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By Scott Beer

What New Technologies Will Drive Economic Improvements? ??Historical ?1060?s: Mainframe Technologies ?1970?s: Mini Computing ?1980?s: Workstation Computing ?1990?s: Personal Computing ?2000?s: Network Computing Internet PDAs Cellular phones ??What?s the next technology improvement? ??What?s next for Mining?

May 1, 2009

By E. Rosseland

Glencore Nikkelverk is operating its Chlorine Leach Process in Kristiansand, Norway, producing nickel, copper and cobalt metals by electrowinning. The copper tankhouse, with an annual capacity of 40 000 tons, is based on traditional technology with copper starting sheets and cast lead anodes. Due to the integration of this copper sulphate process in a nickel chloride refinery, operating conditions are unique. In recent years, operating costs have escalated, and health, safety and environment are top priorities. Test work on a new copper process involving permanent cathodes was therefore initiated in 2007, and a pilot plant was started up in 2012. The objective was to introduce innovative technologies and tailor these to be robust in the Nikkelverk process, to form a basis for a new sustainable copper tankhouse with a high degree of automation. Key learnings from more than 10 years of R&D work is presented, focusing on cathode materials and copper metal deposition including product quality, robotic stripping, coated titanium anodes, electrode contacts and alignment, electrode current monitoring with Hatch HELM tracker technology and acid mist capture using cell hoods with off-gas scrubbing. The new copper tankhouse project was approved in December 2018, and commissioning is planned in 2022. INTRODUCTION The Kristiansand nickel refinery was started up in 1910, processing nickel-copper matte originating from Norwegian mines. It was the first industrial plant in the world to produce nickel by electrolysis using the Hybinette electrorefining process. After roasting to burn off sulphur in the matte, copper was leached and recovered as cathodes by electrowinning with lead anodes. In the first years, the copper cathodes were fire- refined and cast into ingots for sale (Thonstad Sandvik, 2004). The Nikkelverk refinery was acquired by Falconbridge Ltd. in 1929, and since then matte from Sudbury, Canada has been the main feed source. The Hybinette process was in operation until 1975 when conversion to the newly developed Chlorine Leach Process was started (Stensholt, Zachariasen, & Lund, 1986). In this process still used today, nickel and part of the copper in the matte is leached using chlorine gas generated on dimensionally stable anodes in the nickel and cobalt electrowinning tankhouses, as illustrated in Figure 1. The presence of dissolved copper ions in the strong chloride leach solution is essential for effective chlorine absorption and nickel dissolution. To improve copper-nickel separation, slurry from the atmospheric leach is pumped to autoclaves and then to cementation tanks for precipitation of copper as copper sulphide, which is collected in filter presses. The leach residue, also containing the precious metals, goes through a 3-stage wash to remove chlorides before being introduced as a slurry to fluid-bed roasters for sulphur removal. The resulting calcine is then leached in spent electrolyte from the copper electrowinning tankhouse, to dissolve most of the copper and also some nickel, cobalt and other elements. After separation of the leach residue, elements like Bi, Te, As and Ag are removed from the strong copper sulphate solution by reaction with metallic copper in three columns in series filled with cut copper cathodes. The purified solution then passes polishing filters before being mixed with spent electrolyte and returned to the electrowinning cells.

Jan 1, 2019

By J. Fellowes, V. Landais, J. Robson, J. Carr

"Aerospace Al-Zn-Mg-Cu (7xxx) alloys are known to be susceptible to environmentally assisted cracking (EAC). This phenomenon has been studied intensively for many decades, leading to empirically adopted methods to mitigate this problem through overaging and composition design. In parallel, many theories have been developed to explain EAC in 7xxx, but none is yet universally accepted. Today, a number of emerging techniques offer potential to shed new light on EAC in 7xxx. The purpose of the present paper is to demonstrate how X-ray tomography (XCT) combined with electron microscopy can be used to identify the true crack path in 3-dimensions, and hence identify material for site specific electron microscopy analysis. Composition mapping over large areas to high accuracy has been performed using a modern electron microprobe analysis system. This has been combined with transmission electron microscopy to investigate local composition in matrix and precipitates at high resolution. This combination of techniques across length scales offers the potential to provide new insights into the links between local composition, microstructure, and EAC resistance.INTRODUCTION Environmentally-assisted cracking (EAC) is a phenomenon which dramatically decreases the performance of metals and can cause premature failure of large structures. Observed in situations where components were not subjected to critical loads and no widespread corrosion was involved, this type of brittle failure is extremely difficult to predict. The EAC designation covers a number of phenomena, e.g. stress corrosion cracking (SCC), hydrogen embrittlement (HE), corrosion fatigue (CF), etc. Initially identified in steels, EAC can also affect other metals such as high-performance aerospace aluminium alloys, and this phenomenon has been a concern for industries for decades. Extensive research has been conducted on the effects of various environments (moist air, saline water, dry hydrogen gas, etc.) on microstructures and crack propagation, however no consensus has been reached and the exact nature of the mechanisms that control EAC is still being debated (Birnbaum & Sofronis, 1994; Gangloff, 2007; Holroyd & Scamans, 2013; Lynch, 2012; Oriani, 1972; Scamans, Alani & Swann, 1976, Young & Scully, 2002)."

Jan 1, 2018

By A. Moyano

The development of the traditional converting process performed in a PeirceSmith or Hoboken converter is limited by the investment magnitude associated to the fulfillment of the environmental regulations. Thus, the continuous converting process rather than a conceptual process alternative is becoming a necessity for a smelter facing limited converting capacity and/or lacking of fulfillment of the environmental regulation with its maximum converting capacity. The objective of this paper is to present the progress of the Codelco continuous converting process evaluated at pilot-scale level when converting solid mattes or white metal into blister copper. These tests allowed for gathering of relevant data to be considered for a new stage of evaluating the Codelco continuous converting at industrial-scale test. The pilot-scale tests were done in a Teniente Converter pilot scale unit at the Codelco Norte Smelter. The results of processing solid copper mattes (65-75% Cu) and producing low sulfur content blister copper with production of a constant S02 gas concentration, and the production of liquid slag with low copper solubility was achieved and is discussed in the present paper.

Jan 1, 2007

By W. D. Madeley

Synthetic minerals were made from pure starting materials and galena samples were doped with the title metals. Microscopic, microprobe and X-ray examination confirmed that the dopeants were in solid solution. Paired flotations in a Hallimond-tube apparatus were performed to determine relative flotation response using Aerofloat 238 promoter. Results of these tests show that silver-doped galena floats more readily than pure galena and that galena doped with bismuth floats less readily than pure mineral to a 95% confidence level. Galena doped with both silver and antimony as AgSbS2 shows no detectable effect. Antimony-doped galena followed the expected trend, but not to 95% confidence. The results are consistent with the theory that flotation by thiol-type anionic collectors is enhanced by p-type semiconduction.

Jan 1, 1978

By E. P. Wiechrnann, C. M. Castro, G. A. Vidal

In copper Eta plants the optimal current density setpoint depends on the electrolyte composition and temperature. However, conventional plants operate with large standard deviations. A value of 14% with current densities offsets up to ±50% is typical. For worst, during opencircuit or shortcircuit events this variation can be from -100% to +200%. Naturally, energy consumption and copper quality are compromised. Several devices have been successfully employed to reduce set point deviations. Last developments include; Optibar Segmented Intercell Bars, Outotec Electrodes Arranging Method and NTC Selective Electrodeposition Enhancers. This paper researches and compares these technologies. It is shown that short circuits can be effectively reduced in occurrence and magnitude. Moreover, 95% of the electrodes can be forced to operate within ±10% of the set point. The specific energy consumption is reduced from 2,000 KW per Ton to values close to 1,900 KW per Ton.

Jan 1, 2011

By A. R. Farkoosh

Al-Si based alloys have been recently used by automotive industry for highly stressed engine applications. Due to severe working conditions of the engine parts, existing alloys hardly endure high pressures at high temperatures. This necessitates alloy modifications to enhance the elevated temperature performance. In this study, the effects of trace nickel additions on the microstructural and mechanical properties of A356+0.5Cu alloy have been investigated at different aging conditions. Electron probe microanalysis (EPMA), scanning electron microscopy (SEM) and X-ray diffraction (XRD) are used to study the microstructural changes. Aging curves have been obtained by hardness measurement. It was seen that the presence of additional nickel introduced many complex intermetallic phases within the microstructure which led to improved high temperature mechanical and aging response.

Jan 1, 2011

By Geo. E. Cole

A GREAT deal of time and energy is now being devoted to the study of post-war reconstruction and rehabilitation, in spite of the fact that as yet we have not won the war in which we are presently engaged. If you feel that the study of post-war problems takes our thought away from the problem immediately before us, you may well query, "Well! What has all that to do with winning the war, our most urgent problem today?" The answer has been given by Principal James of McGill University, Chairman of the Cabinet Committee on Reconstruction: "Reconstruction is something which must be thought of in advance, partly for the purpose of recognizing exactly the influence of war-time activities, controls, and regulations on the post-war Canadian scene. Many people are acutely interested in this great problem. It is not that they are not interested in the war itself, or epochal events that are taking place from day to day. They have a vision of that future which they hope will be Canada's, and this vision inspires them to even greater efforts at the present time". The trend of events would indicate that changes, economic and industrial, after this war will be greatly out of line with those that followed previous wars in history, for the present struggle has involved every nation in the world. In the peace that will come, every engineer will have a task in bringing the most desirable order out of the most distressing chaos. We certainly are living in a changing world; we are witnessing geo-graphical and economic readjustments that no other generation in world's history has ever witnessed. And there is an opinion gaining strength in our Dominion, as in other lands, that after this war we shall live in a world in which our process of thinking and our very way of life will have to undergo drastic changes to cope with the new order of things. Sadly our world of today has had to revise the sublime vision that nation shall not lift up sword against nation, while salvage operations continue to beat ploughshares into tanks and the peaceful pruning-hook into a weapon for the deviltry of the commando.

Jan 1, 1943

By McGill Metals Processing Centre, S. Chang, L. Calzado, X. K. Cao, C. H. Hsin, M. Isac

"Due to the increasingly stringent cleanliness requirements for final steel products, there has been a growing interest in the possible use of micro-bubbles for the removal of inclusions with diameters smaller than ~50µm, present within the steel passing through a steelmaking tundish. However, several technological barriers have prevented the adoption of this technique in industry. These are related to a) the generation of micro-bubbles in liquid steel, b) the measurement of bubble size distributions, and c) the optimization of bubble injection conditions to create micro-bubbles. In the present study, a novel Aqueous Particle Sensor (APS) system was developed for the in-situ, on-line, detection of micro-bubbles in water, generated by a newly designed full-scale ladle shroud, located at McGill Metal Processing Centre (MMPC). Measurement results from the sensor were validated against bubble size data collected through a high speed camera and post-processed through the commercial software, Image J.Control variables and orthogonal experiments were designed to assess the dependence of average micro-bubble sizes and bubble size distributions on key experimental parameters. Those chosen were the air inlet flowrate, the distance of the gas injection port from the slide gate, and the number of injection ports used. The investigation demonstrated that the APS system can be successfully adapted to detect micro-bubbles up to ~800 micron diameters. Using this novel sensor, it was shown that multi-port injection using low air inlet flowrates, closer to the slide gate, were useful in forming small micro-bubbles within the flow through the ladle shroud. The results from the APS system were compared and validated against data resulting from an optical technique. INTRODUCTIONModern industry expects increasingly stringent cleanliness requirements for final cast products. Therefore, the numbers and sizes of inclusions need to be strictly controlled in steelmaking operations. Thus, the cleanliness of steel products depends on the amount, morphology and size distributions of nonmetallic inclusions in steel (Zhang L. & Thomas B., 2003). Since large, deep, tundishes provide longer nominal residence times for liquid steel passing through it to the exit SEN’s, this can provide the ideal place to separate inclusions, and bubbles can assist by removing help attach inclusions and float them to the top surface."

Jan 1, 2016

By J. E. Dutrizac

Canada is currently the world's largest supplier of zinc concentrates and is also a major producer of zinc metal. This dominant position in the world's zinc market is a fairly recent circumstance and, in fact, the country's zinc industry was founded only in the early part of the twentieth century. By contrast, the American zinc industry was well established by the mid-nineteenth century, largely based on technology originally imported from the still older European practice. Initial attempts to create a viable Canadian zinc smelter were based on the traditional practice and were unsuccessful; success came only with new electrolytic technology, much of which was developed domestically. The purpose of this paper is to outline the early attempts to produce metallic zinc in Canada and to trace the gradual development of these first efforts into a viable zinc industry based on modern science and technology.

Jan 1, 1999

By H. W. Leon, F. J. Ellis

"This paper covers the new six-strand curved-mould billet casting machine at the Contrecoeur Works of SidbecDosco. It commenced production of 3 Yz-in. square billets at the beginning of January 1972. Together with two 100- ton ultra-high-power electric furnaces in a new meltshop, it is the principal source of billets for the existing rod and bar mill also located at Contrecoeur. The paper develops the reasoning for casting-to-size 3Y2 -in. billets and for choosing a six-strand machine. It indicates the significance of Sidbec-Dosco Montreal Works' extensive experience in operating a four-strand curvedmould billet machine since 1965 and the ways in which this experience influenced the design and operation of the new caster. Machine features are described in detail, as are the reasons for some of the features. The installation, checkout and crew training are briefly discussed as well as the tundish teeming trials. The first cast on January 5, 1972, is covered and a log is shown of the first casts to an empty ladle. There are operating statistics covering the first 100 casts, which produced 8000 tons of good billets in ten weeks of operation. Machine performance and billet quality were good and the few minor problems encountered are described."

Jan 1, 1973

By D. Bois, P. Keating, J. Lemieux, M. A. Vallée, M. Allard, R. S. Smith, L. Z. Cheng, M. Chouteau, D. K. Fountain

"Abstract - MEGATEMII airborne electromagnetic data collected over the Iso and New Insco massive sulfide deposits have been modeled using three modeling packages. The EMQ package is a quick inversion tool which indicates that the Iso body is a dipping, plate-like body. The New Insco body is inferred to have a geometry somewhere between a dipping plate and a sphere. The Maxwell package was used to refine the properties of the plate-like body at Iso. The EMIGMA package was able to identify which parts of the New Insco orebody were more conductive. It was observed that the most conductive parts correspond to copper-rich zones and the next most conductive to pyrite-rich zones. The EMIGMA package was also used to show that a thick-prism model might be more appropriate for the New Insco orebody. Gravity modeling constrained by the known geology was successful in identifying the denser sulfide zones. The densest zones appear to be pyrite rich. Magnetic modeling identified diabase dikes. Over New Insco, a small magnetic anomaly was attributed to pyrrhotite-rich sulfides. There was only a weak magnetic anomaly over the Iso body, consistent with the nonmagnetic sulfides logged in the holes drilled at that location. Sommaire - Les données MEGATEMII recueillies au-dessus des dépôts d’Iso et de New Insco ont été interprétées en utilisant trois outils de modélisation différents. L’outil EMQ a été utilisé comme un outil d’inversion rapide suggérant que le dépôt Iso peut être considéré comme une plaque inclinée, et que le dépôt de New Insco se situe quelque part entre une plaque et une sphère. L’outil Maxwell a été utilisé pour raffiner les propriétés du dépôt Iso. L’outil EMIGMA nous a permis d’identifier les différences de conductivité à l’intérieur du dépôt Iso. Il a été observé que la partie la plus conductrice correspond à la zone riche en cuivre, suivie par la zone riche en pyrite. L’outil EMIGMA a aussi permis de montrer qu’un modèle de prisme épais pourrait être plus approprié pour décrire le dépôt New Insco. La modélisation des données gravimétriques, contrainte par la géologie connue, définit bien la zone de sulfures massifs. La zone de pyrite semble être la plus dense. La modélisation des données magnétiques identifie bien les dykes de diabase. Au-dessus du dépôt New Insco, on observe une faible anomalie magnétique correspondant aux sulfures non magnétiques observés dans les carottes de forages à cet endroit."

Jan 1, 2006

By C. W. Davis

AN inclined shaft is usually more difficult to sink than a vertical shaft, yet it is often chosen because of the subsequent saving in cross-cuts required to reach an inclined ore body. This paper briefly discusses the factors which led to the choice of an incline and then describes the operations involved in the preparatory work and in the sinking. These operations included a programme of mining out the underground facilities and installing the structures required for a hoist-room, cable-raise, waste-pass, ore pass, two sets of skip dumps, and a collar station equipped with counterbalanced drop-rails. The shaft was sunk 1,000 feet and four stations were cut, each with loading pockets. As the sinking progressed, the rock changed from hard porphyries and dense cherts to blocky limestones and earthy rubble. These conditions called for a change in methods and it is to the red it of the shaft-sinking crew that they overcame the new difficulties as the shaft progressed, while maintaining a satisfactory monthly advance. The section mined out was nine feet six inches by seventeen feet overall. This gave room for three compartments: two skip compartments four feet three inches by five feet nine inches inside the timber, to handle two-ton skips, and a manway three feet six inches by five feet nine inches. The sinking began on December 16th, 1941, and was completed on February 15th, 1943.

Jan 1, 1945

By J. Dubinski

Poland is the ninth largest coal producer in the world and Coal Company is the largest Polish producer of this deposit yielding 51% of national production. Coal Company mines are located in the Upper Silesian Coal Basin. These are underground mines which operate in difficult geological conditions at great depths of up to 1200 m. One of the most common natural hazards in Polish mines are rockburst and seismic hazard impacting on surface infrastructure and habitants. In the assessment of the rockburst and seismic hazard methods of mining seismology play a leading role. This paper presents progress that was achieved in the last few years in the implementation of new seismic monitoring systems and seismic interpretation methods for the prevention of hazard deriving from seismicity induced by mining. This progress in assessment of rockburst hazard and impact of seismic activity on the surface infrastructure was achieved through close cooperation between the Coal Company and Central Mining Institute ? the country?s leading scientific institute in the field of mining seismology. New theoretical solutions are in the process of testing in mines of Coal Company where seismic monitoring systems are installed and controlled by well-qualified personnel. Some directions of further joint actions to increase the effectiveness of rockburst and seismic hazard assessment are presented as well.

Aug 1, 2013

By A. E. Gran

"QIT -Fer et Titane Inc. currently produces and markets four main products: a titania slag named SORELSLAG for the white pigment production, a high purity pig iron known as SOREL-METAL mainly used in the ductile iron casting industry, an ilmenite ore for blast furnace applications called SORELFLUX and high quality steel billets SORELSTEEL employed in the wire rod fabrication. Moreover , QIT also manufactures high quality iron and steel powders labeled ATOMET for the powder metallurgy industry through its wholly owned affiliate. Quebec Metal Powders Limited. The company operates. rock ilmenite mine near Havre St. Pierre and produces its slag and ferrous products from its metallurgical installations located in the Sorel/Tracy region. QIT. born in 1948 from a joint-venture between Kennecott Copper Corporation and New Jersey Zinc Company, was acquired from BP Minerals by RTZ Corporation PLC in 1989 and remains its wholly owned subsidiary ever since.lImenite is a mineral rich in both titanium and iron oxides. QIT's proprietary mineral enrichment and electric smelting processes permit the concentration of the ilmenite ore and the separation of its main constituents to produce a 80% TiO2, slag and a high purity molten iron which is further transformed into iron ingots (pigs), steel billets, iron and steel powders.QIT's ilmenite deposit is located in the Lake TIo-A1Iard area, 43 km inIand from Havre St. Pierre, a community on the north shore of the St. Lawrence River some 960 km from Montreal. The orebody, covering some 542 000 m2, consists primarily of coarse-grained ilmenite (FeO.TiO2) with disseminated fine lenses of hematite (Fe2O3). The worthless mineral (gangue) associated with ilmenite is mainly anorthosite, a complex silicate. QITs mining operations are carried out using conventional open pit methods in a 500 m by 600 m horse-shoe shaped mine with nine benches developed. Primary blasting is performed on a weekly basis during the mining season. Blasted ore is trucked to the crushing station to be broken down to 15 cm and 7.5 cm sizes, respectively, by means of a primary jaw crusher and a secondary cone crusher. Minus 7.S cm ilmenite is then loaded into hopper cars for the 43 km trip to the Havre St. Pierre terminal where it is stockpiled and reclaimed by under-ground conveyor chutes to a ship loading tower at the dock. The crushed ore is shipped to QIT's smelter located in Sorel in 40 000 tonne carriers from April to December."

Jan 1, 1995

By Robert B. Parsons

"Ontario and Quebec taxpayers will have to dig deeper into their pockets to pay more tax, according to budget papers tabled in these provinces in May 1993. Individuals will be hardest hit, but corporations will also have to ante up in the face of higher rates, reduced deductions, and new taxes.Up, up, and away...Somewhere in the bleak picture of the 1993 Quebec and Ontario budgets, there is a bit of good news for the mining industry.Careful scrutiny reveals:• Ontario will correct a capital tax provision which inadvertently penalizes flow through share issuers;• Quebec's flow-through incentives will be extended to December 31, 1995; and • both Quebec and Ontario will allow deductions for mine site reclamation payments.The industry may also find some comfort in the fact that Ontario's new corporate minimum tax will be profit-based (unlike the federal minimum tax), so that non-producers should not face a liability for this tax. There is some concern though, about Quebec's announcement that the refundable credit mechanism in the Mining Duties Act will be reviewed."

Jan 1, 1993

By J. Font

The RAF or copper fire refining process at the Caletones smelter of CodelcoChile consists of several pyrorefining stages that successively lowers the levels of S, Fe, Pb, As, Sb, Te, Se and to some extent 0 in the copper melt, allowing the production of high quality fire-refined copper of 99.93 % purity (RAF copper). This chemical feature of the RAF copper is only achieved by quite long processing times, and a considerable consumption of fluxes and fuels in the RAF vessels. The main goal of this study was to improve the RAF process performance by thermodynamic considerations and industrial scale tests, i.e., an in situ approach for the process as featured by intensive sampling, characterization and subsequent modifications. Thus, both theoretical and industrial data were derived, and based on kinetic and thermodynamic evaluations, a higher operational standard was achieved for the RAF process. These new operational practices allowed enhancing the overall economic of the RAF process, by reducing the time and operational costs, and consequently increasing the availability of the vessels.

Jan 1, 2007

By Willie van Niekerk

As mining projects get larger and more complex there is a need to examine the use of project management techniques developed for large construction projects in order to ensure completion of the project on time and budget. In recent years the construction/civil industry has sought new methods to ensure that multimillion dollar projects involving multiple contractors, working in an increasingly legislated work environment, are delivered to the clients satisfaction. The paper describes these methods, which range from program management to systems and tools to gather all project information such as schedule and cost, and relates how these can be applied to large international mining projects. The paper also describes the benefits that an independent project manager can bring to a client or owner?s team by setting up the relevant organization and controls together with the appropriate contract and procurement strategy.

May 1, 2009

"Here, we statistically proved that giant earthquakes occur at lunar phases specific to each subduction zone. Enough attention during the lunar period, especially when seismicity is occurring, will significantly reduce damage from giant earthquakes. Two case studies in which giant earthquakes occurred after seismicity in dangerous lunar phases were discussed, and the mechanisms underlying why giant earthquakes occur around neap tide at some subduction zones were explained by prohibition of giant earthquake occurrences due to high strain rates at spring tides at N–S subduction zones. The prohibition was statistically proven for uniaxial creep tests on Inada granite with slight stress disturbances. INTRODUCTIONIn previous studies, we showed that from 1900 to present, giant earthquakes (MW ??8) have occurred at lunar phases specific to each subduction zone (Fujii & Ozaki, 2012; Ozaki & Fujii, 2012). Although we later proposed a possible reason for these occurrences, the study lacked statistical analyses (Fujii et al., 2013). Therefore, this paper shows the results of such statistical testing and presents case studies for the Tohoku 2011 and Chile 2014 events, thereby providing updated data on giant earthquakes through July 2014."

Jan 1, 2015

By ManhKha Trinh, Neal Pyke

Dofasco was the first company to adopt oxygen steelmaking in North America in 1954, two years after the first LD vessel installed and operated successfully in Linz, Austria. Since then, Dofasco has investigated and implemented several strategies to maximize hot metal usage and minimize overall cost. Some key strategies -low hot metal silicon, combined blowing conversion, vacuum degassing tank upgrade and BOF slag carryover control - are discussed. Post combustion, scrap preheat, carbon injection trials along with current operating philosophies are described.

Jan 1, 2004