedly one of the most critical processes in coking coal washing plants. This work was carried out at Bhelatand Coal Preparation Plant of Tata Steel was with an objective of cost optimization in fine coal processing. The sources of raw coal for the plant include coal from underground mines of Jharia coalfield and procured open-cast raw coal. Coal from different sources vary in quality and possess different floatability characteristics.Synthetic collector is being used in plant as a flotation reagent. An alternate collector with new chemistry was developed for reducing total treatment cost without compromising product yield and quality. A series of laboratory tests were conducted to assess the performance of various sources of raw coal and plant scale trial was started. At first, the new generation coal collector was entirely substituted with the existing collector in the laboratory scale. However the plant scale trial data was not in accordance with laboratory results and indicated inferior flotation performanceThe issue was studied and data based conclusions were drawn that the new generation collector aids faster and uncontrollable kinetics. A decision was taken for co-dosing of the synthetic and new collector for the second phase of the trial. A detailed laboratory analysis was done again and few dosing ratios that predicted optimum results were selected for plant trial. The dosing ratio was optimised as per flotation yield and product ashes during the plant trial. The results showed significant improvement from the first phase and optimum dosing rates were decided based on plant observations and data collection. The influence of various process indicators including water quality, feed and product ashes and process yield was studied during all the trials and promising results were established. The co-dosing of both the collectors conferred cost advantage and enabled to achieve superior performance."

Jan 1, 2016

By M. Kumral, E. Dilhuydy, B. Ozdemir

"In-pit crushing and conveyor (IPCC) systems have become increasingly popular in the mining industry as an alternative to truck-and-shovel systems. Deciding whether to haul waste rock by truck or IPCC represents an important gap to be investigated in semi-mobile IPCC systems. A cost analysis is presented to evaluate the feasibility of crushing and conveying waste material in IPCC systems, along with sensitivity and risk assessments through Monte Carlo simulation. Although the capital expenditure is higher, results showed waste crushing will be feasible in deep pits and over long mine life and haul distances.RÉSUMÉ La popularité des systèmes de concassage et de transport dans la fosse minière (IPCC, de l’anglais In-pit crushing and conveyor) n’a cessé de croître dans l’industrie minière ; ils constituent en effet une option intéressante de remplacement des systèmes par camions et pelles mécaniques. Le choix entre le transport des stériles par camions ou par IPCC est encore difficile à faire et devra faire l’objet d’une étude approfondie au niveau des systèmes d’IPCC semi-mobiles. Une analyse des coûts est présentée pour évaluer la faisabilité du concassage et du transport des stériles par les systèmes d’IPCC, de même que des évaluations de la sensibilité et des risques par le biais de la simulation de Monte Carlo. Si les dépenses en immobilisations s’avèrent être plus élevées, les résultats ont cependant montré que le concassage des stériles sera envisageable dans des fosses profondes ainsi que sur une longue durée de vie et de longues distances de transport. INTRODUCTIONThe mining industry is currently facing many challenges such as low commodity prices, increasing environmental concerns and regulations, lower grades, deeper mines, and greater waste-rock quantities. As a result, the profitability of mining operations has decreased, with many mines stopping or suspending operations, and many new projects being postponed. Mining companies have therefore focused on improvements and innovations to increase the cost effectiveness of operations, for example, increasing production capacity to take advantage of the economies of scale (Crowson, 2003) and decreasing the unit operation cost. Changes in production capacity force mining companies to evaluate alternative material handling systems.During the past few decades and within material handling systems, significant improvements have been made to truck performance and capacity. Consequently, operating expenditures (OPEX) associated with fuel and maintenance have risen swiftly. In a mining operation, truck hauling systems now represent 40–50% of the capital cost and approximately 45% of the OPEX (Tutton & Streck, 2009). Additionally, material transportation costs are expected to increase due to longer haul distances arising from deeper and larger mines (Fleet et al., 2015). Finally, large fluctuations in fuel prices result in high risks associated with truck OPEX. According to the United States Energy Information Administration (2015), the cost of crude oil—the largest component of the retail price of diesel fuel—increased from US$24.31/barrel in 1986 to US$46.92/barrel in 2016, peaking at US$151.72/barrel in 2008 (Macrotrends, 2016)."

Jan 1, 2017

By W. A. Lang

RESEARCH has been defined as the link between the present and the future. Science, wonderful though its achievements may be, has but scratched the surface of the unknown. Research is directing its attention to winning new facts in order that their application to the processes of today may open up new sources of wealth for the common benefit. Two classes of research investigations are often recognized-fundamental and applied, but these classes merge into each other and it is often hard to distinguish one from the other. Fundamental research is carried out primarily to develop basic facts, but frequently these are found to have immediate economic value, while applied research, specifically aimed at economic values, often necessitates a preliminary fundamental investigation. Both are essential and both should proceed by scientific method. It is obvious in fuel technology that a knowledge of the physical and chemical constitution of the various coals is fundamental to their industrial utilization, and further, a knowledge of the way these coals react under different conditions of temperature, atmosphere, etc., is necessary in solving such problems as storage, combustion, carbonization, gasification, or con-version to liquid fuels. The wide range of coals, the complexity, of their constitution, and the many uses for coal, makes fuel research no simple subject but one with unending possibilities. The Research Council of Alberta, formerly known as the Scientific and Industrial Research Council of Alberta, was established in 1919, to promote the development and conservation of the natural resources of the Province. The work of the Council was arranged in six major divisions: Fuels; Geology; Road Materials; Soils; Natural Gas; and Forest Products. The office and laboratories are located in the University of Alberta. The Council was financed until the depression of 1933 by a separate vote of the Legislature, but since then has been continued, though on a much smaller scale, as one of the activities of the University. It might, however, be noted that although the Council is now in abeyance, a skeleton organization has been maintained so that it can be brought back to active service as soon as conditions warrant. Annual reports are still submitted to the Legislature. Funds have not been made available, however, for the publication of the last five reports.

Jan 1, 1942

By T. Iwasaki

This paper points out two key elements in resource trade in general and the Canada-Japan relationship in particular. The first is that the advanced countries have a more important role than one would expect in the supply of resources in world trade. Canada 's dual role as a major resource supplier in conjunction with an advanced economy will continue to increase. The second point is the heavy reliance on foreign resource supplies in some advanced economies, particularly in Japan. Finally, as regard the future of the Canada-Japan economic relationship, particularly .in resource development, it is suggested that trade could be enhanced by an accelerated exchange of various types of resources between the two countries. These include natural resource commodities as well as the more abstract capital, technological and human resources.

Jan 1, 1978

By E. Fritz

This paper reviews the history, developments and 10 milestones of the oxygen steelmaking processes, with a special focus on conventional autothermic converters, high-speed converters with a blowing rate up to 5 m3n/t min and allothermic converters with coal addition, post combustion and the possibility to increase the scrap rate up to 50%. Related operating results are introduced. A new process route, which is based on hot metal and chromium ore, is outlined. The cost advantage for the production of 304 stainless steel grade is higher than 100 USS/t. The synthesis of EAF and oxygen converter steelmaking, a comparison of decarburization rates, refining combustion burners for optimized oxygen-management in EAF and an example for a large advanced EAF are outlined. Possibilities of flexible steelmaking and the growth and outlook of worldwide oxygen steelmaking are described.

Jan 1, 2004

By H. J. McQueen

Mineral and energy resource consumption were continuously reduced by process improvements as chemical understanding was developed and applied. During the past two centuries, technological improvements increased human productivity that was accompanied by social advances and labour saving products; however, these sometimes proliferated to endanger sustainability, e.g., automobiles. In the steel industry, precisely controlled rolling of HSLA steels required little extra mineral consumption but reduced weight and heat-treating energy. Continuous casting of slabs reduced scrap compared to ingots and energy for the homogenizing soaking pit. Al alloy extrusions were improved by retaining the strengthening in the near-surface substructure, of high strength textures and of press quenching that is suitable for direct age hardening. Continuous bar casting of Al-0.65Fe, coupled with rod rolling and followed by wire drawing with only a final recovery anneal, yielded electrical wiring for households to replace less plentiful Cu and later for light-weighting use in autos and aircraft Looking backwards, the 1970 decade saw the first oil crisis and inspired Ottawa to undertake a campaign to develop an energy strategy that would decrease dependence on imported fuels. One significant undertaking under Energy Mines and Resources was the organization of industrial energy conservation, managed by each industry association,that collected detailed current statistics and set the goals for a 2-year campaign. The metal producing industries, as compared by E.C.N. Perryman to about 7.2 exajoules (EJ) for the nation, consumed about 0.8 EJ, being about one third of all heavy industries. While manufacturing consumed 30.2% of total energy, it created 87.3% of total national dollar value. Within the industrial envelope, smelting and refining utilized 28% (0.67 EJ, mining beneficiation 6.7%, 0.16 EJ); there was a significant contribution to exports: 80% of iron ore and 70% of aluminium in 1973. A general concern was that decreases in ore grade would lead to a rise in energy expenditures countering benefits from processing efficiency.

Jan 1, 2012

By L. Heber Cole

Introductory During the past few years, salt (sodium chloride) strata have been encountered in western Canada in a number of wells, while prospecting for oil and gas. The ever increasing number of such wells points to the presence of a vast salt basin, the boundaries of which are at present unknown. This basin extends in a northwesterly direction from a point near the United States boundary south of Regina, crosses the Saskatchewan- Alberta boundary northwest of Unity, Sask., and continues with more northerly trend to Waterways and beyond. The beds, as encountered, appear to have a general dip to the southwest of between 10 to 20 feet to the mile and a pitch along the strike to the southeast. Thus one finds the salt strata at Waterways, Alta., at 600 feet below the surface (121 feet above sea level) whereas at Radville, Sask. south of Regina, the top of the salt is at a depth of 6,643 feet below the surface (4,430 feet below sea level). Whether this is a continuous salt basin or a series of separate basins is not yet known. We do know however, that in some of the well~ more than one salt horizon occurs while in others which normally should have encountered corresponding beds, the salt strata are absent. This latter condition, however, may occur only in the southern part of Saskatchewan, where a barren area seems to come in from the southwest. In the northwestern part of the basin, on the other hand, the occurrence of the salt strata seems to be more regular and continuous, and depths at which salt should be encountered in a drill hole in this part of the basin may be predicted with a fair degree of accuracy.

Jan 1, 1948

By L. E. Djingheuzian

Introduction Cylindrical grinding mills have been used for a long time, but during many years of testing no methods were established that gave consistent results. The work by both scientific investigators and operators led very often to contradictory conclusions, and each millman was very much 'on his own' when trying to find the limits for working of his ball-mills. Fred C. Bond, in the introduction to his paper on Wear and Size Distribution of Grinding Balls, freely states that the mathematical immaturity of the grinding process "is the cause of many inefficient designs and installations as well as of much poorly oriented experimental work", and evidently he sees the solution of all our grinding problems in the discovery of the fundamental laws "which can change the empirical art into a mathematically exact science". While the writer is in complete agreement with Mr. Bond that grinding is governed by fundamental laws which can be expressed by mathematical formulae, there are so many variables in grinding, all interwoven with each other and mutually influencing each other, that the coalescing and merging of all these variables into a harmonious mathematical whole appears to be a homeric job. However, a light appeared on the horizon when it was proposed that power be used as an index of the grinding operation. It is pertinent to quote Gow, Guggenheim, Campbell, and Coghill from their paper on Ball Milling, in which they say: "Much of the past literature devoted to the subject has been concerned with the Kick-Rittinger dispute over evaluating grinding, or with dissertations on ball paths and the closely allied impact versus attrition hypotheses or with the exclusive consideration of certain specific variables, such as mill speed or circulating load, irrespectve of the other factors in operation. Such subjects may be dismissed with but little discussion in what may be called, by comparison a new philosophy in the stud of ball milling. Briefly this 'new philosophy' consists ' of using power as an index of the mill operation, and investigating grinding from the standpoint of set and induced variables with emphasis on the latter". But it is safe to assume that it was the work by E.W. Davis, H. E. T. Haultain, F. C. Dyer, A: M. Gaudin, J. Gross, S. R. Zimmerley, and others, that cleared the path for the authors of Ball Milling and induced them and A. W. Fahrenwald to look farther afield and thus to establish a far-reaching relationship between the power and capacity and the diameter of the ball-mills.

Jan 1, 1949

By Michael R. Brown

A facilities success or failure of doing well during a regulatory inspection is typically measured by the number and type of citations that result, and financial liability resulting from those citations. The success of a facility during an inspection depends on several factors including, the preparation prior to an inspection, behavior and activities during and inspection, and finally, action taken following the inspection. This paper contains suggestions for improving inspection results and establishing an attitude of compliance at manufacturing and mining facilities.

May 1, 2002

By Jan W. Merks

The objective of metrology in mineral exploration is to derive unbiased confidence limits for masses of metals contained in reserves and resources. Sets of test results for gold and silver determined in pairs of interleaved bulk samples give unbiased confidence limits for the central value of each metal. The same sets of test results show how to verify spatial dependence by applying Fisher?s F-test to the variance of a set and the first variance term of the ordered set. A significant degree of spatial dependence gives a higher degree of precision for the central values of gold and silver. Plotting variance terms of an ordered set against the variance of the set and its lower limits of asymmetric 99% and 95% confidence ranges gives a sampling variogram. Sampling variograms put in plain view where spatial dependence in sampling units or sample spaces dissipates into randomness. The application of statistical methods to test results for sets of ordered core samples within boreholes, and for sets of ordered ore volumes within profiles, plays an important role in defining reserves and resources.

Oct 1, 2009

By M. Tadayonsaidi

The effect of alloying elements on the mechanical properties and thermal expansion of 336 casting alloy usually used as piston alloy which has low thermal expansion and very good high-temperature mechanical properties and good wear resistance was investigated. The mechanical properties and thermal expansion characteristic of samples with different combination of alloying elements, which enhance to reduce the cost of products, have been studies, The results show remarkable increase in the mechanical properties with increasing the amount of Cu and Mg, while are reduced with increasing amount of Ni, On the other hand, the use of eutectic aluminum alloy as 336 alloy with higher percent of Cu and Mg and lower percent of Ni are recommended for industry, due to economical viewpoint and satisfactory properties.

Jan 1, 2005

By G. M. Carrie

Introduction The subject of basic refractories is daily becoming of increased importance in metallurgical processes, and there is a constantly growing necessity for the development of better materials. This fact, together with the realization that Canada possesses one of the best sources of such refractories in the British Empire, if not in the world, made it appear? advisable that the subject be presented to the Empire Mining and Metallurgical Congress at the 1927 meeting. Having been in close touch with developments in the Canadian product during the past five years, G. M. Carrie was requested to prepare such a paper. The Canadian producers of magnesia refractories have succeeded in developing the product to a place where it has almost entirely displaced imported materials from the Canadian market. These developments were made possible by a close study of the methods of preparation of the material, and by an exceedingly careful control of the manufacturing process so as to obtain a thorough blending of the different constituents with the resultant uniformity of composition. This point is very important to the metallurgist, as un-uniform materials are a potent cause of difficulties in most manufacturing processes and the constant trend is towards their elimination. The temperature at which the Canadian material is burned ensures high specific gravity and thorough shrinkage. The grain size of the product is so controlled that the voids are only just sufficient to allow of proper bonding, thus making possible a dense, hard bottom affording high resistance to erosion and shock. Careful proportioning of the constituent elements absolutely prevents disintegration.

Jan 1, 1927

By Pierre Pelletier, Christian Pichetie, Dany Pelletier

"IntroductionDuring 1994, Barrick Gold Corporation, or American Barrick at that period, acquired Lac Minerals Ltd. properties. One of them was the Bousquet Complex. The Bousquet Complex is divided into three distinct sites: one mine (Bousquet 2), one mill (Est-Malartic Division) and one analytical chemistry laboratory (Les Terrains auriferes).The Bousquet 2 orebody was discovered in 1986. An extensive drilling program was initiated during 1987. Its purpose was to define the orebody extent. At the end of 1997, gold production from Bousquet 2 mine reached 1 290 000 oz of gold from a cumulative tonnage processed of 4 175 000 M t.From 1980 to 1990, the Est-Malartic mill was used for the treatment of ore from the following mines: Bousquet 1, Doyon, Francoeur (Richmont mines), Buckshot and 1-20 stope. At present, the mill receives ore from the Bousquet 2 mine.HistoryThe Est-Malartic mill is located close to the town of Malartic in northwestern Quebec. The mill has been in production since the mid-1930s processing mainly clean, free mill gold ore. Active mining from the Est-Malartic mine ceased in 1979 and the mill was switched to custom processing of ore from La Mine Doyon located some 45 km to the west. This custom processing arrangement continued until 1987 when the expanded mill at Doyon became available to process all of the Doyon production. In 1987, Lac Minerals commenced development of a second mine at the Bousquet site located 40 km west of Malartic. This mine, Bousquet 2, is the down dip extension of the La Ronde mine developed by Agnico Eagle. During pre-feasibility evaluations, it was determined that it would be economically more attractive to modify the existing Est-Malartic mill than building a new facility on site. The Est-Malartic mill modifications for processing the high-copper/gold ore from the Bousquet 2 mine began in late 1989 and new circuits were commissioned in mid-1990. Modifications included the addition of both gravity and flotation concentration circuits to recover coarse, free gold and the copper. The existing leaching circuit continued to operate on the copper flotation tailings with some minor modifications to the solution handling systems. A S02/Air cyanide destruction circuit was also added at that time."

Jan 1, 2000

By W. Leblanc, J. Phalen

This paper tells the story of a serious mine fire on a mechanized longwall face in a submarine coal mine at Glace Bay, Nova Scotia. The story gives, in chronological order, a technical account of the steps taken to investigate, fight and contain the fire. The time during which the events took place spans from June 19 to November 7, 1975.

Jan 1, 1976

By W. P. Campbell

THE investigation herein described had its beginning in the chemical laboratory of the Department of the Interior, Calgary. After the transfer of the natural resources to the Province of Alberta in 1930, the laboratory was closed and the investigation discontinued, but in 1933, with the permission of the Director of the Mines Branch, the work was again taken up and brought to completion. OBJECT OF THE INVESTIGATION The object of the investigation as originally planned may be stated as follows : (1) To determine the chemical composition of the limestone formation underlying Turner Valley gas field. (2) To identify 'beds' in the limestone, if such existed, with definitecharacteristics which would mark them from immediately overlying and underlying measures. (3) To relate information acquired on the composition of the limestone to the occurrence of oil and gas in the particular section examined. Definite information was lacking as to the exact chemical composition of the limestone and of its variations in composition at various depths. The formation was generally referred to in the field as the 'dolomitic' limestone, but the depth to which the dolomitized zone extended and the degree to which the limestone generally had become dolomitized were not known. Jn the drilling and logging of wells, the recognition of suitable 'markers' in the various formations is a matter of some importance. Markers are generally relatively small but widespread members of a formation, which have some characteristic property, of colour, composition, or form, by which they may be identified, and with them, consequently, the formation of which they form a part. In the formations above the limestone in Turner Valley, a number of well defined and easily recognized markers are known to geologists, drillers, and others interested in the field. Many of these markers Hand out in sharp contrast to adjoining measures and are therefore easily recognized; in others, the contrast is less sharp, with consequent difficulty in identification.

Jan 1, 1937

By J. Mrozowski, R. Kurowski, A. Chmielarz, Z. Szolomicki

PbSO4 is a commonly encountered component of the materials used in lead recycling (e.g. battery paste) and in by-products of metallurgical processes (e.g. residues from zinc hydrometallurgy, dust from copper smelting). Smelting of battery paste results in SO2 emission and in generation of significant amounts of hazardous ‘white slag’. Those adverse phenomena can be eliminated by removal of sulphur from the paste. Lead-bearing by-product materials are of polymetallic character with usually low Pb content, which makes lead recovery technologically difficult and uneconomic. However it can be successfully achieved by extraction of lead sulphate from solid phase with triethylenetetramine (TETA) water solutions. That compound has capability for selective solvation of a whole lead sulphate molecule. Virtually pure lead carbonate can be precipitated by means of saturation of lead-loaded aqueous TETA solution with carbon dioxide, and complete regeneration of the extractant is achieved by fixing of sulphate ion into gypsum through operation of calcium hydroxide suspension. The paper presents results of the lab and pilot scale studies into process of battery paste desulphurisation and recovery of lead from the residue of zinc calcine leaching.

Jan 1, 2014

By Harry Perry

By 1980, the free world's need for economic sources of energy is expected to double. As a result, there will be a tremendous potential for all energy sources working together to supply the demand. For coal to continue its dominant role as a low-cost energy source, means must be found for it to meet the challenge of nuclear power and to overcome obstacles placed on its use by air and water pollution regulations. As the more limited reserves of gas and oil diminish, economic ways are also required for converting coal to synthetic liquid and gaseous fuels, and to chemicals, thus resulting in optimum utility of the most abundant low-cost fuel resource. The means for accomplishing these ends can only come about by a vigorous research and development program. Successful efforts by industry and government working together, both in America and abroad, will assure the continued use of coal to meet the world's energy demands. This paper discusses the emerging patterns of energy sources throughout the world and the role that research and development on coal will play in supplying future energy requirements.

Jan 1, 1967

The Autogenous milling of ores holds an increasing attraction as the focus moves towards reducing energy usage, both direct and embodied in grinding media. However, most of the early AG mills were converted to SAG for improved stability and increased throughput. This imposes a huge penalty in steel grinding media consumption. The LKAB iron ore operations in Sweden process highgrade magnetite through fully-autogenous milling lines to a final product P80 of about 45µm. The outcomes of P9O AMIRA research surveys, covering a wide range of mill fillings and throughputs and with different feed blends, are presented. Insights are provided on operational strategies, opportunities, the influence of feed size control and balancing the blend of competent gangue and softer magnetite. Areas of importance in the successful operation and control of energy-efficient autogenous circuits are highlighted.

Jan 1, 2012

By L. E. Djingheuzian

Introduction For many years the immense deposits of bituminous sands of northern Alberta have been attracting the attention of our governments, engineers and .scientists ( 6). Undoubtedly these bituminous sands represent one of the greatest potential resources of liquid fuels in the world. However, their commercial development has been retarded by the complexities of the technological problem and by the economic factors involved in the processing of the sands. The technological problem has been attacked from several angles ( 2, 3, 1, 11), and cold water separation of bitumen is one of them. To the ore dressing engineer, the cold water process is of utmost importance since, by the use of standard ore dressing machinery, it accomplishes most efficiently and economically the separation of bitumen from bituminous sands. The significance of using ore dressing equipment was especially enhanced by the fact that the scientific principles which underlie the design of standard machines were demonstrated in the cold water separation process with an extraordinary clarity. This greatly facilitated the analysing of limitations and advantages of different machines during-the pilot plant investigations and helped to complete the investigations practically in the allotted time.

Jan 1, 1952