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By Joseph T. Roy

MINING revival during the last few years has brought about a considerable increase in the number of gold and silver determinations made, noticeable in all branches of the industry but especially so in the business of a custom smelter. At East Helena, solely a custom smelter the assay department found that the four assay furnaces available were inadequate to handle the increased amount of work. These furnaces were of a standard design, having duplex muffles, one superimposed on the other; each muffle was 12 1/2 in. wide, 18 1/4 in. long and 6 in. high, and could handle 72 cupels or 20 fusions. Since the heat varied considerably between the upper and lower muffles, cupellations were not ruin in both at the same time. To speed up assaying, E. A. Meale, chief chemist, had the happy idea of enlarging a muffle furnace, originally designed by the Montana Power Co., so that one muffle would acconmmodate at least as many determinations as the duplex muffles. An order was given to the Denver Fire Clay Co. for a Carbofrax muffle of the size required and the local engineering department enlarged the furnace to accommodate the muffle. Details of the

Jan 1, 1938

By Y. C. Lo

Grinding process optimization is an exciting new tool for maximizing the performance of existing mineral processing plants. This paper discusses the methodology of optimization which involves plant sampling, pilot tests, modeling, computer simulation and plant verification. The methodology developed emphasizes the interactions among operating variables and design options. Two example applications demonstrate that AG and SAG optimization provides the basis to increase grinding throughput up to 10 percent. This sys- tem optimization technology has been proven to be very cost effective for grinding plant performance improvement.

Jan 1, 1998

By C. Dirscherl, M. Combes

"Declining ore grade, leading to increased material transport and plant throughput requirements, is one of the major challenges in the current mining environment. This is accompanied by rising energy and labor costs, decreasing plant productivity and the requirement for highest plant availability. Siemens’ answer is the latest gearless drive technology for grinding and conveying. Gearless drive solutions are surpassing the mechanical limits of conventional drive systems serving to utilize the principle of economies of scale. By elimination of various components of the drive train the maintenance activities and spare parts inventories are reduced. The advantages are culminating in the incomparable availability of the Siemens’ gearless drive technology of 99.46 to 99.71% - as confirmed by real operational data from the Antapaccay mine in Peru. It was the first plant worldwide to use gearless drives for both applications.INTRODUCTION – THE GEARLESS PRINCIPLE The principle idea behind a gearless drive system is to reduce the number of components and diversity of parts. Especially those components that are at the edge of current manufacturing or power limits are eliminated. The used equipment provides the possibility to scale up and increase the power transmitted to the driven machine. This finally results in a possible increase of throughput respectively transported or processed material. In order to apply this principle of simplification we will take a look at the components of a conventional drive system consisting of: - Driven equipment (mill, conveyor, slurry pump) - Components altering the rated speed (gearboxes, girth gear / pinion) - The electric motor - Starting devices for the motor (VSD, CCV, LRS, clutch), which are necessary because a direct across-the-line start of high power motors with load would result in a significant drop in the line supply voltage - Alternatively a variable speed drive (VSD) or cycloconverter (CCV) to utilize the possibility of speed variation during operation - The electrical supply system (cables, switchgear, transformers, protection equipment)"

Jan 1, 2014

By C. Dirscherl

"Declining ore grade, leading to increased material transport and plant throughput requirements, is one of the major challenges in the current mining environment. This is accompanied by rising energy and labor costs, decreasing plant productivity and the requirement for highest plant availability. Siemens’ answer is the latest gearless drive technology for grinding and conveying. Gearless drive solutions are surpassing the mechanical limits of conventional drive systems serving to utilize the principle of economies of scale. By elimination of various components of the drive train, the maintenance activities and spare parts inventories are reduced. The advantages are culminating in the incomparable availability of the Siemens’ gearless drive technology of 99.46 to 99.71 percent — as confirmed by real operational data from the Antapaccay Mine in Peru. It was the first plant worldwide to use gearless drives for both applications.The gearless principleThe principal idea behind a gearless drive system is to reduce the number of components and diversity of parts, especially those components that are at the edge of current manufacturing or power limits are eliminated. The used equipment provides the possibility to scale up and increase the power transmitted to the driven machine. This finally results in a possible increase of throughput respectively transported or processed material.In order to apply this principle of simplification, the components of a conventional drive system are examined. They consist of:• Driven equipment (mill, conveyor, slurry pump).• Components altering the rated speed (gearboxes, girth gear/pinion).• The electric motor.• Starting devices for the motor (VSD, CCV, LRS, clutch), which are necessary because a direct across-the-line start of high power motors with load would result in a significant drop in the line supply voltage.• Alternatively a variable speed drive (VSD) or cycloconverter (CCV) to utilize the possibility of speed variation during operation.• The electrical supply system (cables, switchgear, transformers, protection equipment)."

Jan 1, 2015

By C. Dirscherl

"Declining ore grade, leading to increased material transport and plant throughput requirements, is one of the major challenges in the current mining environment. This is accompanied by rising energy and labor costs, decreasing plant productivity and the requirement for highest plant availability. Siemens’ answer is the latest gearless drive technology for grinding and conveying. Gearless drive solutions are surpassing the mechanical limits of conventional drive systems serving to utilize the principle of economies of scale. By elimination of various components of the drive train the maintenance activities and spare parts inventories are reduced. The advantages are culminating in the incomparable availability of the Siemens’ gearless drive technology of 99.46 to 99.71% - as confirmed by real operational data from the Antapaccay mine in Peru. It was the first plant worldwide to use gearless drives for both applications. KEYWORDS: Gearless Mill Drives, Gearless Conveyor Drives, Availability, SAG Mill, Ball Mill, Overland Conveyor, Antapaccay INTRODUCTION – THE GEARLESS PRINCIPLE The principle idea behind a gearless drive system is to reduce the number of components and diversity of parts. Especially those components that are at the edge of current manufacturing or power limits are eliminated. The used equipment provides the possibility to scale up and increase the power transmitted to the driven machine. This finally results in a possible increase of throughput respectively transported or processed material. In order to apply this principle of simplification we will take a look at the components of a conventional drive system consisting of: - Driven equipment (mill, conveyor, slurry pump…) - Components altering the rated speed (gearboxes, girth gear / pinion) - The electric motor - Starting devices for the motor (VSD, CCV, LRS, clutch…), which are necessary because a direct across-the-line start of high power motors with load would result in a significant drop in the line supply voltage - Alternatively a variable speed drive (VSD) or cycloconverter (CCV) to utilize the possibility of speed variation during operation - The electrical supply system (cables, switchgear, transformers, protection equipment) Intermediate gearboxes are not required when a motor is used with a rated speed that directly matches the speed requirement of the driven equipment. Furthermore the VSD can be used to smoothly start the motor and to vary speed during operation, which means that it satisfies both requirements."

Jan 1, 2015

By Terry L. Cook

RAG Coal West, Inc., Belle Ayr Mine is located in the heart of Wyoming’s rich Powder River Basin coalfield. Belle Ayr utilizes an open pit, truck/shovel operation to strip the overburden off the 70’seam of sub bituminous coal. Our excavation capacities consist of a 301 Marion with a bucket size of 52 cubic yards, and a 4100 XPB P&H with a capacity of 76 cubic yards. Production levels on these machines are closely monitored utilizing the Modular Mining Dispatch system. RAG Coal West, Inc. is a coal mining business that utilizes the effectiveness of teams as one of their strategies. Technicians have a certain amount of control over their own Team Process. The Drilling & Blasting Team is an assortment of blasters with varying experience levels. We have been able to think outside of the box when it comes to certain “proven” methods of blasting.

Jan 1, 2004

By S. A. Ziebold

There is often a need to increase capacity through existing mist eliminator installations without significant tower modifications. Often there is not enough extra space outside existing vessels unless more expensive changes can be justified. Also, plant downtime must be considered. The challenge in retrofitting is to overcome velocity limitations inherent in the design while at the same time extend performance capability. The solution most often is to create new ways to add extra filter area while remaining constrained to the existing space. This strategy, however, can dangerously backfire if basic design principles are not followed. Mist eliminator design is a complex integration of many conflicting performance parameters. Often the objective is to increase scrubbing capacity while maximizing collection efficiency and service life and minimizing operating pressure drop (energy cost), particle regeneration (re-entrainment) and overall maintenance costs. Results of plant retrofitting using mesh pads, impaction fibre beds and diffusion fibre beds are presented based on actual plant projects. Often the retrofit project can be more effective by increasing the scope and combining other new plant equipment with the upgrade such as new tower components. In some cases, the type of mist eliminators can be upgraded from impaction type (velocity dependent) to Brownian diffusion type (velocity independent) if additional downstream protection or reduced emissions are desirable, especially at turndown rates. Trade-offs between different fibre bed types and styles are discussed as they relate to performance and maintenance.

Jan 1, 2007

By J Wheeler

The objective of this paper is to examine the operation of high frequency screens in closed circuit grinding, where the outcomes achieved indicate favourable economic gains at the comminution stage and downstream processes, including flotation, dewatering, and filtration operations. The classification process in grinding circuits has been slowly evolving within the last century. The history of classification devices brings to mind rake classifiers and spiral classifiers, which although having higher efficiencies compared to hydrocyclones, were not able to keep pace with the evolution of concentrator equipment treating higher tonnages. This higher tonnage throughput has tended to drive the concept of utilising hydrocyclones as the classification stage in closed grinding circuits. The comminution process is commonly the most energy intensive stage of mineral processing. Researchers have determined that the classification stage in the comminution process has the greatest potential for improvement. This paper is intended to inform mineral process engineers of the benefits that high frequency screens offer over hydrocyclones. This will be done by reviewing the purpose for the evolution of classification in the comminution process, documenting past and recent studies, and explaining the modern technology that is currently available.

Aug 8, 2011

By Mark Coleman

Pnuematic Conveying and Process Injection Technologies have been implimented in the metals markets for the last 40 years and have consideribly improved the productivity and the performance of many processes. There have been many steps forward in handling technology and this paper seeks to consider those now offered by Clyde Materials Handling who as an established customer-driven solutions provider, which has turned its attention to supporting the Metals Market. Clyde seek to utilises its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries. With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets. Operators within the metals market have developed and deployed pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustain-able solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes. Operators, such as Codelco in Chile, Corus Steel in the UK, and many others across the World have seen pneumatic injection solutions transform their process and costs. To inject a consistent, pulseless and accurate flow of material to a copper concentrate bath smelter, or injecting granular or pulverized coal as a coke substitute in to a blast furnace via the Tuyeres helps to increase the operational capacity, availability and productivity and reduce the cost of the operation. This paper will discuss and highlight the ways in which pneumatic conveying and injection technologies, created by Clyde Materials Handling, and applied in partnership with the customer, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Lead and Zinc Industries. With examples from Zinc Fuming in Australia, Zinc Calcine and Powder Handling in Korea, Precision coal injection to QSL and TSL Furnaces, and metered distribution of Zinc Calcine to Reactors.

Jan 1, 2008

By M. E. Coleman, G. Money

Pneumatic Conveying and Process Injection Technologies have been implemented in the metals markets for the last 40 years and have considerably improved the productivity and the performance of many processes. There have been many steps forward in handling technology and this paper seeks to consider those now offered by Clyde Materials Handling who as an established customer-driven solutions provider has turned its attention to supporting the Metals Market. Clyde seeks to utilise its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries.

Jan 1, 2008

By M. E. Coleman, G. Money

"Clyde Materials Handling is an established customer-driven solutions provider, which utilizes its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries.With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets.Clyde Materials Handling has supported operators within the metals market by developing and deploying pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustainable solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes.Clyde Materials Handling has worked closely with their customers, such as Codelco in Chile, where their pneumatic solutions have been used to inject a consistent, pulseless and accurate flow of copper concentrate into a bath smelter, which has helped to fuel the operational capacity, availability and productivity.This paper will discuss and highlight the ways in which pneumatic injection technologies, created by Clyde Materials Handling, and applied in partnership with their customers, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Peirce Smith Converter.Clyde Materials Handling has applications injecting Electronic Scraps, Dusts, Reverts, and other additives to the Peirce Smith Converter. They also have experience of modified PS Units used for Slag Cleaning. There experience with the Codelco Teniente Converter is also directly related to this area of operation."

Jan 1, 2009

By H. Sato, Y. Sato, T. Ooishi, K. Sakamoto

"Sumitomo Metal Mining Co., Ltd.(SMM)'s Niihama Nickel Refinery(NNR) produces high quality Nickel cathode, Cobaltcathode and other by-products using hydrometallurgical refining process called “MCLE”(Matte Chlorine Leach and Electro-Winning). In 2005,NNR started to use nickel and cobalt mixed sulfide (MS) produced by one of the SMM’s subsidiaries Coral Bay Nickel Corporation(CBNC)’s HPAL plant in Philippines, although its main and the only raw material until then was nickel matte. With start-up of the second HPAL plant at Taganito in 2013, NNR expanded its production capacity of nickel cathode from 41,000 to 65,000 tpa and finally achieved its target in 2015 by producing 65,980 tpa. SMM developed the technologies to improve poor reactivity of MS and installed new facilities to cope with increased Cobalt and Sulfur production at that time. This paper describes the technical approach to increase MS treatment with high efficiency.INTRODUCTIONThe Sumitomo Metal Mining Co., Ltd.(SMM)Niihama Nickel Refinery(NNR) produces Nickel cathode, Cobalt cathode and other by-products using Matte Chlorine Leach and Electro-Winning (MCLE) process technology. SMM uses nickel matte and nickel & cobalt mixed sulfide (MS) as raw materials for the MCLE process. Table 1 shows typical composition of these raw materials. Nickel matte had been only raw material until 2005, and with start-up of Coral Bay Nickel Corporation (CBNC) operation in the Republic of the Philippines, MS became major part of it. In 2009, when CBNC doubled its production capacity, NNR also expanded its plant capacity of electrolytic nickel from 36ktpa to 41ktpa, keeping an eye on the possibility of 65ktpa with oncoming SMM’s second HPAL in Philippines. Poor reactivity of MS was the prime concern at that time because our intention was to increase production with MS. Nickel extraction rate deteriorated with increasing usage ratio of MS in raw materials. To keep high nickel extraction rate under high ratio of MS, NNR developed a new leaching technology. Another concern arising from treatment of MS was Cobalt and Sulfur contents that are much more than those of nickel matte as shown in Table 1.NNR introduced new technology of solvent extraction process as to Co/Ni separation process in order to keep cost competitiveness instead of the conventional cobalt oxidation–neutralizing method. As to sulfur products, new sulfur productive facility was installed to improve the exposure to sulfur dust and the hot working conditions for workers. As a result of process development and installation of new facilities against the problem with MSusage,65 ktpa production was achieved in 2015."

Jan 1, 2017

By John L. Floyd

The use of explosive energy to displace overburden or waste material can provide substantial savings to operations which normally rely on mechanical means for material removal. To optimize the available explosive energy, it is important to quantify the rock's response to the type of explosive and explosive accessories used. During a blast, rock breakage and movement occur so rapidly that the naked eye cannot detect the details of the fragmentation process. A relatively high speed motion picture camera (500 frames per second) can provide the extended time base needed to analyze in detail the site-specific rock response to the explosive detonation. The data of importance to blast casting that can be quantified from these films includes initial face movement, trajectory of rock, and differential face velocities of the material shot. In addition, the ground swell velocities, stemming confinement, and stemming ejection velocity can be determined. The performance of explosive products and delay element accuracy can also be ascertained. The use of high speed motion picture photography and analysis can reduce the number of field trials necessary to maximize explosive performance and increase the benefit provided by blast casting, and in turn, lower production costs. This paper will discuss the methods used for data accumulation and analysis. In addition, three field studies conducted at three separate mining operations will be presented.

Jan 1, 1988

By E. Benguerel, G. Monteith, L. Centomo, S. Pelletier

In early 2007, it became apparent that with changing concentrate feeds, the magnesium (Mg) load projected for CEZinc starting in 2009 and beyond would quadruple and overwhelm the current Mg process bleed capacity. A project was started, following design for six sigma (DFSS) standards, to select both the optimal process and to evaluate its target capacity for the Mg bleed circuit. The economic and process risks of under or over-designing while Mg reduction efforts were underway at the mines also needed to be evaluated. This paper describes the project methodology, the impact on the plant, and some potential optimizations for CEZinc's basic zinc sulphate (BZS) Mg bleed process.

Jan 1, 2008

By H. L. Riley, B. W. Gandrud

As far as the present writers know, this system of flotation has not been used elsewhere in this country, but in the last couple of years it has been introduced, with minor variations, at one plant in England and one in Wales. The system has been described and discussed in a number of publications. The following is quoted from an abstract of the latest of these," a paper presented at an International Conference on Industrial Combustion in 1952. On the basis of experience to date with the commercial plants, it is believed that the kerosene-flotation process incorporates all the necessary elements to make it greatly superior to anything else now available for treating of fines in wet processes of coal preparation. Additional study and investigation are still needed, however, to determine if certain phases of the process can be improved to such an extent as to make it generally satisfactory and acceptable to the industry. Further improvements will be needed with respect to the capacities of the flotation cells and the reagent consumption.

Nov 1, 1955

The recovery of coarse particles has been widely recognized as being limited by the froth in mineral flotation. In response to this, FLSmidth has developed the Selective Froth Recovery (SFR) System. The SFR System is an extraction system that vacuums material from select locations within the froth and separates the recovered solids into coarse and fine fractions with a hydrocyclone. The SFR is supported and located by an actuator connected to the cell?s level control so that the suction heads are maintained at an offset distance from the slurry level. This can increase the recovery of coarse material by selectively recovering the material close to the bottom of the froth where drop-back of coarse particles typically takes place. The SFR System has been tested at two separate mine sites, and has been proven to increase the copper recovery in both trials. TEST RESULTS The SFR prototype was installed in a copper recovery circuit, on a rougher scavenger 160-m3 flotation cell. Figure 1, shows the SFR System, which consists of four conical skimmer heads that are plumbed together and share a common actuator. The SFR System, raised out of the froth prior to a test, can be seen in Figure 2. The SFR prototype was able to maintain a variety of set points using the level control to determine the slurry height.

Feb 27, 2013

By Michael McDonald

The cold-rolled steel output of cold-rolling mill (CRM) complexes are sometimes constrained by their batch annealing facilities (BAF). This paper examines a cost-effective solution to increasing capacity and quality of the BAF thereby making additional capacity available for CRM output. The solution involves applying a structured system of scheduling and operation to the BAF, using a proven level-2 software model. The system presented has been applied to a wide variety of BAF with all the leading furnace brands. Whether using traditional HN atmosphere or 100% hydrogen, peak performance can be achieved when using a properly configured, on-line, physical thermodynamic model. Given that it is not practical to place a thermocouple in each coil that is being annealed, various methods have historically been used to estimate the time required to properly anneal all the coils in the charge. This paper examines how the latest technology, in wide use throughout the USA, uses a physical thermodynamic model to shorten average cycle times, thereby increasing productivity and reducing energy consumption. The paper also examines the benefit of building thermodynamically balanced charges to further optimize the BAF operation and improve quality consistency by decreasing mechanical property variations.

Jul 30, 2018

By J. Contreras

In the period 2003-2004, the situation of the copper concentrate market was unfavourable for smelters and refineries, with low TC/RC values and euro-dollar parity affecting European companies negatively. Within this scenario, Atlantic Copper decided to develop a plan to increase its competitiveness and to improve its results in these market circumstances. The plan affected all departments in the Company and was based mainly on cost reduction in energy and manpower. A general analysis of the Complex's overall efficiency was carried out and, based on this analysis, two major Projects emerged, "Primavera" and "KF". Each Project consisted of smaller sub-projects which aimed at improving the areas which could perform better according to our general analysis. The paper describes how this entire project developed and the final results obtained by the Company.

Jan 1, 2007

By T. Boyd, K. McTaggart, J. Qiu

"Hudbay Minerals’ Flin Flon process plant produces a copper concentrate and zinc concentrate from the three ores it processes: 777, Reed and Lalor. Unlike many Cu-Zn ores, the average Zn: Cu ratio in feed is around 2:1, whereas, in many Cu-Zn separation plants the Zn: Cu feed grade is substantially higher than 2:1. The lower Zn: Cu in plant feed is a challenge for limiting Zn recovery to the Cu concentrate. While total recoveries of Cu and Zn at Flin Flon are very good; selectivity is the key challenge and small changes in ore or plant, can result in quite variable Zn recovery to Cu concentrate, and accordingly, Zn recovery to Zn concentrate. Magnetic conditioning has been shown to be selective between the two paramagnetic minerals chalcopyrite and sphalerite. Statistical testing of magnetic conditioning was undertaken at Flin Flon with the objective of increasing Cu recovery to Cu concentrate without increasing the Zn recovery to Cu concentrate - in effect increasing Cu-Zn selectivity. This has been achieved elsewhere with magnetic conditioning with the probable mechanism being an increase in fine chalcopyrite recovery, and a reduction in entrained, ultrafine, non-activated sphalerite to Cu concentrate. The results did indeed show an increase in Cu recovery to Cu concentrate of 0.8% to high confidence, but the decrease in Zn recovery to Cu concentrate was not to high confidence. This is effectively an increase in Cu: Zn selectivity in the Cu circuit – higher Cu recovery with no change in Zn recovery. However, while there was an increase of 1% in Zn recovery to Zn concentrate with magnetic conditioning, the variability in this parameter meant that this increase, though larger in magnitude than the Cu result, was not to high confidence."

Jan 1, 2019

By Thomas Read

PERSONNEL work is a term recently introduced to cover the great variety of activities in industrial work that deal with the human factor. Much attention has been focussed upon individual phases of personnel work, such as accident prevention, sanitation, "welfare" work, reducing labor' turnover, and so on. In most cases these activities have been carried on as though they were distinct and separate fields; as a matter of fact, they are only different phases of the single problem of human engineering, and each has important and fundamental relations with the others. Thus, for example, high labor turnover is one of the most .important causes of a high accident rate, and unsatisfactory housing conditions are an important cause of labor turnover. In the early stages of the study of these problems, it was necessary to take them up separately; the time has now arrived at which it is desirable to consider them as a whole in order to bring them into the right relation to each other. When thus considered as phases of an interrelated whole, they may be grouped as personnel work. A discussion of the importance of personnel work as a means of in creasing dividends in industry may be objected to by some as a too materialistic way of looking upon work that is humanitarian. Nothing could he more mistaken than such an opinion. Humanitarianism, per se, has no place in industry, and nothing is gained and much is lost in pre tending that it has. The only reason why a corporation engages in business is to make profits, and any activity of the corporation that does not tend either directly or indirectly toward that end is poor business. It is equally poor business to overlook any activities that do tend indirectly to the making of profits. On this basis, personnel work can be justified as a corporate activity; there is no justification whatever for abstract humanitarianism from the business standpoint. One characteristic of the American workman is a general high level of intelligence, and it is an insult to intelligence to ask a man to believe that anything so impersonal as a corporation is really desirous of benefiting

Jan 10, 1917