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By Jason Prno

Context ? Climate change an issue of global significance ? Research is lacking ? Study initiated by the David Suzuki Foundation, led by ArcticNorth Consulting Industry Surveying ? 34% and 48% of respondents indicated climate change is already affecting operations ? Majority believed climate change would have negative impacts in the future ? Cost and uncertainty of Future impacts are major barriers to adaptation

May 1, 2010

By Ron Ferris

The Westinghouse Temptifier TM, using heat pump principles, recovers lowgrade waste heat in the 600P to 1600P temperature range and amplifies it to usable levels of up to 2200P. Coefficients of performance (C.P.D.) normally encountered are from 3.0 to 6.0, with capacities from 200,000 to 10 million Btu/hr.

Jan 1, 1979

By M. Coleman, M. E. Reed

The control of feed delivery quality to the flash furnace remains an unsolved problem. Many operations around the world still have limited control of feed quality to their flash furnace. Schenck Process and WorleyParsons continue to work towards the ‘holy grail’ of simple quality feed delivering both radial feed distribution and pulseless feed delivery. Ten years ago they joined forces to offer a system based on then Clyde Process RotoFeed system which could deliver ground level installation, online mixing of materials, pulseless feeding direct to the burner, with good radial distribution. Unfortunately, this proved to be too large a step for the Flash Smelting community and met with resistance from the process owners. Since then the community has developed a range of options some of which have been implemented over this period. Despite these improvements there are still areas of concern including safety issues associated with concentrate leaks and spills, uncontrolled variations in feed rate including massive flooding events, intermittent distribution improvement and set up of the burner continues to be trial and error and hard to repeat the success in each burner campaign. These continue to impact flash furnace performance globally on a daily basis. Following the community reticence to pursue the complete solution a number of interim steps are now available to pave the way to the ultimate feed system. The mixing of material has been installed and is delivering line blended materials on a daily basis. This paper will investigate the developments over the last 10 years and discuss the pros and cons of this incremental step process for overall furnace control. INTRODUCTION Schenck Process and WorleyParsons have continued to interact and observe changes in the flash smelting industry and to consider application of the Clyde RotoFeed now incorporated in the Schenck Process ProStreamTM range for delivery of feed directly to the concentrate or matte burner. Schenck Process pneumatic injection from the Clyde Process range, ProStreamTM, utilises two types of volumetric feeders to accurately control the feed of material into an injection pipeline. These are referred to as the RotoFeed and RotoScrew technologies and the choice of feeder type is dependent on the characteristics of the material to be handled. The RotoFeed is generally used for finer, granular and powdered materials which cannot be accurately handled with a screw such as pulverised coal and copper concentrate, whilst the RotoScrew is particularly suited to coarser lump materials, particularly abrasive of cohesive materials like zinc powder, electronic scrap and metal ashes. Both units can operate at high pressures and many systems work at 3 to 10 bar with the occasional system working at 20 or 30bar for carbon to gasifiers. For the Flash furnace the ProStreamTM units can be used to deliver each of the furnace feed materials into a single line, mixing the materials homogeneously and live to the burner.

Jan 1, 2019

By A. A. Sizikov, V. A. Sizikova

Key parameters to consider for any producer: bring down production cost and lead time; Lean production as a tool to achieve maximum efficiency; How to implement lean principles: discontinuous vs. continuous production (aluminum industry); About RUSAL: global top-three aluminum producer; Lean tools at use at RUSAL's production facilities; Pull system, Standardization of work, Just in time, Continuous improvement, Customer-Supplier relations, etc.

Jan 1, 2006

In the leaching and recovery of gold from copper containing gold ores using cyanidation, some copper minerals also dissolve which can have a detrimental effect on the process efficiency and economics. There are also environmental concerns with current operations discharging cyanide and copper cyanide species into tailings dams, and strict regulations prohibit this for greenfield plants. Cyanide destruction however is not an economic option for new plants treating copper-gold ores. This paper evaluates a potential recovery process to overcome the copper cyanide problem. Despite gold dissolution occurring in copper cyanide solutions having no free cyanide, gold recovery from ores is lower compared to free cyanide. Thus, cyanide addition has to be optimised to maximise the gold recovery whilst endeavouring to eliminate free cyanide at the completion of leaching (CN:Cu less than 3:1). Subsequently, copper cyanide can be recovered using activated carbon. The loaded copper cyanide is easily recovered from the carbon with a cyanide soak and distilled water wash such that the eluted CN :Cu ratio is less than 4:1. The copper could be recovered efficiently by electrowinning, by decreasing the pH of the eluant to 5. The remaining cyanide solution, after electrowinning, is then neutralised to form NaCN and recycled.

Jan 1, 2005

By K. Iturralde

Dense transport infrastructure areas lack green facilities, they produce annoying noise and they are big energy consumers. As far as there is no free land or space, adding a vegetal covering to existing infrastructures has become a choice in order to get a more pleasant and comfortable environment. Noise barriers are getting spread all over the highways and sometimes they install photovoltaic panels. Is this just a hype or are there real causes? A green acoustic barrier with an energy generator could be interesting for covering the existing urban transport infrastructures. The specific geometry of the infrastructures requires a personalized product. If we measure the infrastructure environment's characteristics, which are humidity, temperature, sunlight and size, we can create an accurate 3D model. This model would be used for various purposes. For instance, it could be a useful tool to design and fabricate the customized prefab acoustic barriers and plant containers. And it would be helpful for adjusting efficiently the future performance of the vegetation and photovoltaic panels. But the insertion of vegetal elements in infrastructure surroundings can be a tough operation. It requires special skills and techniques. Nowadays, those tasks are performed almost manually and they require a big effort. The prefab containers for vegetal elements would ease the robotic assembly on site.

Aug 1, 2013

By P. Tracy

An advanced real-time monitoring system, called a "Tapblock Diagnostic System" is under development to help furnace operators manage the operation and maintenance of their tapblocks. The life of a water-cooled tap block in a smelting furnace ranges from several months to several years, depending on the operating conditions. Tapblocks are typically replaced at regular maintenance intervals; a strategy based largely on historical records and not on the actual condition of a particular tapblock. The Tapblock Diagnostic System monitors the tapblock throughout its life and accumulates probable wear events to help the operator assess the residual integrity of the tapblock. Benefits of this system include the ability to provide early warnings of tap block wear to provide improved safety and maintenance planning. Using cooling-water flow together with copper and water temperature measurements, the system performs calculations that compare the present tapblock performance with the expected operating envelope using a multivariate statistical method (Principle Component Analysis). The operating envelope is pre-calculated for a wide range of operating conditions using transient thermal modeling (Computational Fluid Dynamics). A state indicator in the form of a green, yellow and red light is used to inform operators of the tapblock performance and health status.

Jan 1, 2007

By Paul A. Glapa

Quality is much more than providing a product that functions properly. True quality is a way of thinking, a way of doing business, and, ultimately, a way of satisfying a customer?s long-term needs. A true commitment to quality requires a top-down management commitment, with a willingness to change what needs to be changed and to expand upon ?best practices? that are already done well. Is there a cost to creating and maintaining a quality program? Of course there is, but the cost of not having a focused program is much greater. We have come to regard quality as an investment that pays dividends to both the supplier and customer. The lack of quality costs everyone and the customer pays the ultimate penalty. With modern, highly engineered surface mining equipment the end user calculates cost in terms of lost production (revenue), not simply the cost of the part. Bucyrus International, Inc. is a company that has listened to its customers and has dedicated itself to implementing an advanced quality program. The ultimate goal being the creation of a high quality product with extended reliability for the customer. The result is reflected in Bucyrus? current product offerings and highlighted by the new 495HF electric rope shovels at Albian Sands mine.

May 1, 2003

By L. E. Djingheuzian

"ForewordTHE FOLLOWING excerpt is taken from Fine Grinding Investigations at Lake Shore Mines (C.I.M., Trans., Vol. XLIII, 1940, p. 307):""MacCalman, who has carried out exhaustive testing on the accuracy of screen analysis, makes the following statement in his report, The Accuracy of Sieving Tests, Industrial Chemistry (London, England), Vol. XIV, p. 231:"" 'It will be shown that, as no specific relationship between the sieving value and the various dimensional features of the sieve is evident, though there is an apparent tendency for the sieving value to follow the average aperture size, it is apparently impossible to define the sieving value of a screen from dimensions alone, and the calibration of sieves for important tests on a specific material, whereby the sieving values of these sieves are related to that of an arbitrarily chosen master sieve by correction values, will be recommended."" 'It will be emphasized that these correction values are probably not applicable to other materials, or the same material of different size composition. Sieve users, for important tests or in cases of dispute, will be recommended to calibrate their sieves against a mutually acceptable standard with specified conditions of test, and to recalibrate at intervals' ""."

Jan 1, 1953

By Ken G. Kress

Syphons can be a simple, reliable and proven alternative to otherwise more complex pumping systems or low level outlet works. In a simple form they consist of a pipeline constructed over the top of an embankment or high topographic feature, connecting a source pond to a receiving pond or channel (see Photograph 1). The syphon action is initiated by removing air from the pipeline (priming) using simple devices which can be purchased ?off the shelf?. Once primed, the syphon flow rate can be controlled or stopped using conventional gate, valve, orifice plate or other devices. Repriming is not required even if the flow is stopped, provided the syphon is not drained. A limiting factor in considering a syphon as a design option is the maximum lift (i.e., vertical distance from source pond level to summit of syphon) which is approximately 9 metres, or less, dependent on syphon pipe features and site conditions. Pipeline syphons can be quickly constructed from readily available materials including steel, polyethylene and PVC pipe. They are particularly well suited to many of the unique conditions often encountered at minesites. This paper identifies situations that can sometimes be best resolved using pipeline syphons. It provides basic principles for pipeline syphon design and includes case histories of their successful application.

May 1, 2001

By M. A. Kelly

Pit Optimisation using the Lerchs Grossman algorithm has been successfully applied in many deposits. Pit shells often form the basis for scheduling. Pre-assigned costs may not accurately reflect the costs that strategic scheduling decisions are based on. This can affect all mines, but is particularly true for commodities requiring blending. Adoption of Maximiser technology addresses these cost based scheduling and blending challenges.

May 1, 2007

By Tim Bekhuys

Equator Principles ? Applies to projects > $10 million ? Voluntary agreement between 58+ EPFIs ? Categorized projects based on environmental risk, consequences ? Requirements for EA, EMP, use of safeguard policies, consultation ? IFC Performance Standards on Social and Environmental Sustainability ? Apply if the project is in a low or lower-middle income country ? Low-middle income countries defined by the World Bank Development Indicators Database

May 1, 2008

By A. L. Williamson

Bio-mining is a cost-effective, energy efficient and potentially environmentally protective method of exploiting a variety of ore deposits, from high-grade base metal deposits of nickel to lower-grade uranium and rare earth deposits such as are found in the uraniferous quartz-pebble conglomerate beds of the Quirke Syncline, Elliot Lake, Ontario. The effectiveness of bio-mining in Elliot Lake depends on the success of bacterially-influenced dissolution of metals of economic importance. The determination of both the dissolution efficiency and rate controls for uranium and rare earth elements from bio-extraction processes is critical to assess the potential for success of bio-mining along the Quirke Syncline. This poster provides an overview of proton-mediated biogeochemical dissolution of more than 50 elements, including uranium and rare earth elements from samples of the low grade uraniferous ore collected as drill core from the Elliot Lake area. The elemental data is quantified using advanced spectroscopic tools (ICP-MS and ICP-AES) to analyze solutions obtained from a series of environmentally controlled biologically-mediated uranium ore extraction experiments. The findings are being to guide design of larger scale bio-leaching experiments to further assess the potential for success of bio-mining along the Quirke Syncline.

Aug 1, 2010

By Engin Burak Anil

Objective, accurate, and fast assessment of damage to buildings after an earthquake is crucial for timely remediation of material losses and safety of occupants of buildings. Laser scanners are promising sensors for collecting geometrical data regarding the damaged states of buildings, as they are able to provide high coverage and accuracy at long ranges. Yet, we have limited knowledge on the performance of laser scanners for detecting earthquake damage, and requirements of such data collection. This paper focuses on characterizing the performance of laser scanners for detecting thin cracks for damage assessment of reinforced concrete frames. We identified a series of crack parameters based on the state-of-the-art damage assessment codes and standards. Similarly, we identified parameters, which affect the performance of laser scanners for detecting cracks, based on prior research in this area. We studied the width, depth, and orientation of cracks; sampling interval of the scanner, and the range of the laser beam from the surface. Effects of these parameters on the detection of the minimum crack size were determined in an experimental setting. An automated algorithm was used to analyze the data. The results show that it is possible to detect as small as ~1mm cracks.

Aug 1, 2013

By Denilson Coutinho, Euler Soares, Paulo de Tarso, Jordana Ferreira, John R. Goode, Andreas Sprecher, Alexandre Rocha

The Serra Verde Project is located in the northern part of Goiás state, Brazil, and comprises 49 mineral claims covering an area of 69,814 ha. The Serra Verde deposit is a rare earth element (REE) enriched weathered granite comparable to the weathered granite, or ionic-clay, deposits found in southeastern China. The Mineral Reserves of the Serra Verde Project total 388 Mt (Measured and Indicated) at an average grade of 1,484 ppm of REE oxide (REO). Several hundred agitated leach and column leach tests have confirmed recovery of about 40 to 55% of the REE, except for Ce, using simple desorption techniques. Present plans call for a heap leach operation followed by precipitation of impurities and precipitation of a pure REE carbonate suitable for refining and separation. The project plan includes initial production of 5,000 t/a of REO, with a high content of heavy and critical REO, rising to 10,000 t/a of REO. This production rate will be obtained by mining of the Mineral Reserves over a 22-year mine life at an initial rate of 6 Mt/a for the first four years with the mining rate thereafter increasing as required by grade and production targets.

Jan 1, 2014

By Dwayne D. Tannant

The Fox Pit at EKATI Diamond Mine reached a depth of approximately 150 m as of September 2005. The pit is designed with 11 m wide benches excavated using a double benching technique leaving 30 m high bench faces. A series of blasting tests were conducted to improve catch bench reliability and increase the percentage of benches that meet an 11 m catch width. The design changes focussed on reducing damage to the bench crest because maintaining the bench crests is the most important factor in achieving good bench reliability. The most significant improvement was obtained by raising the bottoms of the lower trim blastholes by 0.5 m. This change decreases the depth of broken rock below the final bench elevation, and consequently reduces damage to rock that forms the bench crest below. Another improvement was the use of smaller diameter (165 mm vs. 270 mm) blastholes in the A and B rows for the upper trim blast. This change reduces the charge per delay during detonation, reduces the powder factor slightly, and reduces the energy affecting the final pit wall and crest. As mining and the blast testing progressed, the portion of the bench with crest achievements (>11 m) increased from 57% to 75%.

May 1, 2006

By H. T. John

"The objective of this paper is to demonstrate how the optimum cut -off grade can be calculated for typical large tonnage openpit mines. In the examples, it is assumed that the concentrator tonnage is fixed and that there are no market restrictions. The mining rate is assumed to be variable. This is usually the situation at an operating property.ModellingA model of the ore body is required to examine alternate cutoff grade strategies. The model must be accurate in its relationship between grade and tonnage. Table I shows a typical relationship between ore tons and grade for various cut-off grades. The average strip ratio is also shown. For higher cutoff grades, the ore tonnage is decreased and the ore grade is increased. Strip ratio increases with the cut-off grade.Using the relationship between ton s and grade, and assuming a homogenous, long life orebody, a simple calculation of the optimum cut-o ff grade can be made. The objective is to maximize the present value of cash flows. For the long life homogenous orebody example this objective is satisfied by maximizing present cash flows.Cash flow is calculated by subtracting operating cost from revenue . Operating cost will increase with the cut -off grade as the strip ratio increases."

Jan 1, 1985

By V. Itkin

"Three methods were tested for the beneficiation of aluminum scrap, generated by heavy medium separation of non-ferrous automobile scrap residue. These were: crushing in a shredder followed by screening; grinding in a ball miff followed by screening; and eddy current separation. The best results were obtained with the grinding-screening method. IntroductionThe usual method of aluminum alloy reclamation from non-ferrous automobile scrap residue consists of a two-step heavy medium separation to remove materials lighter than and heavier than aluminum. The resulting aluminum scrap still contains over 15% impurities such as stones and glass, heavy rubber, insulated copper wire , plastics and heavy metals entrapped by macerated aluminum piece s, composite fragments, etc.(2). Upon melting, these impurities create difficulties and yield a low ingot recovery-65% to 70%, hence small foundries avoid this material.There are a number of ways to improve the quality of aluminum scrap such as:(1 ) crushing of the scrap, which powders the brittle content , a major impurity component, followed by screening out of the dust(2) eddy current separation , which removes metals from the material flow, and(3) implement better methods for density separation.The eddy current separation and two variants of the comminution-screening technique were studied by Intermetco Ltd., Hamilton , Ontario."

Jan 1, 1986

By P. W. Ware

The majority of all refined copper is consumed to produce electrical conductors. Most copper conductors are drawn into wire from 8 mm ETP copper rod produced from high purity copper cathodes. Southwire Company has more than 40 years experience using, designing, fabricating and marketing a process for continuously producing ETP copper wire rod. This process is called the SCR® (Southwire Continuous Rod) process. Today, approximately half the copper wire rod produced in the world, or more than one third of all refined copper consumed, is produced using the SCR process. Southwire has sold 75 SCR copper rod mills to metal producers and wire manufacturers around the world. Southwire is North America's largest electrical wire and cable producer. Southwire operates a 48 metric ton per hour SCR® copper rod system in Carrollton, Georgia. This allows Southwire to provide technical support for existing SCR® system customers based on first-hand knowledge. Rod fabricators and their wire customers are always striving for copper rod that improves productivity. They are looking for improved surface quality, finer wire sizes and fewer wire breaks per ton of rod drawn. This paper will present a brief history of the SCR® process, a description and recent process developments.

Jan 1, 2007

By P. R. Stephenson

Mining projects depend on the amount and quality of the mineral reserves, which in turn depend on the amount and quality of the mineral resources. Only Measured and Indicated Resources may be converted to mineral reserves and Inferred Resources may not, with certain exceptions, be used in economic studies. Responsibility for the estimation of mineral resources rests with the Qualified Person (QP) and there is a wealth of literature, text books and case studies to guide the QP. Responsibility for the classification of the mineral resources also rests with the QP. While there is some industry guidance and common practice on approaches to resource classification on which the QP can draw, the process is (or should be) heavily dependent on the exercise of judgement by the QP. However, this inevitably leads to situations where, for example, one QP?s Inferred Resource is another QP?s Indicated Resource. If the QP?s judgement is poorly reasoned or illogical (as is sometimes the case), it can have a major impact on the project, often with substantial cost or value implications. Project managers and company executives should not unquestioningly accept QP?s classification decisions and should apply the same intensity of due diligence that they apply to other critical elements of the project.

May 1, 2011