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The total current inventory of mature fine tailings is estimated to be nearly 850 million m³. Pressure has come to bear on the industry to accelerate its tailings management practices and prevent this inventory from steadily growing. The present paper describes the treatment, management and reclamation of fluid fine tailings. New technologies being evaluated include: i) Thin layered - fines dominated deposits, ii) Deep - fines dominated deposits, iii) Fines enriched sand deposits, and finally iv) water capped disposal in end pit lakes. A brief overview for each of the methods of treatment and disposal for fluid fine tailings is provided.

Aug 1, 2013

By Peter Chmara

The measurement of dust concentration in Ontario mines since 1926 has been accomplished by konimetry, based on South African experience and methods. The introduction of a voluntary program of semi-annual surveys of air conditions at all operations throughout Ontario mines created a need for an instrument that would assess konimeter spots rapidly and accurately. The development of the Electronic Scanner, it is felt, answers this need. A program whereby all konimeter spot samples taken at Ontario mines will be counted at the MAP AO field offices in North Bay is described.

Jan 1, 1969

By Osvaldo A. Bascur

Industrial complexes rely on measurements of flow rates, qualities, and concentrations for monitoring and optimizing their operation. Corporations use the data from the various sensors and measurements to make business decisions, which affect the profitability of the operation. However, gross errors, due to a variety of reasons like faulty sensors, bad instrument calibration, or incorrect process models may corrupt the actionable information supplied to operations, quality managers, and maintenance personnel. The solution is to use the sophisticated new tools to model the process, sift through the available data to locate the gross errors, and use statistical data reconciliation to validate the sensors and instruments. In this way the data are unified to give the most accurate plant information for use by the monitoring and decision making processes. Most mining and metallurgical plants use predictive maintenance policies based on statistical analysis and special techniques, like vibration analysis, and oil and lube analysis for critical equipment. Process control strategies are installed in several metallurgical sites. All of these depend on reliable and accurate data. The data unification methods validate the individual measurements by using the concept of balances and statistical techniques where each instrument is no longer independent of the other measurements in the facility. This paper refers to the data unification and analysis methods required for profitable plant operations. Continuous improvement and monitoring of the measurement system at the plant and analysis of the reconciled data provide the best information for the decision-making process. On-line gross error detection and elimination methods are required to ensure efficient evaluation of process performance and process optimization. An open discussion of the new methods for gross error detection and data unification will be presented.

May 1, 2001

By Joerg Hammerschmidt, Marcus Runkel, Steffen Haus

Given the limited number of new plant construction, focus is turning to the optimization of existing metallurgical roasting plants. To meet the goals of high process efficiency with limited capital expenditure, plant owners are looking for new strategies, including digitization and expert support. As a supplier for numerous roasting, gas cleaning and sulfuric acid plants, Outotec has intensified its effort in recent years to develop solutions to accommodate increasing customer need. This article presents a short review on how Outotec is applying advanced control tools for the fluidized bed industry. Focus will be given on how to transfer the existing technology (used in selected Zinc roasting plants for over a year now) to copper roasting. Outotec has developed the Pretium Roaster Optimizer, a system based on heat and mass-balanced simulation models. Direct experience with this technology will be shared and will highlight similarities to the Partial and Sulfate Copper roasting processes. Pretium detects equipment and plant bottlenecks and provides consistency in process development. The Pretium program combines 24/7 advanced online digitalization tools, along with expert personal support when required. INTRODUCTION Fluidized bed reactors have been used for commercial-scale zinc and copper roasting since the 1950s. While the principles of roasting remain unchanged, over time, the technology has advanced to improve process control of roasting plants. In the past, environmental and safety standards were the driving forces for improvement of equipment and plant design. Today, the emphasis is on plant efficiency and optimization. Another change has come in process control philosophy. While plant control and operation have traditionally been the responsibility of owner/operators, they have now shifted to include both integrated digital tools and specific know-how from engineering companies. This can be seen from the earliest design stages through commissioning and into production, as evidenced by zinc roasting plants in Mexico, Brazil and Turkey.

Jan 1, 2019

By Sylvain Castonguay, Sylvain Pilon

"Operator competency is an important factor in the safe and successful operation of today’s complex processes. Competent process unit operators deliver superior performance and results. In greenfield projects, operator competency is particularly critical, as the lack of specific operations experience must be offset with proven practical knowledge and skills to avoid mistakes that can cost millions in terms of start-up delays, production losses and equipment damage. It is, therefore, important to know precisely what competencies are required for a project or site, and what any gaps in operator competency need to be addressed and improved. The success of plant commissioning, start-up and sustainable operations is directly tied to operator competency. The significant investments required for new projects, the exploitation of more challenging ore bodies, and the increasing complexity of plant operations have placed renewed emphasis on the need for competent operators. Furthermore, many large capital projects are being developed in remote regions, often with ties to the delivery of social benefits for the local population in terms of jobs, training and other development opportunities. While automation and processing technologies have helped do more with less, indicators now point to a bottleneck in human performance limiting operational results.Automation industry development in managing abnormal situations, including solutions for simulation and operator training, has produced applications to provide customized and flexible training methods. This paper will discuss tools to automate the operator competency process in order to guide trainers to effectively teach, measure, control, provide feedback, and monitor operator skills. Today’s competency management solutions can be effectively applied throughout the course of an operator’s professional life, as a guide to hiring new operators, for developing competencies to support operations, and also to develop and refine best practices and share lessons learned."

Jan 1, 2016

By J. J. Jonas, G. R. Stewart, N. Pokutylowicz, S. Yue, R. Varano, A. Elwazri

Differing thermal histories in and around a weld can lead to differences in grain size, phase composition and morphology of precipitates; mechanical properties will vary accordingly. Hardness testing gives limited information and the machining and testing of tensile and/or impact specimens that would reveal these variations (which may occur over very small distances) is not practical. Therefore, in this investigation, shear punch testing was applied to measure the variation in the room temperature mechanical properties of a welded pipeline steel.

Jan 1, 2005

By S. Akhlaghi

In many electronic/optoelectronic devices, interaction between the metal stack and solder is undesirable. If a reaction happens, a nonuniform joint containing spikes and voids is likely to form and as a result the heat dissipation deteriorates significantly, which in turn, leads to the degradation of the bond. In the present work the interaction between Ti/Mo/ Au metallization system, which was sputter deposited on AlN substrates, and Pb-Sn solder was studied by using scanning electron microscopy (SEM). Also, an EDX system was used to trace the changes in chemical composition of the layers after solder tests. The microstructural examinations show that the Ti and Mo layer from the Ti/Mo/ Au metallization system are not impermeable enough and thus Ca from the surface of the substrate moves all the way up to the interface of Au/Mo and forms an intermetallic at the interface, which grows over time.

Jan 1, 2006

By M. Imamura

Sumitomo Metal Mining Co., Ltd. has developed a novel hydrometallurgical process for producing not only copper metal but also iron metal from copper concentrates. Because copper concentrates generally contains the same amount of iron as copper, cost-effective rejection of the iron is a key issue for the development of the process. Conventional hydrometallurgical processes produce a large volume of goethite or hematite for disposal and the residues are not environmentally friendly. In the novel Sumitomo hydrometallurgical process, copper is leached effectively from chalcopyrite concentrates using chlorine gas, followed by purification through solvent extraction and electrowinning for copper and iron recovery. This process has many advantages such as the minimization of the volume of solid waste by the recovery of metallic iron and the production of high purity copper. Iron metal with a purity of more than 98% can be recovered from the purified raffinate. This paper presents the results of the batch and continuous tests of the process flowsheet.

Jan 1, 2006

By Ian S. Leslie

Seismic monitoring systems for mining operations are being utilized more than ever before in the characterization of rock mass response to underground and open pit mining. This paper provides a review of the use of microseismic monitoring for rock mechanics applications at mines throughout the world. Some practical considerations for the installation of these systems are presented along with techniques for optimizing seismic array coverage. Case studies and installation examples are also provided. Recent applications of advanced seismic analysis techniques are discussed including the determination of event mechanisms, mapping of maximum peak particle velocity (PPV) and seismic hazard fields, and the use of source parameter data for large event re-entry protocol.

Jun 1, 2012

By B. Schulz, T. Leißner, R. G. Merker

"Ores enriched in critical rare earth elements (CREE) keep on being of particular interest. The CREE are Nd, Eu, Tb, Dy, including Y. In conjunction with beneficiation tests on Y-mineral bearing flotation tailings of complicated mineralogy, the Mineral Liberation Analyses (MLA) was used to work out processing characteristics fraction-wise in terms of modal mineralogy, mineral recovery, locking and liberation, and particle size.Size fractions from mechanical sieving (“real fractions”) as well as fractions created virtually by using filters on the MLA-data of the unsieved head material (“virtual fractions”) were investigated comparatively thereby. The ""virtual-sizing-approach"" features a much simpler sample preparation procedure and considerably lower cost if a fraction-wise investigation of a head sample is needed. It can be conveniently applied to intimately locked ores needing a fine grinding to a particle size distribution (PSD) range below 25 microns for instance. However, its practical use is sometimes disputed in terms of the reliability of the results. Results are shown for the main Y-bearing mineral xenotime and selected main gangue minerals of a low grade REE-ore.The influence of sample representativeness, sample preparation and particle counting statistics turned out to be of crucial importance. Given that all preconditions for reliable results are met, locking characteristics, modal mineralogy, and even PSD trends can be read from virtual fractions.The authors encourage processing engineers to use the virtual approach. They propose practical measures to improve the reliability of the MLA results, identify and tackle conflicting results, and mitigate evaluation problems that may arise."

Jan 1, 2016

By J. E. Carrasco, J. D. Stinnette, R. A. Alvarez

"Chuquicamata Underground Mine is one of the main projects for the Chilean government copper company (CODELCO). Underground mine project has been under construction since 2013 and presents a solution for the lower production levels of the open pit and prolongs the life of the mine for the next 40 years. Currently, around 2000 workers operate in the mine daily. Dozens of trucks and heavy machines drives through all main routes and access in the mine. As a mine under construction not all the infrastructure necessary to operate safely in the mine has been completed. Risk of a truck or fixed facility fire is always a challenge to keep under control. One important part of fire simulation relays on what we can do prevent a fire and what can be done with the existing infrastructure to control a declared fire and start evacuation plans. This study has been made as a feasible emergency plan to implement, in this case, of a mine under construction, were limited resources are available. Several fire scenarios have been made to support all the emergency plan strategy and a detailed step by step procedure indicates what the elements of a fire emergency plan and risk analysis are.INTRODUCTIONThe main objective of this study is to describe the importance of fire risk analyses (FRAs) and different methods to be used before commencing fire simulation and methodology steps utilized for a fire emergency plan strategy (EPS) at the Chuquicamata underground mine. It also describes how to classify zones which are going to be affected by fumes and gases propagation derived from the exact location of a fire event. Fire simulation study is helpful to determine the impact on a ventilation system with the main purpose of providing relevant information to complement emergency plans and stablished control techniques in ventilation design and its operation. Most fire simulation studies only concentrates in simulation techniques on itself. But what is the next following step in developing an emergency plan? How can we evaluate, classify and treat risky areas? This study is focused mainly in the phases before and after a fire simulation process. Phases corresponds to a good FRA and how output data can be used for an EPS."

Jan 1, 2019

By H. Staton, V. Suontaka, E. Sharifi

"Flotation circuits are typically controlled using on-line elemental assays obtained from the slurry lines. In base metal applications, X-ray fluorescence (XRF) analyzers are the most common instruments for elemental analysis of the slurries. Eagle Mine has been utilizing a Courier XRF Analyzer since 2014. Typically, in XRF analysis, the sampling rate is 10-25 minutes which is good enough for manual process control. In 2018, Eagle Mine upgraded the Courier XRF analyzer with the Rapid Measurement module that is based on reflectance spectroscopy. This option reduces the sampling rate to 10-15 seconds, while maintaining the superior accuracy of the XRF analyzer. This paper presents the results from implementation of Rapid Measurement at Eagle Mine.INTRODUCTION Eagle mine is an underground mine producing nickel and copper concentrates. Eagle Mine is owned by Lundin mining and located in the Upper Peninsula of Michigan, USA. The Humboldt Mill, previously an iron ore processing facility, was refurbished in 2014 and is used to process the ore and produce separate nickel and copper concentrates. Approximately 2,000 metric tonnes of ore is milled per day. Ore is processed using a conventional crushing followed by single stage ball mill and flotation. Nickel and copper concentrate are transported to facilities in North America via rail car. A bulk copper-nickel concentrate is produced by separating the copper and nickel minerals from gangue material by flotation. The copper-nickel bulk concentrate is reground, followed by one stage of cleaning to reject further gangue minerals. The bulk cleaner concentrate is then subjected to a final flotation stage where the copper and nickel minerals are separated from one another through the addition of lime. Final concentrate grades are 14% Ni and 2% Cu in the nickel concentrate and 31% Cu and 0.8% Ni in copper concentrate."

Jan 1, 2019

By S. Esmaeili

The yield strength model developed by Esmaeili, Lloyd and Poole [1] has been adapted to model isothermal aging in Cu-containing AA6xxx alloys, with (a) a moderate and (b) a very low Cu content in the solution-treated, as-quenched, condition, Isothermal calorimetry has been used to analyze the kinetics of precipitation in these alloys, While the kinetic parameters for the low Cu alloy has been derived from the present experiments, the previously determined kinetic parameters for the high Cu alloy AA6111 has been used to model the precipitation kinetics in the moderate Cu alloy. The age hardening responses of both alloys have been well predicted by the model.

Jan 1, 2005

By A. Henk, C. M. Aruffo, K. Fischer

"Geomechanical reservoir modeling offers a valuable tool to predict tectonic stresses, in particular the local perturbations in orientation and/or magnitude which occur at lithological boundaries and faults. The paper presents a workflow for building and calibrating such geomechanical models. The numerical simulations are based on the Finite Element method and can range from field-scale models to smaller, highly detailed submodels of specific fault blocks. The approach considers the reservoir-specific characteristics with respect to subsurface geometry (lithostratigraphic boundaries, faults), mechanical properties and ambient stress field. During the subsequent calibration stage calculated stresses are compared to stress data actually observed in borehole data. Poorly constrained input parameters are iteratively modified within reasonable limits until a satisfactory fit between calculated and measured stresses is achieved. This validated model can then be used for stress predictions between wells and in undrilled parts of the reservoir, respectively. The workflow is applied to two case studies - a large gas field in Northern Germany and a CO2 sequestration project in Australia – to test and illustrate its practical value. INTRODUCTIONDetailed knowledge of the tectonic stress field is crucial for the optimal exploration and use not only of conventional and unconventional hydrocarbon reservoirs, but also for deep geothermal reservoirs, carbon capture and storage (CCS) projects as well as underground mining and nuclear waste repositories. Any reliable stress prediction is hindered by the observation that the magnitude and orientation of the stress field can vary significantly – not only in time, but also in space. Such spatial stress variations comprise all scales, i.e., from the scale of lithospheric plates down to the grain-scale. On the reservoir- and fault blockscale, the local stress field can be influenced by faults and different mechanical properties of lithologies (Sassi & Faure, 1997). The resulting variations in stress magnitude and/or stress orientation are commonly referred to as stress perturbations and give rise to a unique, reservoir-specific stress pattern (Yale, 2003). Thereby, local stress fields can deviate by up to 90° in orientation and several tenth of Megapascal (MPa) in magnitude from regional trends."

Jan 1, 2015

By J. J. Barakso, C. Tarnocai

This paper outlines a method of testing for the mercury content of rocks, soils and plants. Techniques of sample collecting are described and the analytical procedures outlined. Examples are given of mercury determinations in two known mineralized areas in British Columbia - Copper Mountain Mines and Pacific Nickel Mines.

Jan 1, 1970

By D. J. Lucifora

Monitoring-While-Drilling (MWD) is a proven technique that records instantaneous on-drill parameters which can be used to supply contextual information for in-situ, down hole conditions, such as: changes in geology, the presence of pre-existing fractures and dynamic alterations, down hole conditions including bit bailing, bit blockages and bit wear, and improper drill operation. This technique has been widely used in the oil and gas industry and, eventually, it was transferred to the mining industry. A challenge when analyzing and interpreting MWD data is in utilizing proper filtering which enables one to properly eliminate any ?noise? from the signals of interest. Overall the importance of MWD data is that, through the collection of operational field-based data, a dataset can be acquired which allows experimentation and analysis to be carried out. Such a dataset is often impossible to replicate in a laboratory setting. If successful, and through iterative refinement, any promising method can eventually be implemented on-machine and using real-time monitoring techniques. This paper will provide a state of the art review of presently used MWD techniques and applications in industry. The paper?s primary focus will be on shallow, mining-style, blast hole drilling but will also take into account techniques and applications utilized in oil and gas drilling which have not been adopted in the mining industry. In the cases where MWD techniques and applications exist solely in oil and gas drilling the paper will examine and comment on the potential utility of technology transfer to mining applications.

Aug 1, 2013

By A. C. Hatton

Doped SrCoO3.8 was found to be a promising material for use as a cathode component in intermediate temperature SOFCs. In this work, strontium cobaltite ceramics doped with 10 mol% to 90 mol% samarium were synthesized using the glycine nitrate process in order to study the electrical conductivity and thermal expansion at temperatures of up to 800°C. As-synthesized powders were deagglomerated, pressed and sintered at temperatures ranging from 1100-1250°C. The effect of temperature and composition on electrical conductivity and thermal expansion are presented and discussed.

Jan 1, 2005

By J. A. Hurd

Towards the goal of a better understanding of the structure-proton conductivity relationship in PEM materials, this project concerns the design of ordered polymeric solids containing well-defined sulfonate aggregates. The approach employed involves the templation of sulfonated monomers using core principles of crystal engineering. In addition to sulfonate groups, the monomeric units contain crosslinkable functionalities to enable formation of a covalently linked network. The templation strongly directs the construction of well-defined sulfonate clusters and aggregates. Structural, sorption and conductivity data for the networks will be shown.

Jan 1, 2005

The mining industry has generally been slow to apply ion exchange processes to hydrometallurgical applications even if ion exchange offers an ideal solution for a particular problem. Two notable exceptions are in gold and uranium recovery. The largest application of ion exchange in the metals processing industry has been the use of resin-in-pulp (RIP) for gold recovery as an alternative to activated carbon. Iron is a ubiquitous impurity in hydrometallurgical solutions. In many cases, bulk removal of iron from the process solutions is accomplished by precipitation. However, precipitation for iron control is often accompanied by losses of base metals by co-precipitation. Increasingly, the option of ion exchange for removal of smaller amounts of iron from process solutions has been favoured. A number of applications have been developed and proven at the commercial scale for the removal/control of iron from a range of metal processing solutions. This paper provides an overview of the application of ion exchange for iron removal from a range of metal processing operations, including Cu, Ni and Co solutions. A number of case studies are provided which review operational and resin regeneration strategies and the impact upon the commercial operation of metal processing with improved iron control.

Jan 1, 2006

By Yasser Mohamed

Daily field management of earthmoving operations requires quick and regular decisions for allocating available equipment to different jobs on a project. A general foreman?s day starts with matching several activities with a suitable set of available equipment to achieve the highest productivity and lowest unit cost. Usually, this decision-making process needs to be quick, and depends to a great extent on the foreman?s experience, which varies from one individual to another. Many analytical solutions with various degrees of sophistication and optimization exist to address such decisions. However, adopting any of these solutions is contingent on how accessible and easy-to-use the solution is. This paper discusses the development process of a webaccessible solution for evaluating earthmoving fleet composition and allocation scenarios. The solution relies on discrete event simulation and an optimization backend engine, but introduces the user with a simplified and easy-to-use interface that is accessible from any mobile device, and is customized to specific user?s needs. The developed system gathers most equipment and site-related input data from a company?s information systems to minimize user input. The user mainly needs to formulate equipment and job combinations and allocation scenarios (e.g. soil type, quantity, and hauling distance), according to equipment availability each day. Then the system will evaluate the productivity and unit cost estimates for each scenario, allowing the user to choose the most suitable one. It may also be used to automatically recommend the optimum solution given an available list of equipment. The paper presents the process followed in prototyping the proposed system in collaboration with a major Canadian earthmoving contractor, and customizing it to the user needs within the company. It also describes the overall structure of the developed system and its core simulation model.

Aug 1, 2013