com 2009: technical program - tuesday, august 25,...

Tuesday, August 25, 2009 AM

HYDROMETALLURGY of Nickel and Cobalt Symposium including the Processing of Valuable By-Products Containing Materials Presentations from 8:30:00 AM to 12:00:00 PM - Fraser Lower SULPHIDES Abstract ID: 1747 Nickel and Cobalt Recovery from a Bulk Cu-Ni-Co Concentrate Using the CESL Process D. Jones1, S. Knoerr2, K. Mayhew2, L. O'Connor2 and T. Williams2. 1Teck Corporation, 2CSIRO Minerals Presenting from 8:30:00 To 8:55:00 - Tuesday CESL has developed a hydrometallurgical process for treating Copper and Nickel sulphide concentrates, including bulk concentrates. Both Cu and Ni are leached efficiently into solution, using a proprietary pressure oxidation process, along with other base metals, notably Co. A previous publication (2002) has described the Cu recovery from a low grade bulk concentrate, Mesaba, using this CESL Process, including an extensive piloting campaign. Ni and Co recovery from the same solution was contemplated at the time, but not finalized. This paper will describe the latest work at CESL on Ni and Co recovery from the same concentrate. The flowsheet includes Ni -Co separation, and describes available options for Ni products. Abstract ID: 1721 The Recovery of Cobalt from Baja Mining Corp's El Boleo Project D. Dreisinger1, R. Molnar2, T. Gluck1, K. Baxter3 and J. Riordan4. 1Baja Mining Corporation, 2SGS Lakefield Research Limited, 3Bateman Engineering Pty Ltd, 4Bateman Solution Purification Group Presenting from 8:55:00 To 9:20:00 - Tuesday The Boleo Copper-Cobalt-Zinc-Manganese Project of Baja Mining Corp. is situated adjacent to Santa Rosalia on the Baja Peninsula of Mexico. The El Boleo ore is a mixed oxide-sulfide deposit with major values in copper, cobalt, zinc and manganese. The metallurgical process designed to treat the El Boleo orebody involves a sulfuric acid leach in seawater using oxidative and then reductive leaching to maximize metal extraction. The leach solution is separated from the barren solids via counter current washing through a series of high rate thickeners. Copper is recovered using conventional SX-EW processing as cathode. Zinc and cobalt are extracted from the copper SX raffinate after iron and aluminum precipitation. The CSIRO DSX solvent system (Versatic® 10 and LIX® 63 mixture) are used in this extraction. Manganese remains in the DSX raffinate and is recovered by soda ash addition as a high quality manganese carbonate precipitate. Zinc and cobalt are acid stripped from the loaded DSX solvent. Zinc is then re-extracted away from cobalt using Cyanex® 272 extractant and stripped into a highly concentrated strip liquor (+100 g/L Zn) and directed to either a spray dryer or a granulator for production of zinc sulfate monohydrate. The zinc solvent extraction raffinate, containing cobalt, advances to a further SX circuit using Cyanex® 272, for the recovery of cobalt as cobalt cathode. In this paper, the detailed results from bench and integrated pilot plant testing for cobalt recovery from the El Boleo ore will

COM 2009: Technical Program - Tuesday, August 25, 2009

be described. The results will highlight the use of solvent extraction and specialty ion exchange resins to recover high purity cobalt electrolytic cathode. The results of this testing are currently being used to engineer the commercial plant at El Boleo. Abstract ID: 1751 Reductive Leach Process for Improved Recovery of Nickel and Cobalt in the Sherritt Hexammine Leach Process J. Budac1, R. Kofluk1 and D. Belton1. 1Sherritt International Presenting from 9:20:00 To 9:45:00 - Tuesday A new process has been developed, at Sherritt, which can improve the extractions, across the ammonia leach process, for nickel and cobalt from 99.3% to 99.8% and 96.5% to 98.6% respectively. The new process involves treatment of the refinery tailings with a reductive leach step followed by selective precipitation of iron to leave nickel and cobalt in solution. An extra benefit of the new process is that by including a floatation step unreacted sulphides can also be collected and recyled back to the head of the leach circuit. Abstract ID: 1726 Pressure Oxidative Leaching of Slags from Nickel Smelters: An Update I. Perederiy1, V. G. Papangelakis1 and C. Jia1. 1University of Toronto Presenting from 9:45:00 To 10:10:00 - Tuesday Smelter and converter slags produced at non-ferrous smelters inevitably contain entrapped base metals, such as Ni, Co and Cu. It has been found that base metal entrapments occur in the form of localized sulfide (matte) inclusions as well as oxides evenly dispersed in fayalite. These metals can be extracted from both types of slags by means of pressure oxidative acid leaching. However, the metals in the form of oxide can be extracted only if the fayalite matrix is completely dissolved in sulfuric acid. Moreover, the addition of oxygen at high temperatures (~250°C) enables the regeneration of sulfuric acid through hematite precipitation which is essential to high metal/Fe ratios of the leachate. The extent of acid regeneration and the effect of oxygen overpressure on iron oxidation were investigated in detail. Abstract ID: 1722 Recovery of Cobalt from Polymetallic Concentrates - NiCo Deposit, NWT, Canada - Pilot Plant Results R. Molnar1, M. Canizares2, A. Mezei2 and M. Samuels3. 1SGS Lakefield Research Limited, 2SGS Mineral Services Lakefield Laboratory, 3Fortune Minerals Limited Presenting from 10:30:00 To 10:55:00 - Tuesday This paper provides an overview of the NICO deposit process development work throughout the past decade, with emphasis on the latest results on the recovery of cobalt. The results presented in the paper were produced by an integrated pilot plant carried out in 2008. The NICO “IOCG” (iron oxide - copper - gold) type deposit is located in the Mazenod Lake district near the Snare hydroelectric complex, approximately 160 km northwest of Yellowknife, Northwest Territories, Canada. Cobalt is recovered by flotation into a concentrate wherefrom it is leached by pressure oxidation followed by solution purification (involving copper solvent extraction and iron removal), ion exchange, precipitation and electrowinning.


The pressure oxidation occurs with selective rejection of arsenic and iron allowing environmentally acceptable tailings disposal as ferric arsenate. The process relies entirely on commercially proven unit operations and equipment and the integrated pilot exercise proved its technical feasibility. This paper summarizes the results of the purification of the cobalt solution and its electrowinning as cathode. Abstract ID: 1718 The Recovery of Nickel And Cobalt from the Northmet Deposit Using the Platsol™ Process with Production of Mixed or Separate Nickel and Cobalt Hydroxides D. Dreisinger1, R. Molnar2, A. Mezei1, K. Baxter3 and M. Wardell-Johnson3. 1University of British Columbia, 2SGS Lakefield Research Limited, 3Bateman Engineering Pty Ltd Presenting from 10:55:00 To 11:20:00 - Tuesday The NorthMet deposit of PolyMet Mining contains a large reserve of copper-nickel-cobalt-precious metal mineralization. Historically it has been difficult to recover separate copper and nickel concentrates of a quality broadly acceptable to custom smelters using conventional mineral processing techniques. Recently, improved flotation methods have yielded the ability to produce separate and saleable concentrates during a projected initial startup period for the NorthMet deposit. However, after the initial transition period, it is expected that production of a bulk flotation concentrate followed by PLATSOL™ hydrometallurgical treatment will be used to produce copper, nickel/cobalt and precious metal products. The PLATSOL™ process uses chloride-assisted total pressure oxidation treatment of a bulk concentrate to digest the base and precious metal content of the bulk concentrate into an autoclave solution. Following solid-liquid separation, the solution is then treated sequentially for precious metal recovery by reductive precipitation, copper solvent extraction and electrowinning and finally, nickel and cobalt recovery by precipitation. During the pilot plant testing of the PLATSOL™ process for NorthMet bulk concentrate treatment, two variations on nickel and cobalt recovery were tested including mixed hydroxide precipitation with magnesia and separate nickel and cobalt hydroxide precipitation following solvent extraction separation with Cyanex 272. The results of the pilot plant testing of the nickel and cobalt recovery circuits for NorthMet are presented. Abstract ID: 1701 Sulfur Dispersing Agents in the Oxygen Pressure Leaching of Nickel Concentrate L. Tong1 and D. Dreisinger1. 1The University of British Columbia Presenting from 11:20:00 To 11:45:00 - Tuesday The properties of nickel concentrate and sulfur dispersing agents, including lignosulfonate, Quebracho, ortho-phenylenediamine (OPD) and humic acid, were investigated. The adsorption mechanism of sulfur dispersing agents on elemental sulfur and nickel concentrate was discussed. The effect of sulfur dispersing agents on dispersing molten sulfur was evaluated by the interfacial studies. Both organic materials and inorganic materials have the ability to change the sulfide mineral surface from sulfophilic to sulfophobic. The effect of sulfur dispersing agents on nickel extraction was evaluated in pressure leaching experiments conducted in a 2 L batch autoclave. The stability of sulfur dispersing agents was discussed.


HYDROMETALLURGY of Nickel and Cobalt Symposium including the Processing of Valuable By-Products Containing Materials Presentations from 8:30:00 AM to 12:00:00 PM - Room F441 PURIFICATION Abstract ID: 1692 Extraction of Nickel with Pre-neutralized Organic Acids using Outotec Mixer Settler Technology E. Paatero1, B. Nyman2, H. Laitala1, J. Tamminen3, E. Ekman2 and T. Kankaanpaa2. 1Outotec Oyj, 2Outotec Research Oy, 3Lappeenranta University of Technology Presenting from 8:30:00 To 8:55:00 - Tuesday Good pH control is essential for selectivity in the extraction of metals using reagents that are organic acids. Common industrial reagents in this category are di(2-ethylhexyl)phosphoric acid, bis(2,4,4trimethylpentyl)phosphinic acid (the active compound in Cyanex®272 by Cytec and in Ionquest® 290 by Rhodia) and the tertiary carboxylic acids as the Versatic™ Acid 10 by Hexion Specialty Chemicals. In order to avoid precipitation in the extraction apparatus, the reagents are often used partly pre-neutralized, e.g., by ammonia or caustic soda solutions. When these extractants are partly saponified, they start behaving like surfactants and form microemulsion and other aggregate structures. As the partly pre-neutralized solution is contacted with a metal-containing feed solution, the complexation takes place in a pseudo-homogeneous environment allowing fast extraction kinetics. The paper describes the theoretical basis of the phase behavior involved in these systems using the extraction of nickel with Versatic Acid 10 as an example. The paper reports how this phenomenon can be exploited in the Dispersion Overflow Pump (DOP®) unit of the Outotec mixer-settler for nickel extraction with illustrations from pilot size experiments. The extraction process was visually followed by taking high-speed photos of the dispersion inside the DOP as well as by recording the rate of extraction based on chemical analysis of samples from the DOP outlet channel. Abstract ID: 1742 Manganese Removal From Nickel Laterite Mixed Hydroxide Precipitation Circuit By Oxidative Precipitation with SO2/Air W. Zhang1, D. Robinson1, D. Muir1 and D. Collinson1. 1Commonwealth Scientific and Industrial Research Organisation (CSIRO) Presenting from 8:55:00 To 9:20:00 - Tuesday Soluble manganese(II) in nickel laterite high pressure acid leach solution is one of the major impurities which would partially co-precipitate with nickel and cobalt in the mixed hydroxide precipitation (MHP) to affect the quality of the MHP product for subsequent refining process and limitation to the nickel/manganese ratio in the feed ores for using MHP technology. Investigations have been carried out to examine the feasibility to partially remove soluble manganese(II) before MHP at two possible neutralisation stages: (1) primary neutralisation at pH 3.0 and 80°C and (2) secondary neutralisation at pH 4 and 60°C. The rate of manganese oxidative precipitation with SO2/air from the primary neutralisation slurry was very slow at pH <3.5 and 80°C, most likely due to the slow mass transfer of oxygen in air through the viscous slurry at relatively high temperature. The oxidation rate was substantially improved by


using the secondary neutralisation solution at 60°C, depending on the solution pH. At pH 3 and 60°C with 3.8% SO2 in air, only about 15% of manganese was precipitated within 240 minutes with a few percent co-precipitation of nickel and cobalt. At pH 4, about 56% of the manganese was precipitated within 240 minutes with 10% nickel and 25% cobalt co-precipitations. All the nickel and about half of the cobalt in the precipitate could be recovered by recycle leaching with 30 g/L H2SO4 at 95°C. About 35% of the manganese precipitated was leached, indicating that about 65% of the manganese precipitated was in insoluble MnO2 form. The laboratory results have shown that the partial removal of manganese by oxidative precipitation before MHP is potentially applicable. The system needs further investigations to optimise the conditions for more efficient removal of manganese by the oxidative precipitation with minimum loss of nickel and cobalt. Abstract ID: 1680 Nickel and Cobalt Sulphide Precipitation. A Proven Method of Selective Metal Precipitation in Laterite Process Flowsheets N. Molina1. 1AMEC Americas Presenting from 9:20:00 To 9:45:00 - Tuesday The precipitation of Nickel and Cobalt as Mixed Sulphides with Hydrogen Sulphide gas have been used successfully at Moa Bay, Cuba, since the plant started operations in 1959. Two other HPAL laterite processing plants, Murrin Murrin in Australia and Coral Bay on southern Palawan Island , Philippines, are using a similar process route whilst a new plant, Ambatovy, currently under construction near Toamasina in Madagascar contemplate also a mixed Sulphide precipitation stage in the flow sheet. This paper analyses the impact of the main process parameters on the Nickel and Cobalt recovery and at the same time makes a comparison between the high pressure and low pressure systems currently in use. The paper also incorporates some comments on issues to be taken into consideration during the plant design. Abstract ID: 1730 The Development of an SSX System for the Separation and Purification of Nickel and Cobalt from Laterite Leach Solutions C. Cheng1, G. Boddy2, W. Zhang1, M. Godfrey1, D. Robinson1, Y. Pranolo1 and Z. Zhu1. 1Csiro Minerals, 2Rio Tinto Technology and Innovation Presenting from 9:45:00 To 10:10:00 - Tuesday The synergistic solvent extraction system consisting of Versatic 10/LIX63/TBP was used for the separation and purification of nickel and cobalt from synthetic laterite leach solution after iron removal. Batch, semi and fully continuous tests were conducted to optimise operating conditions. Very encouraging results were obtained for separating nickel and cobalt from manganese, magnesium and calcium. In batch tests, the organic composition of the synergistic system was optimised and very large synergistic shifts for nickel and cobalt were observed. The ΔpH50(Mn-Co) and ΔpH50(Mn-Ni) values were as large as 1.65 and 2.40, respectively. The extraction kinetics of nickel and cobalt was fast with 91% nickel and 97% cobalt extracted within 30 seconds. The stripping kinetics of nickel and cobalt was also fast: after 2 minutes of mixing, 92% nickel and 98% cobalt were stripped. Semi continuous extraction tests were conducted using the synergistic organic system consisting of 0.50 M Versatic 10, 0.45 M LIX63 and 1.0 M TBP in Shellsol D70. With a pH profile of 5.5/5.9/6.3 in three stages at 40°C, the nickel and


cobalt extractions reached 99.9% with only 5 mg/L nickel and <1 mg/L cobalt left in the raffinate. With two stages of scrubbing, two minutes of residence time, a pH profile of 5.4/5.0 at 40°C, about 2 mg/L manganese and less than 1 mg/L magnesium and calcium were left in the scrubbed organic solution. With two stripping stages, two minutes residence time and an O/A ratio of 10 at 40°C using 50 g/L H2SO4 as strip solution, the stripping efficiencies of nickel and cobalt reached over 95% (see paper for full abstract). Abstract ID: 1686 Cobalt Solution Purification: By Solvent Extraction or by Selective Precipitation? P. Louis1. 1PEL Consult Presenting from 10:30:00 To 10:55:00 - Tuesday Cobalt is usually a by-product of Cu or Ni hydrometallurgical plants. The largest Co reserves in the world are located in Central Africa where Co is associated with Cu with typically a ratio Cu/Co of 10. After leaching mixed ore, Cu is first removed by SX / EW and the acidic raffinate is recycled to leaching. From the Cu circuit, a Co bleed is done with treatment starting with acid neutralisation, Fe removal and Cu/Al precipitation. Afterwards solution has to be purified by selective precipitation or by SX before electrowinning or salt production. Cu present in the Co bleed can be recovered by SX or by lime precipitation. The SX route is cheaper but the precipitation route will allow substantial acid and lime savings. DEHPA and CYANEX are classical extractants used for solution purification. Direct or reverse SX can be considered and reagent can be added in the acidic form with pH control or after saponification. In the original selective precipitation process, there are two sulphide precipitations steps for Ni and Zn followed by Co lime precipitation and dissolution before electrowinning. High purity cobalt broken cathodes were produced. Different improvement can still be considered. The precipitation route is a simple proven environmentally friendly technology using mostly local produced reagents. Cobalt losses are, however, higher than with an optimized SX route. Some improvements in the precipitation route can nevertheless be expected. Abstract ID: 1743 Removal and Recovery of Manganese from Nickel Laterite Waste Solutions W. Zhang1, C. Cheng1 and Y. Pranolo1. 1Commonwealth Scientific and Industrial Research Organisation (CSIRO) Presenting from 10:55:00 To 11:20:00 - Tuesday The manganese concentration in nickel laterite process waste solutions has to be reduced to less than 10 mg/L to meet environmental guidelines for disposal. However this solution could also be viewed as a potential secondary source of manganese. Precipitation methods have been investigated and compared for removal and recovery of manganese from a typical synthetic laterite waste solution containing 2 g/L Mn, 15 g/L Mg and 0.5 g/L Ca at 60°C. We found the selectivity for manganese over magnesium and calcium by hydroxide or carbonate precipitation agrees with the thermodynamic predictions based on single metal solubility constants. However, we also found significant deviations in the measured and derived equilibrium concentrations of the metals in the synthetic effluent, suggesting the importance of the factors such as kinetics, ion interactions and condition controls in a real precipitation process. Significant precipitation of manganese hydroxide occurs at pH 8.2 with 71% Mn, 5% Mg and little calcium


precipitated. Less than 100 mg/L and 10 mg/L Mn were left in the solution at pH 8.5 and 9.1 with magnesium co-precipitation of 60% and 90%, respectively. Precipitation using carbonate showed better selectivity for manganese over magnesium than calcium. About 90% Mn was precipitated by carbonate at pH 8.0 with 13% Mg and 43% Ca co-precipitated. Less than 10 mg/L Mn was left in the solution at pH above 8.5 with 71% Mg and 97% Ca co-precipitated. Oxidative precipitation of manganese with air was slow at pH below 7: less than 10% Mn precipitated within 60 minutes. At higher pH, the rate increased due to both oxidisation and hydroxide precipitation at the expense of more co-precipitation of magnesium. The use of pure oxygen improved the oxidation rate, but higher pH was still needed to remove manganese to lower levels. In comparison, the rate of oxidative precipitation of manganese with SO2/air was fast at neutral pH 6-7 with a high selectivity for manganese over magnesium and calcium. The manganese precipitation rate reached maximum at pH 6.5 under the test conditions and 99.5% manganese precipitation (<10 mg/L) was obtained within 60 minutes (see the paper for the complete abstract). Abstract ID: 1745 Solvent Extraction Technology for Nickel and Cobalt Separation with Crowding Reaction N. Matsumoto1, S. Matsumoto1, N. Nakagawa1 and I. Sugita1. 1Sumitomo Metal Mining Co. Ltd. Presenting from 11:20:00 To 11:45:00 - Tuesday Sumitomo Metal Mining Co., Ltd. (SMM) developed its own solvent extraction process at Niihama Nickel Refinery. This process which is called "crowding organic bypass (COB)", produces 15,000t/Y of nickel sulfate. There are two advantages in COB process. One is the application of nickel and cobalt crowding reaction. The other is the intentional organic bypass from the stripping to crowding stage. As a result, high purified nickel sulfate is obtained. In addition, this process enables to reduce an operation cost and diminish the facilities size.

ENVIRONMENT - Green Technologies for the Mining and Metallurgical Industries Presentations from 8:30:00 AM to 12:00:00 PM - Room F335 SLAG, EAF DUST, WASTE GASES Abstract ID: 1855 Thermodynamic Analysis of the Reaction of Electric Arc Furnace Dust with Waste Polyvinyl Chloride Plastic M. Camball1 and C. A. Pickles1. 1Queen's University Presenting from 8:30:00 To 8:55:00 - Tuesday Waste plastics are a potential resource that could be utilized as reagents in extractive metallurgy processes. In particular, waste polyvinyl chloride (PVC) is a possible source of chlorine that could be used to chlorinate and separate the non-ferrous metals found in electric arc furnace dust. As the first stage in the study of this process, a detailed thermodynamic analysis has been performed in order to determine the most significant operating parameters and to define the optimum conditions for the recovery of the non-ferrous metals as metal chlorides. It is shown that under selected conditions of temperature, amount of PVC and oxygen potential, the zinc and lead can be recovered as chlorides. In


comparison to conventional selective dust reduction processes, the separation of the non-ferrous metals from the iron by chlorination can be less effective due to the formation of gaseous iron chloride. The calcium in the dust consumes chlorine as a result of the high stability of calcium chloride. Abstract ID: 2012 Agglomeration of Dusty Feeds at the Copper Cliff Nickel Refinery S. Mroczynski1. 1Vale Inco Presenting from 8:55:00 To 9:20:00 - Tuesday The Copper Cliff Nickel Refinery (CCNR) is required to lower particulate emissions from the main plant stack in order to comply with the new legislative requirements. Vale Inco has undertaken a research and development project to briquette a friable Clydach Nickel Refinery residue feed and provide an effective medium for adding this material to the top blown rotary converter (TBRC) without downgrading the throughput capability. Addition rates of this material are limited due to the dust loading in the electrostatic precipitators servicing both TBRCs. This paper focuses on the development of a briquetting operation to produce durable briquette that will hold together in the TBRC long enough to become assimilated by the molten bath before it has a chance to dust. The paper also addresses the problems encountered by the exothermic hydration chemical reactions within the briquette. Abstract ID: 1996 Research and Application of Dry Cold-Briquetting Technology for Converter LT Dust T. Chen1, Y. Zhang2, T. Liu2 and J. Huang2. 1Wuhan University of Science and Technology, 2Wuhan University of Technology Presenting from 9:20:00 To 9:45:00 - Tuesday Dusts collected through the Lurgi-Thyssen Steel Gas Process (LT method) during converter smelting are high in temperature, rich in metallics, liable to spontaneous ignition, and thus difficult in transportation and recycling. Through experiments, we developed a dry cold-briquetting technology for reutilizing the dusts. A production line has been built and in operation using this technology to produce 120,000 tonnes of briquettes per annum from LT dusts at Taiyuan Iron and Steel Company (TISCO). The briquettes produced can be used to substitute scrap iron, iron ores or flux. Successful recirculation and reutilization of the dusts by means of this technology in the process of converter smelting have achieved significant economic benefit. Abstract ID: 2018 Nickel Matte Granulation Off-Gas Characterization and Treatment C. Normand1, S. Seyer1, M. Comeau2 and M. Dubel2. 1Seneca, 2Vale Inco Presenting from 9:45:00 To 10:10:00 - Tuesday Reducing environmental impact of mineral ores transformation is a continuous and stimulating challenge at Vale Inco. Important capital expenditures are presently devoted to the installation of new equipments and technologies to ensure compliance with new Ontario environmental regulations. One project, presently at equipment acquisition stage, relates to selection of a new air pollution control system to reduce fine particulate emission from the nickel matte granulation process at Copper Cliff Nicckel Refinery The project was executed in collaboration with Seneca Engineering from Montreal. The


approach included scoping study and pilot testing of the most promising technologies. This article describes the methodology used in this application. Abstract ID: 1961 Piloting Regenerative SO2 Scrubbing at Xstrata Nickel D. G. Tisdale1 and V. Leveille2. 1Xstrata Nickel, 2Cansolv Technologies Inc. Presenting from 10:30:00 To 10:55:00 - Tuesday A pilot SO2 scrubbing unit was operated at the Xstrata Nickel Sudbury smelter to demonstrate the effectiveness of the technology in a non-ferrous smelter setting, treating industrial gas steams containing variable SO2 and dust concentrations. The unit was designed and constructed by Cansolv Technologies, based on their regenerative, amine-based scrubbing technology. The five-month demonstration campaign included treatment of slipstreams from two process gas streams at the smelter. The technology proved robust, with little down time while treating gas containing up to 250 mg/m3 of dust, and yielded a cleaned gas stream with less than 250 ppm of SO2.

PROCESS CONTROL Applications in Mining and Metallurgical Plants Presentations from 8:30:00 AM to 12:00:00 PM - Room A226 FLOTATION Abstract ID: 2005 (KEYNOTE) Towards the Optimization of Flotation Column Operation A. Desbiens1, R. del Villar1, M. Maldonado1 and J. Bouchard2. 1Universite Laval, 2Xstrata Process Support Presenting from 8:55:00 To 9:45:00 - Tuesday Even after having been used for several years in mineral processing plants, the full potential of the column flotation process is still not fully exploited. The difficulty of measuring some key variables is certainly an important reason to explain this situation. LOOP researchers have been working on this issue for more than ten years. Adequately measuring on-line variables such as froth depth, bias, gas hold-up, frother concentration, bubble surface area flux and bubble size distribution opens the way to various advanced control strategies and real-time optimization based on an economic criterion. This paper describes recent advances in that field. It also discusses some future investigative issues. Abstract ID: 2033 Model Predictive Control for Flotation Plants M. Lunch1, S. Gaulocher1, J. Pettersson1, H. Lindvall2 and E. Gallestey1. 1ABB, 2Boliden Mineral AB Presenting from 9:45:00 To 10:10:00 - Tuesday This contribution summarizes the results of a project for optimization of a froth flotation circuit. A model predictive control based approach has been developed and tested on a zinc flotation circuit in Sweden. The basic idea is to use air flows and chemicals to control the concentrate in the product and in the tailing. The activities in the project covered modeling, design, implementation, and tests at a customer site. The on-line model predictive controller implementation has been done using Expert Optimizer. The


result from the site test demonstrates the benefit of using model predictive control compared to the existing manual strategy. Abstract ID: 2046 Model Predictive Control of SAG Mills and Flotation Circuits M. Forbes1 and B. Gough1. 1Andritz Automation Presenting from 10:30:00 To 10:55:00 - Tuesday Precise control of SAG mill loading and flotation cell level is critical to maximize production and recovery in mineral concentrators. While expert systems are commonly used to optimize these process operations, the underlying regulatory control is often implemented using traditional proportional-integralderivative (PID) controllers or rule-based schemes in the expert systems themselves. This paper describes the use of a model-based predictive control (MPC) algorithm which has been proven to provide superior regulation for these processes. The controller is easy to apply due to its unique process modeling method based on Laguerre polynomials, with most applications installed in less than two weeks. Abstract ID: 1916 Online Measurement of Xanthate in Flotation Circuits by Means of UV Spectrophotometry B. Lalla1, B. Knights1 and C. Steenkamp1. 1Mintek Presenting from 10:55:00 To 11:20:00 - Tuesday Mintek is developing an instrument aimed at providing online measurements of the xanthate concentration in flotation circuits. The instrument employs spectrophotometry as the mode of measurement. Extensive laboratory test work has been conducted to ascertain the feasibility of developing the instrument, including an analysis of chemical interferences in the measurement, a differential analysis for disturbance mitigation, investigation of the reaction kinetics in treating samples, sampling filtration techniques, analysis of industrial samples and verification of results through comparative testing and longterm cycle analysis to verify its robustness. Abstract ID: 2010 Improved Flow and Flotation Monitoring for Process Efficiency Improvements Through New Technology Utilizing Non-Invasive Passive Arrays C. O'Keefe1, R. Maron1 and P. Rothman1. 1Cidra Minerals Processing Presenting from 11:20:00 To 11:45:00 - Tuesday New technology, based on arrays of passive sensors, has spawned new capabilities in flow and flotation monitoring, allowing a higher degree of process efficiency. This new technology, which performs accurate, robust, non-invasive flow measurements, gas volume fraction (entrained air) measurements, and other performance measurements, will be described. Its use in the presence of magnetic ore such as magnetite and pyrrhotite and in flow with entrained air to potentially increase the accuracy of mass balance calculations and enhance hydrocyclone performance will be detailed.

MANAGEMENT - Current Management and Human Resource Issues Presentations from 8:30:00 AM to 12:00:00 PM - Governor Lounge


Abstract ID: 1783 (KEYNOTE) Best Practices in Attracting, Recruiting, and Retaining Tomorrow's Workforce R. Montpellier1. 1Mining Industry Human Resources Council (MIHR) Presenting from 9:00:00 To 9:50:00 - Tuesday Over the next 10 years, the Canadian minerals and metals sector will face a significant skills shortage. To mitigate this gap, the industry must collectively take action to attract, recruit, and retain tomorrow's workforce. This presentation will provide details on the Mining Industry Human Resources Council (MiHR)'s latest labour market information, industry trends and employment forecasts. Mr. Montpellier will also highlight new research, conducted in collaboration with the Conference Board of Canada, into the most effective industry practices to attract, recruit, and retaining Aboriginal people, women, youth and new Canadians. The presentation will detail the research methods, key findings, and provide examples of innovative practices from leading mining companies in Canada. Abstract ID: 1785 Future Prospects: Preparing Workers for a Career in Mining S. Barnard1. 1Cambrian College Presenting from 9:50:00 To 10:15:00 - Tuesday In order to remain competitive, Canada\'s mineral industry requires access to a well educated, trained workforce. This presentation will outline how Cambrian College prepares new workers for the mining industry. President Barnard will demonstrate how industry partnerships are key to the development of new programs, and the continuous renewal of curriculum to ensure graduates are prepared for the workplace. Models, approaches and delivery strategies will be shared that address the needs of various learner groups including adult and aboriginal students. Integratration of technology into learning processes, Apprenticeship models, short courses and full time post secondary program approaches will be highlighted. Abstract ID: 1837 Canadian University Students' Perspective on the Metallurgical Industry A. Oliazadeh1. 1University of Toronto Presenting from 10:15:00 To 10:40:00 - Tuesday In Canada, each year hundreds of students graduate with technical skills strongly applicable to the metallurgical industry. However, the students may or may not know what to expect from this field based on their academic experience and exposure to the industry. Many students might have already selected a career path in the metallurgical industry, while others may not be attracted to it. This presentation summarizes and discusses the results of a survey undertaken among Canadian university students. The latter could aid managers to better understand the current state of interest and perception that the students have towards the metallurgical industry. Abstract ID: 1883 Awakening Student Interest in Exploration/Mining/Mineral Processing in Secondary Program S. Gallagher1 and L. Urisk1. 1Rainbow District School Board Presenting from 11:00:00 To 11:25:00 - Tuesday


The Ontario Ministry of Education has introduced programs that allow students in secondary schools to focus on knowledge and skills that are of particular importance in a specific sector of interest. A number of schools in Ontario are offering the Specialist High Skills Major (SHSM) in Mining, a program that includes five key components that set it apart from other existing programs. Through a SHSM in Mining, students obtain a focused education highlighting processes in the mining industry through a bundle of nine courses in their senior years. They experience a number of field trips in the industry (e.g.,underground mine, mill, smelter) and connect with the post secondary institutions to explore associated programs. Students obtain certifications recognized by the sector as they work toward meeting the requirements of an Ontario Secondary School Diploma. Students are required to complete 2 credits in co-op (200 hours) in a placement specific to the sector. Students who graduate with a SHSM Mining designation on their diploma are prepared for success in the post secondary destination of their choice, whether it is apprenticeship training, a college or university program, or the workplace. Through a Specialist High Skills Major in Mining students are able to explore the career opportunities available to them in the mining sector, provide them with an opportunity to experience the industry through co-op placements and to make a more informed decision about pursuing post secondary programs in the sector. Abstract ID: 1971 Attracting Students to the Mining & Metals Industry to Meet the Anticipated Future Demand - Queens University Perspective J. Peacey1, J. Brown1 and V. Pakalnis1. 1Queens University Presenting from 11:25:00 To 11:50:00 - Tuesday In response to the aging workforce and anticipated resources boom, the Queens University's Department of Mining Engineering has been successful recently in increasing its undergraduate intake from an average of about 30 up to about 50 undergraduates per year. Career orientation in Applied Science at Queens is entirely a student choice but the Department and industry have been working together to try to make the choice of Mining as a career as attractive as possible. Most students entering University have little knowledge of the Mining industry but the higher availability of financial support and summer jobs for mining students compared with other disciplines are strong attractions. However, the availability of summer jobs, and full-time jobs on graduation, fluctuate with the business cycle. The most recent downturn has been faster and more severe than any since the Great Depression. As a consequence, the availability of both summer jobs and full-time jobs for graduates, has shrunk to almost nothing. Possible ways to attract and stabilize undergraduate recruitment to the Mining industry at the levels required for the future will be discussed. Abstract ID: 1922 A Global Approach to Learning and Development S. Bettencourt1. 1Barrick Gold Corporation Presenting from 11:50:00 To 12:15:00 - Tuesday Change is the direction of the future-our job is to bring about change, be more innovative and perform efficiently but we are inadequately equipped to deliver what is required. This presentation will point out our industry challenges and costs of skills shortage, the Barrick's approach to learning driven


performance, our view on enhancing employee's learning experience while meeting the needs of the business and the Barrick's practice-based approach and commitment to life long learning. This practice-based learning is the most potent resource for any organization to enhance its capacity to be more effective.

MATERIALS - Materials Development and Performance of Sulphur Capture Plants Presentations from 8:30:00 AM to 12:00:00 PM - Room F336 PROCESSING AND PROPERTIES Abstract ID: 1896 (KEYNOTE) Factors Influencing Hot Tearing of Aluminum Alloy 206.0 Poured in Metal Molds Y. Fasoyinu1 and M. Sahoo. 1CANMET Materials Technology Laboratory Presenting from 8:30:00 To 9:20:00 - Tuesday The commercial viability of permanent mold casting of engineering components from Al-Si family (e.g. 356.0) and Al-Si-Cu family (e.g. 319.0) for automotive and other applications have been demonstrated over the years. This is not the case for the Al-Cu family (e.g. 206.0) because of its propensity to hot tearing during solidification in metal molds. This paper presents the results of the processing techniques that have been shown to improve the hot tearing resistance of prototype components poured from alloy 206.0 in metal molds. It was demonstrated that a combination of grain refinement and high mold temperature (greater than or equal to 400 degrees celsius) significantly reduced hot tearing of aluminum alloy 206.0 during its solidification. Computer simulation results seem to suggest that the reduced hot cracking in the hotter mold is associated with the reduced principal strain that develops during the last stages of solidification. Abstract ID: 1908 (KEYNOTE) Structural and Thermal Characteristics of 357 Alloy With and Without Be W. Kasprzak1 and M. Sahoo1. 1Natural Resources Canada Presenting from 9:20:00 To 10:10:00 - Tuesday The 357 aluminum alloy is commonly used for moderate to high strength premium quality castings for aerospace applications using sand and permanent mold technologies. Typical mechanical properties in the heat treated condition are: UTS~360MPa, YS~290MPa and E~8%. In the past, the Be addition was used in concentration of up to 0.07 wt% to gain certain improvements such as Fe phase modification, reduction of melt oxidation, etc. Consequently, this resulted in the improved mechanical properties in the as-cast and heat treated conditions. Beryllium is a highly toxic element and recently its utilization was prohibited to meet the safety and health standards. For this reason, development of 357 alloy modification technology is desired to effectively substitute Be and produce comparable properties. This paper presents preliminary experimental results pertaining to characterization of 357 alloys with and without Be using permanent mold cast test bars. Experimental results revealed that Be addition of up to 0.06% significantly refined the grain size. Corresponding thermal analysis data revealed the increase in liquids temperature by 10oC and decrease in undercooling temperature with increasing Be content. Additionally, detailed


results on structural analysis including XRD phase identification and mechanical properties are presented for as-cast and heat treated 357 alloys with various Be and Fe levels. Abstract ID: 2031 Semi-Empirical Method to Predict Hardness During Fast Induction Heating of a Tempered Martensitic AMS6414 Steel C. Ducassy1, F. Bridier1, P. Bocher1 and P. Arkinson2. 1Ecole De Technologie Superieure, 2Pratt & Whitney Presenting from 10:30:00 To 10:55:00 - Tuesday During superficial induction heating of a quenched-tempered gear, the surface experiences very high temperature gradients in a very short time, resulting in a beneficial hard layer of martensite and strong compressive residual stress at the surface of the gear. A commonly called ‘over-tempering” region is observed between the hardened surface layer and the core of the part. In this area, the hardness can be significantly lower than the bulk hardness before the induction treatment. In order to quantify the size and amount of the hardness “drop” in this region, the tempering kinetics were studied for the very particular conditions experienced during induction heat treatment, i.e., very short times and high temperatures. The specific influences of time and temperature on the alloy tempering kinetics were investigated and analyzed with regards to the over-tempering phenomenon. The present work proposes to quantify the hardness drop for parts made of AMS6414 steel. Abstract ID: 2053 The Effects of Manipulating Heat Input and Current Waveform on Submerged Arc Beadon-Plate Weld Profiles J. Pepin1, D. J. Ivey1, J. Wiskel1, H. Henein1, C. Penniston2 and J. Boyd3. 1University of Alberta, 2Evraz Inc. NA, 3Queen's University Presenting from 10:55:00 To 11:20:00 - Tuesday The development of new steels and their weldability for arctic gas transmission applications has highlighted the need to formulate the relationship between welding parameters, weld metal penetration and deposition rates, and mechanical properties. To address this, a study was undertaken to explore the effect of welding parameters on weld bead geometry. A series of bead-on-plate submerged arc welds were performed on X70 HSLA steel plate. Lincoln Electric AC/DC 1000 power supplies were utilized to allow for the use of both single-electrode and tandem electrode welds, as well as to allow for AC square-wave waveform manipulation, including modifications to the relative current amplitudes and time periods of the direct current electrode negative (DCEN) and direct current electrode positive (DCEP) phases of the AC current. Constant current DCEN and DCEP polarities were investigated too, as were changes to current, voltage, travel speed, and frequency.

MINERAL PROCESSING - Mineral Processing of Complex Sulphides Presentations from 8:30:00 AM to 12:10:00 PM - Fraser Upper Left FLOTATION: FROTH AND FROTHERS


Abstract ID: 2077 (KEYNOTE) The Total Air Addition and the Air Profile for a Flotation Bank C. Smith1, K. Hadler1 and J. Chilliers. 1Royal School of Mines, Imperial College Presenting from 8:30:00 To 8:55:00 - Tuesday Numerous studies have shown the potential of air rate profiling to significantly improve the flotation performance of a bank of cells. To date many profiles have been implemented; balanced, increasing, decreasing and combinations of these. Previous work has typically shown using an increasing air rate profile, where the air rates are increased proportionally to each cell down the bank, yields a higher grade for a given recovery compared to other profiles. Air rate profiling can then be thought of as having two distinct components; determining the correct distribution of a given volume of air and, perhaps more importantly determining the correct total volume of air to add to the bank. To date no method for this second component has been established. In an alternative technique the air rate to each cell is adjusted in order to optimise the air recovery from that cell. Air recovery is the fraction of the inlet air which overflows the weir of a cell as unburst bubbles. The peak in air recovery (PAR) is a robust measurement that indicates optimal performance for the operating conditions in the cell, and sets the PAR air rate. By doing this for each cell in the bank, the optimal total air rate to the bank and the optimal distribution of that air can be simultaneously determined. In this study plant trials evaluated different air rate profiles, and profiling based on PAR. The total air rates to the bank for all profiles tested were approximately equal, allowing direct comparison. The results showed that the highest cumulative mineral recovery was achieved by operating at air rates which gave the PAR for each cell down the bank. Different distributions of the same total air rate to the bank gave the same cumulative upgrade ratio, but lower cumulative recoveries. In this study, the increase in cumulative mineral recovery, at the same upgrade ratio, was more than 33%. Peak in air recovery (PAR) based optimisation of air rates to banks of cells and to the individual cells has been shown to significantly improve flotation performance as it simultaneously determines the optimal air rate to the bank, and the optimal distribution of that air. Abstract ID: 1939 Effect of Frother Blends on Hydrodynamic Properties A. Elmahdy1 and J. Finch1. 1McGill University Presenting from 8:55:00 To 9:20:00 - Tuesday Blending frothers is becoming common in flotation practice apparently enhancing performance. However, there have been no studies to understand the blend mechanism. In this paper, the effect of two frother blends of F150 (polyglycol) with MIBC or pentanol (both alcohols) on bubble size, gas holdup and froth height is reported. The blends focused on a small addition of the polyglycol to the alcohols as base frother. The tests showed that the bubble size at blend concentration below the critical coalescence concentration (CCC) of the base frother was decreased but was significantly larger above the base CCC. Froth build-up showed a strong synergistic effect. Abstract ID: 1985 On-line Estimation of Frother Concentration for Flotation Processes M. Maldonado1, A. Desbiens1, R. del Villar1 and R. Aguilera2. 1Université Laval, 2University of


Concepcion Presenting from 9:20:00 To 9:45:00 - Tuesday This work details the application of a multiple model approach to estimate frother concentration in flotation processes. The methodology consists of identifying a set of linear dynamic models representing the effect of gas rate on the collection-zone gas holdup at different known frother concentrations (calibration step). An adaptive law is then obtained using Bayes' rule to evaluate the conditional probability that each model represents the observed system behavior. In this way, a frother concentration estimate is calculated as a weighted sum of model probabilities and their associated (known) frother concentrations. Experimental results conducted in a two-phase system using Dowfroth250C are promising. Modeling and analysis for MIBC frother are also provided. Abstract ID: 1975 Frother Analysis in Industrial Flotation Cells A. Zangooi1, C. O. Gomez1 and J. A. Finch1. 1McGill University Presenting from 9:45:00 To 10:10:00 - Tuesday Flotation is a separation process based on the collection of particles on the surface of bubbles. Flotation machines disperse air into bubbles using a variety of techniques. The characteristics of the bubble population, for a particular cell, will be strongly affected by the selection of frother type and concentration. As metallurgical results depend on the bubble distribution, the measurement of frother concentration in cells is vital to understand and control performance. A colorimetric technique has been proposed and refinements to the method are described. Application at several concentrators have demonstrated that the method is robust and accurate. As well as relating frother concentration to gas dispersion measurements, the results can be also used to establish potentially important operational details including how well a frother dissolves, how stable in time is the concentration in a cell, how evenly frother is distributed down a bank, and the distribution of frother between pulp and froth. These points are illustrated from plant experiences. Abstract ID: 1953 Water Recovery and Bubble Surface Area Flux W. Zhang1, J. Nesset1 and J. Finch1. 1McGill University Presenting from 10:30:00 To 10:55:00 - Tuesday Frother influences water recovery through control of bubble size and a chemical effect. De-coupling the two is necessary to establish the extent of the chemistry effect. A setup is described to give steady state water overflow rate (JWO) along with measurements of bubble size into and on top of the froth. Arguing neither bubble size correlates directly with water overflow, a frother mass balance is solved to estimate the bubble surface area flux in the overflow (SbO). The solution required measurement of frother concentration using TOC analysis and frother adsorption density using surface tension data. The relationship between JWO and SbO reveals the frother chemistry effect, quantified for discussion purposes by an equivalent water layer thickness. Abstract ID: 1990 Frother and Collector Effects on Flotation Cell Hydrodynamics and Their Implication on Circuit Performance


F. Cappuccitti1 and J. E. Nessett2. 1Flottec, Llc, 2McGill University Presenting from 10:55:00 To 11:20:00 - Tuesday Significant progress has been made over the past few years on characterizing and understanding the hydrodynamic properties of frothers and collectors and their affects on flotation performance. This new understanding of the relationship between chemistry and hydrodynamics has dramatic implications on how flotation circuits should be controlled and optimized. Previous work in this area has shown that choosing the right frother "strength" is even more critical than previously thought when optimizing a flotation circuit. But we also know that collectors in themselves have hydrodynamic properties that need to be taken into consideration when choosing the right frother. To achieve the desired hydrodynamic conditions that give optimum performance in a circuit, the total system of reagents and operating parameters must be considered. This paper will describe some of the findings from the fundamental research on frother and collector chemistry affects on hydrodynamics and how this information can be used to improve flotation performance in actual plant practice. Examples from actual plant experience will also be discussed. Abstract ID: 2072 A Comparison of Bubble Rise Velocity Profile of Two Surfactants to Explain Gas Holdup Data A. Rafiei1 and J. A. Finch1. 1McGill University Presenting from 11:20:00 To 11:45:00 - Tuesday AA previous study comparing n-pentanol and the polyglycol F150 showed that the two reagents could give the same gas holdup but with different size bubbles. The finding implies that bubble rise velocity depends on the surfactant (frother) type. A study using bubble swarms supported the frother type effect but bubble interactions were a possible confounding factor. This study resolves the question by measuring the rise velocity of single bubbles of 0.8-2.5mm diameter over a distance ≈ 300cm in n-pentanol and F150. It is shown that at typical frother concentrations used in flotation that the rise velocity in n-pentanol remains comparable to that in water alone while in F150 the velocity is significantly reduced. The results confirm the suspected impact of frother type. It is illustrated that in n-pentanol the rise velocity does not reached terminal; while in F150 it does and this is the source of the velocity difference. Abstract ID: 2112 Modifications to Foam Volume Measurements R. Cunningham1 and J. Finch1. 1McGill University Presenting from 11:45:00 To 12:10:00 - Tuesday The amount of foam volume generated in relation to the gas flowrate has long been used to define the foaminess of a solution and to characterize surfactants. The vessel geometry and gas flowrate range can affect the foam volume results. A fixed area column was tested alongside a variable area conical vessel with two surfactants. It was found that the fixed area vessel will cause foam volume to expand or contract which masks the effect of the surfactant. The conical vessel showed two regimes of foam volume production dependant on gas flowrate. The low gas flowrate regime revealed the physiochemical nature of the surfactant while a high gas flowrate revealed kinematic properties. Foaming properties of a surfactant is best determined with a variable area vessel at low gas flowrate.


PYROMETALLURGY - Advances in the Processing of Nickel, Cobalt and PGMs Using Pyrometallurgical Techniques Presentations from 8:30:00 AM to 12:10:00 PM - Fraser Upper Right TRADITIONAL AND NEW TECHNOLOGIES – REVIEW AND ADVANCEMENTS Abstract ID: 2049 (KEYNOTE) The Evolution of Copper Smelting Practices in the Last Four Decades C. Diaz1. 1Consultant Presenting from 8:30:00 To 9:20:00 - Tuesday The lecture will provide a retrospective look at the dramatic changes that have taken place in copper smelting in the last four decades. Topics include: the development of autogenous, increasingly more intensive, environmentally sound and energy efficient smelting processes; significant improvements in Peirce-Smith converting practice and at the same time the commercialization of alternative continuous converting routes; the consequent expansion and modernization of smelters; the increasing compliance with strict government environmental regulations in most copper producing regions of the world; the realignment of the copper smelting industry throughout the world; and trends in copper smelting R&D. A look at the future closes these reflections on the advancement of copper smelting technology. Abstract ID: 1873 High Intensity Slag Resistance Furnace Design M. Kennedy1 and H. Haaland1. 1Elkem As Presenting from 9:20:00 To 9:45:00 - Tuesday Intensity of electric slag melting/reduction furnaces have progressed in generations from roughly 100 kW/m2 hearth area in the 1960′s, up to 3-400 kW/m2 today, through a series of technological advances, for example from: 1. immersed electrodes (~100 kW/m2) to 2. brush arc (~200 kW/m2) to 3. shielded arc (~300-400 kW/m2), often involving extensive use of copper coolers and complex mechanical tensioning devices to maintain good copper to refractory contact. Development work is taking place on 4th generation high intensity resistance designs (500-1000 kW/m2), incorporating nearly 100% copper bodies, pressure vessel standards, unique electrode and cooling system designs. Furnaces up to 1.5 MW have been constructed and pilot furnaces up to 10 MW are now being designed. Abstract ID: 1841 Fluxing Strategy for Nickel Slags Containing Magnesia E. Grimsey1 and B. Tran2. 1W.A. School of Mines, Curtin University of Technology, 2BHP Billiton Presenting from 9:45:00 To 10:10:00 - Tuesday Liquidus temperatures within the FeO-Fe2O3-MgO-CaO-Al2O3-SiO2 have been assessed using FACTSage software to provide a better understanding of the effect of silica, calcia and alumina fluxes on slag liquidus temperatures for Fe/MgO in slag ranging from 4 to 8. A feed-forward fluxing strategy is


suggested for liquidus control in which Fe/MgO and SiO2/MgO ratios are coupled with Al2O3/MgO and CaO/MgO ratios to provide relationships for flux additions which relate directly to tonnes of flux per tonne of MgO in slag, as a direct measure of fluxing efficiency. Abstract ID: 2069 Technology Development in Jilin Jien Nickel Industry Co., Ltd. P. Donghe1. 1Jilin Jien Nickel Industry Co., Ltd. Presenting from 10:30:00 To 10:55:00 - Tuesday Jilin Jien Nickel Industry Co., Ltd. was founded based on the advantageous assets of the former Jilin Nickel Industry Group. The company now has developed into large-scaled nonferrous metals enterprise integrated with mining, dressing, smelting and chemicals. It originally produced high grade nickel matte with electric furnace. Now the main products include nickel sulfate, nickel matte, electrolytic nickel, nickel hydroxide, nickel chloride, copper sulfate, copper concentrate, sulfuric acid and etc. The Ausmelt process has been installed and will be start-up in 2009. The pressure leaching of matte has been developed and used for several years. High and low pressure carbonyl processes have been developed and the demstation plant has been completed. The new nickel electrolysis process has been adopted. Abstract ID: 2052 Sulphur Based By-Products for the Non-Ferrous Metals Industry M. King1 and R. Forzattii1. 1Hatch Presenting from 10:55:00 To 11:20:00 - Tuesday Non-ferrous metals such as copper, nickel, lead, zinc and platinum group metals are often found in sulphide mineral deposits. Various pyrometallurgical and hydrometallurgical processes are employed to extract the valuable metals from their minerals. These processes result in the production of sulphur bearing by-products or wastes. This paper provides a comprehensive review of sulphur bearing by-products and the techniques used for their production. It focuses primarily on elemental sulphur, sulphuric acid and various fertilizer options. To a lesser extent, liquid SO2, oleum and gypsum by-products are discussed. Abstract ID: 2048 Burning Pyrites Compared to Sulphur: Update 2009 G. Warren1. 1SNC Lavalin Presenting from 11:20:00 To 11:45:00 - Tuesday Present day capital costs are analyzed for a 2,000 metric tonne per day (MTPD) pyrite burning plant and compared with a sulphur burning plant of the same capacity. Power, raw material and steam production rates are then compared for the two facility types. Potential impacts from pyrite impurities and design trade-offs relating to the gas cleaning section of the pyrite plant are briefly reviewed. Technological improvement effects on capital cost and energy recovery are also discussed. Besides the steam produced from the burning of pure sulphur or pyrite, plants using an advanced form of heat recovery can produce up to 10 bar steam using heat from acid formation. The quantity depends on the overall water balance which is influenced by such factors as gas strength and product acid concentration. Modern materials and innovative process design also improve the ability to increase the high pressure steam from


the roaster boiler in pyrite plants above the traditional 1.25 kg of superheated steam per kg of acid produced. High activity catalyst can reduce the capital cost of the contact section through low O2 to SO2 ratios and maintain long operating times between screenings. Operating factors for pyrite plants can approach 95% to 99% and is primarily dependent upon gas treatment design. Abstract ID: 1956 Towards Commercialisation of Mintek's ConRoast Process for Platinum Smelting R. Jones1, I. Geldenhuys1, G. Denton1 and T. Curr1. 1Mintek Presenting from 11:45:00 To 12:10:00 - Tuesday Mintek's ConRoast process for the treatment of nickel sulfide and platinum group metal (PGM) concentrates offers a more environmentally favourable alternative to traditional matte smelting. The process involves the reductive smelting of low-sulfur concentrates (typically obtained by fluidized-bed roasting), and the collection of precious and base metals in an iron-rich alloy. PGM smelting of high chromium concentrates can be readily accommodated with extremely high recoveries. A 3 MW DC arc furnace, designed to smelt 2000 tons per month, has been in operation since October 2008. Plans are currently underway for a 10 MW DC arc furnace.

Applied MINERALOGY Presentations from 8:55:00 AM to 12:00:00 PM - Room F337 Abstract ID: 1825 Deportment Methodology for Low-grade Ni-Cu-PGE Ores M. Nelson1, L. Cabri2 and C. J. Martin3. 1Barrick Gold Corporation, 2Cabri Consulting Inc., 3SGS Canada Inc. Presenting from 8:55:00 To 9:20:00 - Tuesday The metallurgical response of platinum-group element (PGE) ores to conventional grinding and bulk flotation is driven by (a) the distribution of PGE as discrete platinum-group minerals (PGM), (b) the speciation of PGM, and their size range, (c) the deportment of the PGE in host sulphides and (d) the degree of alteration of the host rock. Accordingly, characterising such materials is a complex exercise, and a challenge to the applied mineralogist. In a recent case study, we will describe how PGM balancing using gravity pre-concentration and SEM techniques, automated mineralogical analysis of the host sulphide and non-sulphide minerals, and analysis of host sulphides using LAM-ICPMS (laser ablation microprobe - inductively coupled mass spectrometry) were integrated to characterise such a PGE-bearing material. We will also describe how these data can be used to predict likely metallurgical response. Abstract ID: 2054 Mineral Liberation Analysis of Stillwater Mining Company's East Boulder Mill Circuit P. Miranda1 and J. Sargent2. 1Montana Tech of the University of Montana, 2Stillwater Mining Company Presenting from 9:20:00 To 9:45:00 - Tuesday The Center for Advanced Mineral and Metallurgical Processing (CAMP) has utilized the Mineral Liberation Analyzer (MLA) for over 3 years and has currently evaluated multiple projects using the technology during this timeframe. The MLA is able to both analyze and quantify minerals, slags, and other phases using


scanning electron microscopy techniques. For this presentation, CAMP received samples from Stillwater Mining Company’s East Boulder Mill. Since the Platinum Group Metals (PGMs) report to both chalcopyrite and nickel containing pentlandite in micro sized particles, the MLA can be used to determine overall mineral matrix, encapsulation issues, and mineral sizes of sulfides, PGMs, and gangue material. For the project, MLA results will include potential losses and other data from samples taken within the mill circuit. Abstract ID: 1788 Predicting Clarabelle Mill Recoveries Using Mineral Liberation Analyzer (MLA) Grade-Recovery Curves F. Ford1, A. Lee1, C. Davis2, M. Xu1 and V. Lawson2. 1Vale Inco Technical Services, 2Vale Inco Limited Presenting from 9:45:00 To 10:10:00 - Tuesday A virtual flotation model for Clarabelle Mill that recovers minerals to a model bulk concentrate based on the relative floatability of particles in the Mineral Liberation Analyzer image set has been developed, validated, and incorporated into ore evaluation and business planning. Flotation probabilities are calculated for ~40,000 particles in a data set. The calculation is sensitive to both particle mineralogy (mineral composition) and texture (mineral locking). Sequential model bulk concentrates are produced as a function of increasing time. When joined together, these model concentrates produce grade-recovery curves for the various orebodies feeding the mill. The various grade-recovery curves for individual ore bodies can be weighted as a proportion of the daily feed to predict mill performance on that day. Abstract ID: 1845 Using Mineral Liberation Data in Simulating Mineral Processes P. Lamberg1 and J. Liipo1. 1Outotec Research Presenting from 10:30:00 To 10:55:00 - Tuesday Mineral liberation analysis is widely used in diagnosing mineral processing plants but very limitedly in simulating the processes. Because of incapability in reading the liberation data, in simulation packages minerals must have been divided in liberation classes, which in many cases is an oversimplification of the data and much information is lost. HSC Chemistry can read and pack liberation data and use the measured particles in simulation. The simulator can handle unit operations where particles are broken (e.g. grinding) and classified by their physical properties (classification, flotation, magnetic separation). This paper describes the procedure with an example from a flotation process. Abstract ID: 1836 Discriminating Hematite and Magnetite and Quantifying Their Associations Using the JKTech Mineral Liberation Analyzer™ M. Shaffer1. 1Memorial University Presenting from 10:55:00 To 11:20:00 - Tuesday The JKTech MLA™ and Intellection QEMScan™ have generally been the modern tools of choice for characterizing iron ore minerals and their processing products. This has been adequate for characterizing the iron oxides' relationships with other minerals, however at practical analytical speeds, the EDX x-ray spectra acquired with these SEM-platformed image analyzers is statistically imprecise for discriminating magnetite from hematite. This paper describes a technique developed here, most recently


supplemented by tools from JKTech, which allows Mt and Hm, discriminated independently with backscattered electron imagery, to be merged with the MLA x-ray spectral method. Also discussed are the method's limitations, which are generally related to particle size.

Tuesday, August 25, 2009 PM

MINERAL PROCESSING - Mineral Processing of Complex Sulphides Presentations from 1:35:00 PM to 5:30:00 PM - Fraser Upper Left FLOTATION: DEVELOPMENTS AND PRACTICES Abstract ID: 2079 (KEYNOTE) Advances in Fine and Course Particle Flotation G. Jameson1. 1University of New Castle Presenting from 13:35:00 To 14:00:00 - Tuesday Flotation works very well for particles that are typically in the range 20 to 150 µm in diameter, for base metal ores. In this range, it is possible to get quite high recoveries in conventional flotation machines. Outside this range, the recoveries decline progressively, whether it be with the very fine or the coarse end of the size spectrum. In this paper, the reasons for the drop-off in recovery will be briefly reviewed, together with strategies for future work. Recent progress in the author’s laboratory will be described. These include the Concorde Cell, which takes advantage of the high dissipation rates in the shock wave created when a gas-liquid mixture reaches supersonic velocities. The environment thus created is very beneficial for the flotation of ultrafines. For coarse particles, the reasons for the drop-off in recovery can be related to the highly turbulent nature of the pulp in a conventional flotation cell. To improve recovery, it is necessary to find a way of bringing particles and bubbles into contact in a quiescent environment. A new process for coarse particle flotation will be described, in which a fluidized bed is created in the flotation cell. The flow conditions are very gentle, and the high solids concentration leads to rapid rates of capture of the particles. Experimental results will be shown, illustrated with short movie clips. It is apparent that the maximum floatable size for coal and minerals can be increased by a factor of ten over the limits found in current practice. Abstract ID: 2074 The Impact of Crushed Ore Ageing on Metallurgical Performance D. Lascelles1, O. Peters1 and R. Caldwell1. 1SGS Minerals Services Presenting from 14:00:00 To 14:25:00 - Tuesday Ageing tests on a crushed Cu-porphyry ore were conducted to assess the impact of sample oxidation on flotation performance. The objective of the testwork was to simulate ageing of ore that would be blasted through block caving but not milled for possibly several months. Ageing was performed in specially designed columns, using site and deionised water to keep the samples moist over the entire ageing period. Samples from each ageing interval (0, 0.5, 1, 2, 4, and 8 months) were examined for physical and


metallurgical changes resulting from the ageing process through chemical analyses, size analyses, and batch flotation tests. Abstract ID: 1895 Flowsheet Development for Thompson Ultramafic Low-Grade Nickel Ores Z. Dai1, J. Bos1, P. Quinn1, A. Lee1 and M. Xu1. 1Vale Inco Technical Services Limited Presenting from 14:25:00 To 14:50:00 - Tuesday A flowsheet is being developed for processing Thompson ultramafic low-grade nickel ores. This type of ore is characterized by high content of serpentinized magnesium silicates which generate slimes during comminution. Flotation of this type of ore proves difficult due to problems associated with the slimes. The flowsheet, based on extensive laboratory and miniplant flotation tests, consists of two key components: desliming by hydrocyclones prior to flotation and using soda ash for pH control in flotation. Satisfactory metallurgical results have consistently been achieved in laboratory full circuit simulation and miniplant tests. Abstract ID: 1844 A Property Based Model of Flotation and Application in a Dynamic Simulator for Training Purposes P. Lamberg1, S. Paloranta1, A. Aaltonen1 and H. Myllykangas1. 1Outotec Presenting from 14:50:00 To 15:15:00 - Tuesday A property based dynamic model of flotation was built and validated for training purposes. The model is based on the work of the AMIRA P9 project. The recovery of each particle with composition and size is calculated in a given simulation step. The model takes into account machine and operational parameters such as air flowrate and froth height. The model was created using full-scale test data on Pyhäsalmi Cu-Zn-pyrite ore with flotation kinetics of multiphase particles determined. Simulation and validation shows that model can predict the dynamic behavior of the process accurately enough for training purposes. Abstract ID: 2061 Increased ZnS Flotation Response Due to Slime Removal With Methanol Treatment M. Holuszko1, M. Hampton2, A. Nguyen2, J. Franzidis3 and E. Manlapig2. 1University of British Columbia, 2University of Queensland, 3University of Cape Town Presenting from 15:35:00 To 16:00:00 - Tuesday Methanol treatment of ZnS particles has been found to remove slimes and facilitate flotation. The removal of slimes renders the ZnS surface more hydrophobic, resulting in an increase in the hydrophobic attractive force between the particle and bubble. Hallimond tube flotation, induction time measurement and particle-bubble force analysis with the atomic force microscope (AFM) were undertaken to link the beneficial effect of methanol treatment of ZnS particles to their increased floatability. Abstract ID: 1809 Microbially-Induced Selective Flotation for Complex Sulfides K. Natarajan1 and M. Chandraprabha1. 1Indian Institute of Science, India Presenting from 16:00:00 To 16:25:00 - Tuesday


Selective separation of minerals from complex sulphide ores is a challenging task and it is often difficult to get commercially acceptable individual concentrates by conventional selective flotation using inorganic collector reagents. Microbially-induced mineral beneficiation has proved to be more effective, economically viable and an environmentally benign process for the effective separation of various minerals. Applications of microbially-induced mineral beneficiation are demonstrated in this paper with respect to beneficiation of complex multimetal sulfides. The role of adapted microorganisms and bioreagents in the beneficiation of complex sulphide minerals are also illustrated. Abstract ID: 2058 Coarse and Fine Particle Flotation H. Wyslouzil1, J. Kohmeunch2, L. Christodoulou2 and M. Fan1. 1Canadian Process Technologies Inc., 2Eriez Manufacturing Presenting from 16:25:00 To 16:50:00 - Tuesday Conventional, mechanical flotation has long been considered the workhorse of the flotation industry. However, column and other non-traditional flotation approaches continue to provide benefit where traditional means fall short. This is best demonstrated in applications treating ultra-fine material where the use of micro- or pico-bubble flotation and counter-current froth washing can provide additional capacity and provide a high-grade float product. Alternatively, applying flotation fundamentals in a fluidized-bed regime offers the opportunity to improve the flotation recovery of particles up to, and in excess of 3-mm. This technology is best applied in applications where liberation is achieved at relatively coarse sizes such as when recovering potash, phosphate, and diamonds. More recent work shows that this approach may also reduce the amount of material that needs to be re-ground for liberation given that this technology can provide "clean" throwaway reject. This paper will review the design and guidelines for column flotation as well as provide up-to-date information on the flotation of ultra-coarse particles. In addition, operating guidelines will be provided such that an efficient flotation circuit can be developed. Abstract ID: 1715 Dynamic Bubble Nucleation in Flotation Z. Zhou1, R. S. Chow1, P. Cleyle2, Z. H. Xu3 and J. H. Masliyah3. 1Alberta Research Council, 2Suncor Energy Inc., 3University of Alberta Presenting from 16:50:00 To 17:15:00 - Tuesday Bubble nucleation in water under dynamic conditions was investigated using an autoclave at an air saturation pressure of 7 ATM. Agitation during air saturation of water was found to be crucial in enhancing tiny bubble formation. More bubbles nucleated on hydrophobic surfaces at a higher agitation rate, due to cavity formation by the more intense hydrodynamic conditions. Flotation recovery of bitumen from oil sands demonstrated a significant role of bubbles nucleated in water: more than 50-170% increase in bitumen recovery from different oil sands was obtained by using air supersaturated than the regular water.


PYROMETALLURGY - Advances in the Processing of Nickel, Cobalt and PGMs Using Pyrometallurgical Techniques Presentations from 2:00:00 PM to 5:30:00 PM - Fraser Upper Right TRADITIONAL AND NEW TECHNOLOGIES – REVIEW AND ADVANCEMENTS Abstract ID: 1676 Ausmelt Technology for Nickel and PGM'S A. Kaye1, M. A. Reuter1 and S. Hughes1. 1Ausmelt Ltd. Presenting from 14:00:00 To 14:25:00 - Tuesday Ausmelt Top Submerged Lancing (TSL) Technology has gained increasing commercial acceptance in the Nickel industry, as well as for PGM recovery, as an efficient and highly flexible pyrometallurgical reactor with accompanying excellent environmental performance. For the processing of Nickel and PGM bearing feed materials, five (5) Ausmelt furnaces at four (4) sites are either in operation, or in the final stages of construction or commissioning. With an ever increasing focus on the sustainable use of metals, interest in the processing of secondary feed material sources and metal bearing residues has substantially increased in recent years. Ausmelt Technology has proven to be well suited to the economic recovery of values from such sources through niche process developments or by co-processing these materials with concentrates. Abstract ID: 1940 ISASMELTTM TSL-Making a Splash for Nickel M. Bakker1, G. Alvear and M. Kreuh2. 1Xstrata Technology, 2Xstrata Nickel Canada Presenting from 14:25:00 To 14:50:00 - Tuesday The ISASMELT™ process is top submerged lance (TSL) bath smelting technology. The technology has been developed over the last 25 years and currently treats more than 6,000,000 tonnes per year of feed materials in copper and lead smelters around the world. What is less well known is that the technology is equally effective for smelting nickel sulfide concentrates, and converting nickel mattes. This paper demonstrates how the features that make ISASMELT™ attractive for copper and lead smelting can be equally applied to nickel smelting and converting operations. Conceptual flowsheets are presented supported by results from recent pilot plant campaigns. Abstract ID: 1910 Developments on FeNi Refining at Falcondo Xstrata Nickel M. Zamalloa1, A. Reyes, J. Fanas and J. Frias. 1Xstrata Nickel Presenting from 14:50:00 To 15:15:00 - Tuesday Xstrata Nickel's Falcondo operation is a ferro-nickel producer in the Dominican Republic. This is an integrated site operating a nickel laterite mine and a ferronickel processing plant producing a refined 38% Ni Fe-Ni product for the market. The shaft furnace-electric furnace (SFEF) process produces a crude metal material that contains a number of low-level impurities like phosphorus and sulphur prior to refining. Process variations in the feed preparation and upgrading practice, as well as the use of sulphur-containing naphtha fuel in the drying and pre-reduction steps all contribute to some variability in the


impurity level of these impurities. Unchecked, this result can impact the productivity and operating cost at the plant. The present paper provides a description and evaluation of a series of refining tests on the metal from the electric furnace. The paper includes discussions of the main factors affecting the efficiency of the refining process such as temperature, flux composition, impurity concentration, slag making reactions, oxygen potential, and process time, together with supporting data provided by thermodynamic predictions. As a result of this work, a fully optimized refining practice has been successfully implemented at the plant. Abstract ID: 1779 50 Years of Nickel Flash Smelting - Still Going Strong T. Ahokainen1 and T. Makinen1. 1Outotec Oyj Presenting from 15:35:00 To 16:00:00 - Tuesday Outokumpu commenced an integrated nickel smelter and refinery at Harjavalta in 1959 - 50 years ago. Owing to continuous research and development efforts Flash Smelting technology is still noted for its capability to treat various types of sulphidic Ni-concentrates with high energy efficiency and minimal occupational and environmental impacts. Today, Flash Smelting is a dominating method to treat sulphide-based nickel raw materials corresponding to about 50 % of smelting capacity. Until 1995 the Flash Smelting - Peirce-Smith (PS) converting route was applied in Harjavalta. High grade nickel matte from the converting step was further refined by means of leaching and electrowinning to produce cathode nickel. In 1995 the nickel production capacity was increased from 17 000 t/a to 52 000 t/a based on the Direct Outokumpu Nickel Smelting Process (DON). The expanded refinery capacity is based on hydrogen pressure reduction, producing nickel powder and briquettes. The smelting operation is currently part of Boliden Group and the nickel refinery part of Norilsk Nickel Company. The DON process enables production of high grade nickel matte with low Fe-content directly in the flash smelting furnace (FSF) without subsequent converting. Metal values from the smelting slag are recovered in the electric furnace (EF) as iron containing Ni-matte. As expected, adoption of the DON process at Harjavalta further improved environmental conditions. The low melting points of the high-grade nickel mattes produced in the DON furnace, particularly those low in copper, have brought about challenges for the furnace design, in particular for the hearth thermal engineering. Processing of high-magnesia concentrates, the fluidity of slags, the recoveries of nickel and copper, as well as those of PGM’s and cobalt are key issues of the smelting technology. These factors can be affected by a proper selection of the process concept, and the operational conditions in the processing vessels. Thanks to modern computational tools, new knowledge about the phenomena occurring in the smelting vessels can be obtained reliably and quickly. Today, these methods complement or even replace experimental research carried out in laboratories, pilot plants or in industrial installations. This paper outlines some special features of Outokumpu Nickel Flash Smelting technology including the significant improvements in environmental conditions. Selected results of the thermodynamic modelling of high-magnesia slags are reviewed, with the reference to the mattes produced. Also opportunities to utilize CFD modelling for the furnace design are presented. Abstract ID: 1905 Testing of Nickel Laterite Smelter Dust Insufflation - Part I


J. Liu1, M. Prokesch2, R. Riddle2, A. Vahed1, M. Jafri3 and R. Barus3. 1Vale Inco, 2FLS, 3PT Inco Presenting from 16:00:00 To 16:25:00 - Tuesday Dust insufflation has been practiced in the cement industry for decades as an effective way to recycle plant dust back to the rotary kiln. However, this technology has never been used in the nickel laterite smelters. Since its startup in 1977, PT Inco has been a major fully integrated nickel laterite mining and smelting company. Presently, the dryers and kilns dust are recycled to the drying step without agglomeration. The proposed insufflation method is to inject the nickel laterite smelter dust into the main kiln burner flame where the temperature is expected no less than 1300ºC. The advantages of the insufflation option are its low cost and quick payback time. In theory, eliminating the current dust recycle via insufflation could increase PT Inco calcine production by maximum 15%. This paper summarizes the bench and pilot plant scale nickel laterite insufflation testwork. The results and observations confirmed that nickel laterite smelter dust insufflation is possible with burner flame temperature ≥1300ºC. Abstract ID: 2082 Replacing Nitrogen with Sulphur Dioxide in Nickel Matte Converting T. Price1, C. Harris2, S. Hills2 and A. Wraith3. 1TKTV, 2WorleyParsons Minerals & Metals Toronto, 3Not Available Presenting from 16:25:00 To 16:50:00 - Tuesday Many non-ferrous pyrometallurgical processes use air or oxygen enriched air. A significant proportion or indeed the majority of the gas passing through the process is nitrogen. Nitrogen carries out several important duties. It controls the temperature of the vessel by carrying away heat from the reactions, both globally and locally at the reaction site (tuyere tip, flash flame, lance tip). However, in bath smelting reactors, nitrogen adds energy to the bath and contributes to splashing, which limits the blowing rate. High oxygen smelting has made streams of gas containing high concentrations of sulphur dioxide commonplace, which can be used to substitute SO2 for nitrogen and can drastically change the characteristics of these pyrometallurgical processes These high SO2 streams also lend themselves to easy concentration of SO2 using liquefaction, presenting the possibility of large quantities of pure SO2

being available. A lesser flowrate of SO2 is required to carry away the same quantity of heat when compared to nitrogen, which allows higher concentrations of oxygen for a given total flowrate. This leads to the possibility of increased production. The paper investigates this substitution, its impact on productivity, and on the remainder of the plant.

PYROMETALLURGY - Advances in the Processing of Nickel, Cobalt and PGMs Using Pyrometallurgical Techniques Presentations from 2:00:00 PM to 5:30:00 PM - F443 SLAGS, FLUXES AND SMELTING Abstract ID: 1800 Cleaning of Copper Cliff Converter Slag A. Wolf1, T. Tan2, A. Vahed3 and T. Utigard2. 1Hatch Assoicates, 2University of Toronto, 3Vale-Inco Presenting from 14:00:00 To 14:25:00 - Tuesday


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NEW: Abstract ID: 2028, Larry Southwick When Muscular Metallurgy is Not Enough-An Example from the Early Copper Smelting Industry Presenting from 16:50 TO 17:15 - Tuesday, Abstract not available.

Slags from the converting of flash furnace matte to nickel rich Bessemer matte, have been treated using various reducing conditions. In order to potentially develop a separate slag cleaning process, various treatment options have been investigated. The slags were industrial samples with about 2.1 to 2.4 % Ni and Cu, as well as 2.0% S. Laboratory slag cleaning tests were carried out on 0.5 kg of slag samples, heated to above 1200 degrees celsius and reduced using various reductants. As reductants, alloys of Fe-Si, Fe-C and Cu-Si were tested in addition to coke. Tests were carried out with and without stirring. In many of the tests, a thermocouple was located within the slag sample and the thermal effects associated with the addition of room temperature reductants to the hot slag were followed. In addition to the reducing power of the reductants, other important factors such as melting behaviour, exothermicity as well as the ability to form a good “matte” product all affect the performance of the reductants used. Abstract ID: 1909 Phase Equilibria Studies of Ferronickel Smelting Slags B. Zhao1, R. Schonewille2, E. Jak1 and P. Hayes1. 1University of Queensland, 2Xstrata Nickel Presenting from 14:25:00 To 14:50:00 - Tuesday Phase equilibria studies have been carried out on the “FeO”-SiO2-MgO-Al2O3-Cr2O3 system in equilibrium with iron in the range of compositions and temperatures directly relevant to the nickel laterite deposits being investigated by Xstrata Nickel within the Araguaia belt in Para State, Brazil. Liquidus temperatures and primary phase fields have been measured as a function of composition using equilibration, quenching and electron probe X-ray microanalysis measurements. The results are presented in the form of pseudo-ternary sections. It was found that in the composition range investigated, olivine (Mg,Fe)2SiO4 and pyroxene (Mg,Fe)SiO3 are major primary phases. In addition, tridymite SiO2 and spinel (Mg,Fe2+)O·(Al,Cr,Fe3+)2O3 are also present in the higher SiO2 and lower SiO2 regions respectively. The results of the phase equilibria studies were validated in a subsequent pilot smelting test Abstract ID: 1754 The Physical Chemistry of Flash Smelting: Iron and Sulphur Oxidation and Magnetite Reduction J. Matousek1. 1Self Employed Presenting from 14:50:00 To 15:15:00 - Tuesday September 2009 marks the 60th anniversary of the commencement of commercial flash smelting of copper by Outokumpu Oy in Finland; this first furnace operated with pre-heated air to off-set the deficient heat balance. Three years later, the International Nickel Company of Canada (Inco) brought on-line an alternative flash smelting process using technical grade oxygen. For the next fifty years, Outokumpu technology dominated copper production in the world. The physics, physical chemistry, and thermodynamics of flash smelting have been studied for these same 60 years, and the subject remains a fruitful area of industrial, laboratory, and theoretical investigation. This paper presents a cross-section review of these studies with emphasis on: -- the chemical reactions of sulphur and iron oxidation -- the mechanism of magnetite reduction -- matte and slag formation -- flame temperatures -- oxidation potentials -- mineralogy of burner products Abstract ID: 1965 Mechanical Slag Losses in Laterite Smelting


M. Solar1. 1Hatch Presenting from 15:35:00 To 16:00:00 - Tuesday Nickel recoveries in laterite smelters are normally 90 to 97%. About two thirds of the loss occur in the electric furnace slag, both as dissolved oxide and entrained metal prills. “Chemical” and “mechanical” losses are reportedly roughly equal and some operations have actually started to subject their furnace slag to magnetic separation. However, the partition coefficients experienced vary from 80 to 260. This is a much wider range than can be accounted for by the reduction potentials used by various operators. Different plants must thus experience different levels of mechanical losses. The present paper attempts to estimate more precisely the proportion of the two loss mechanisms for eleven selected smelters. The conclusion is that the mechanical losses do vary significantly from plant to plant, from about 0.6 to 2 times the chemical losses. Abstract ID: 2011 TBRC Slag Flux Control at the Copper Cliff Nickel Refinery S. Mroczynski1. 1Vale Inco Presenting from 16:00:00 To 16:25:00 - Tuesday The first step in the Copper Cliff Nickel Refinery process is the smelting of nickel sulphide and oxide feeds in top blown rotary converters (TBRCs). In the TBRC, feed undergoes a series of phases that include charging/melting, oxygen blowing, and reduction in order to produce a matte that is later granulated and further upgraded in the INCO Pressure Carbonyl (IPC) Process Reactor. This paper focuses on the development of a system to control TBRC slag metallurgy in the periclase region of the ternary phase diagram for CaO-MgO-SiO2-10%Al2O3. Reducing the variability in the slag and maintaining the periclase region of the phase diagram at a 1600°C liquidus has optimized refractory lining life, ladle refractory life and matte granulation ability. The performance of the refractory lining dramatically increased from an average of 180 heats per campaign to 300 heats per campaign and new records continue to be achieved as the variability is reduced. Abstract ID: 1850 Liquid Mixing in Thick-Slag Covered Metallurgical Baths L. Tafaghodikhajavi1 and M. Barati1. 1University of Toronto Presenting from 16:25:00 To 16:50:00 - Tuesday Liquid mixing in bottom blown gas stirred reactors has a critical influence on process efficiency and product quality. Cold physical models were used to simulate mixing behavior of the actual system. The dependence of blending time on specific energy input rate, slag height and physical properties of metal and slag was studied. A new parameter, called the “effective bath height” is defined as a function of the slag and metal thicknesses and their relative densities. Consequently a unified correlation for blending time of slag-less and slag covered baths is established. Furthermore, energy dissipation associated with interfacial area increase has been investigated. Abstract ID: 1814 Physico-Chemical Modeling of Slags and Mattes for Ni and Co production I. Jung1, S. Decterov2, A. Pelton2, P. Waldner3 and N. Grundy2. 1McGill University, 2Ecole Polytechnique,


3University of Leoben Presenting from 16:50:00 To 17:15:00 - Tuesday To understand the complex chemical reactions among slag/matte/refractory/gas during pyrometallurgical Ni and Co production, the thermodynamic properties of all phases are required. In order to meet industrial demands, thermodynamic modeling of the CaO-MgO-FeO-Fe2O3-SiO2-Al2O3-CoO-NiO-Cu2O-etc. oxide system and the Fe-Ni-Co-Cr-S matte system has been carried out over many years. Recently, a new structural viscosity model for molten slags has also been developed to better understand the physical properties of molten slags. In the present report, our recent achievements in modeling the thermodynamic properties and viscosities of oxides and mattes of importance to Ni and Co production will be presented.

ENVIRONMENT - Green Technologies for the Mining and Metallurgical Industries Presentations from 2:00:00 PM to 5:30:00 PM - Room F335 SECONDARY MATERIALS Abstract ID: 1995 Extraction of Vanadium from Low-Grade Vanadium Shale Using Double Recirculation and High-Efficiency Oxidization Roast Technology J. Huang1, Y. Zhang1 and T. Liu1. 1Wuhan University of Technology Presenting from 14:00:00 To 14:25:00 - Tuesday This paper proposes a new technology for extracting vanadium from low-grade vanadium shale. This technology consists of several unit operations such as de-carbonization, high-efficiency oxidization roasting, water leaching, acid leaching, ion exchange adsorption and ferrous precipitation. The core of the technology is double recirculation and high-efficiency oxidization roasting. Experiments using this technology indicate that, for a low-grade vanadium shale, at a de-carbonization temperature of 700 oC for 30 minutes, an oxidization roast temperature of 780 to 820 oC for 90 minutes with an additive dosage of 9%, a product assaying >99% V2O5 was produced at an overall vanadium recovery of 75%. Abstract ID: 1702 Thermophile Bioleaching of Low-Grade Chalcopyritic Ore in Presence of Iron Ions M. Lotfalian1, M. Ranjar1, E. Darezereshki1, Z. Manafi2 and S. Seyedbagheri2. 1Shahid Bahonar University, 2Sarcheshmeh Copper Complex Presenting from 14:25:00 To 14:50:00 - Tuesday The effects of ferrous and ferric ions on the bioleaching of a chalcopyritic low-grade copper ore using moderately and extremely thermophile bacteria have been investigated. The copper in the ore was mainly chalcopyrite (0.78%). The pyrite content was inconsiderable (3%). Bioleaching tests were conducted in shake flask mode and the effects of some variables in two levels like concentrations of ferrous and ferric ions (0 and 1.5 g/l), temperatures (50 and 70 C) and pH (1.6 and 2.2) were studied. The results showed that the copper ore dissolved better with extremely thermophile bacteria in low pH value and in the presence of ferrous iron. Maximum copper recoveries in the above conditions in media containing ferrous and ferric irons were 92.6% and 81.7% respectively and it can be concluded that the optimum conditions


for the bioleaching of this ore include using extremely thermophile bacteria in 70 C, pH equal to 1.6, Fe+2 concentration of 1.5 g/l. Abstract ID: 2057 Kinetic Study of Nickel Leaching from Spent Catalyst with Sulfuric Acid M. Nazemi1, F. Rashchi1, N. Mostoufi1 and E. Vahidi1. 1University of Tehran Presenting from 14:50:00 To 15:15:00 - Tuesday Large quantities of spent nickel catalysts are produced annually from fertilizers, petrochemicals, vegetable oil and other industries. Due to the heavy metal content of spent catalysts, they are considered as hazardous industrial wastes and disposal of spent reforming catalysts results in environmental problems. This piece of work focuses on the leaching kinetics of the catalyst and is part of a research on the recovery of nickel and aluminium from spent NiO/Al2O3 catalysts which is being investigated through pyro-hydrometallurgical processes; including leaching, solvent extraction and effect of synergism on the extraction process. An alkaline roasting stage was performed prior to the leaching experiments. The leaching parameters were optimized followed by the kinetic study. Effect of various parameters such as temperature, pH, aqueous to organic phase ratio was investigated. The optimum leaching conditions were determined to be, 3h leaching period, 30% v/v sulfuric acid as the leaching reagent, 90 degrees celsius temperature and solid to liquid ratio of 1:10. Aluminum was recovered as a high purity alumina powder and nickel was extracted as an impure solution. A 98% nickel and 88% aluminium recovery yielded under the optimum conditions. Abstract ID: 1925 Energy and High Value Ash from Rice Husk V. I. Lakshmanan1, R. Sridhar1, R. Laughlin2 and R. R. Roy1. 1Process Research Ortech Inc., 2Torftech (Canada) Incorporated Presenting from 15:35:00 To 16:00:00 - Tuesday Metallurgical industries require electrical power and fuel for pyrometallurgical processes and steam for hydrometallurgical processes. Conventional coal and petroleum-derived fuels are a concern in terms of greenhouse gases. Process Research Ortech has been examining the use of biofuels, which are CO2 neutral from the greenhouse gases point of view for such applications. This paper presents the work related to combustion of rice husk in a Torbed Reactor at Process Research Ortech’s pilot plant. It has been found that clean combustion can be achieved with the production of an environmentally acceptable amorphous silica ash suitable for use in high strength concrete.

HYDROMETALLURGY of Nickel and Cobalt Symposium including the Processing of Valuable By-Products Containing Materials Presentations from 2:00:00 PM to 5:30:00 PM - Fraser Lower PURIFICATION Abstract ID: 1911 Factors Affecting the Precipitation of Hematite Rather than Jarosite in Nickel Sulphate-Chloride


Solutions J. Dutrizac1 and T. Chen1. 1CANMET-MMSL Presenting from 14:00:00 To 14:25:00 - Tuesday Laboratory experiments were carried out to identify the conditions favouring hematite precipitation over sodium jarosite formation when nickel sulphide concentrates are leached under autoclave conditions. Increasing retention times, to 5-6 h at 150°C, result in the precipitation of more hematite from a typical processing solution containing 1.3 M NiSO4-0.2 M Fe(SO4)1.5-0.15 M H2SO4-0.3 M LiCl but no Na2SO4. Increasing temperatures promote the precipitation process and improve the crystallinity of the hematite. Increasing chloride concentrations slightly decrease the amount of hematite precipitated, but have no effect on its composition. Increasing H2SO4 concentrations dramatically reduce the amount of precipitate, but have no effect on the composition of the hematite formed. Increasing concentrations of Fe(SO4)1.5 augment the amount of hematite precipitated but do not affect its composition. Although the mass of precipitate increases in a complex manner with increasing NiSO4 concentrations, the composition of the precipitated hematite remains essentially constant. Notable is the fact that even modest concentrations of Na2SO4 result in the extensive precipitation of sodium jarosite. However, the presence of hematite seed significantly suppresses jarosite precipitation while promoting hematite precipitation. In this regard, autoclave leach residue, which contains major amounts of hematite, is an effective seed material for hematite precipitation. In contrast, neither goethite nor elemental sulphur is an effective seed material for hematite precipitation. Regardless of the experimental conditions, the hematite precipitates are poorly crystallized and typically contain ~60% Fe and 5-7% SO4. Supporting mineralogical studies indicate that the 5-7% SO4 is associated with the hematite and is likely adsorbed on the individual hematite crystallites. Abstract ID: 1791 Iron Control and Tailings Disposal in the Xstrata Chlorine Leach Process O. Dotterud1, E. Peek2, O. Stenstad1 and P. Ramsdal1. 1Xstrata Nikkelverk AS, 2Xstrata Process Support Presenting from 14:25:00 To 14:50:00 - Tuesday Iron is by tonnage the most significant impurity in a variety of feed materials that Xstrata Nikkelverk AS treats in its chlorine leach process. Iron removal in the chloride system through pH-Eh controlled precipitation and its subsequent disposal into caverns as practiced at the refinery in Kristiansand, Norway is the primary focus of this paper. Topics such as the chlorine leach process, iron precipitation operating conditions, the co-precipitation of minor impurities and environmentally acceptable disposal of iron bearing and other hydrometallurgical residues into caverns will be discussed. Abstract ID: 1999 Alternative Options for the Cobalt Manganese Separation in Hydrometallurgical Acidic Circuits C. Ferron1 and P. Louis2. 1Hydroproc Consultants, 2PEL Consul Presenting from 14:50:00 To 15:15:00 - Tuesday Cobalt is often associated in nature with manganese that will be present to a variable extent in most cobalt acid leach solutions. In the case of the production of pure cobalt salts, manganese has to be removed quantitatively, while for the production of cobalt cathodes, it is allowed to build to a point where a bleed has to be introduced to keep it to an acceptable level. Several options exist to selectively separate manganese from cobalt in leach solutions. The paper will discuss three of these options: selective


oxidation of manganese using SO2/O2 mixtures, manganese separation by DEHPA and selective cobalt precipitation using lime or caustic soda. The principles of each process will be reviewed, discussed, and examples of application presented. Advantages and disadvantages of each process will be evaluated. Abstract ID: 1919 Commercial Development of the Magnesia Mixed Hydroxide Process for Recovery of Nickel and Cobalt from Laterite Leach Solutions D. T. White1. 1Consultant Presenting from 15:35:00 To 16:00:00 - Tuesday In 1995 Centaur Mining and Exploration commenced development of the Cawse Laterite Nickel Project. The flowsheet chosen involved precipitation of a Mixed Hydroxide Intermediate from a neutralised Pressure Acid Leach solution. This was followed by re-leaching in ammoniacal solution, solvent extraction and electrowinning. The Cawse processing plant began operations in October 1998 and achieved sustainable design throughput in May 2000. A similar “front end” process was developed for the Ravensthorpe Nickel Project in Western Australia, with Mixed Hydroxide Intermediate Product shipped to Queensland for refining. This paper tells the story of the Mixed Hydroxide Process flowsheet development and outlines the chemistry issues involved in making the MHP Process work. Abstract ID: 1696 Nickel Recovery From Lateritic Ore in the Presence of Ferric Iron Using Bispicolylamine Chelating Resin C. Marston1 and M. Rodgers1. 1The Dow Chemical Company Presenting from 16:00:00 To 16:25:00 - Tuesday Dow Water Solutions (DWS) has an improved bispicolylamine (BisPA) chelating resin XUS-43578 for the recovery of nickel from lateritic ores. The resin is more highly selective for nickel then ferric iron at low pH (1-3) which allows for selective removal of nickel without the need for large pH adjustments to precipitate iron prior to resin treatment. Ferric iron in the pregnant leach solution can be utilized to increase the resin performance. DWS has explored the powerful synergy of using continuous ion exchange engineering technology with this resin for lower cost separations while maintaining the highest resin usage efficiency. Abstract ID: 2035 Opportunities for Ni/Co Extraction and Separation Using Cyanex® 301 I. Mihaylov1, B. Grinbaum2, I. Ilan2 and a. efraim1. 1Vale Inco, 2Inco Vale Presenting from 16:25:00 To 16:50:00 - Tuesday Cyanex® 301 solvent extractant was developed by Cytec in the early 1990’s and adopted by Vale Inco for their Goro process for the separation and recovery of nickel and cobalt from laterite leach solutions. A key feature of Cyanex® 301 is its ability to selectively extract nickel and cobalt from a sulfate medium rich in other metals, e.g. manganese, calcium, magnesium. Both nickel and cobalt may be stripped with hydrochloric acid. While both metals are extracted well at pH<2, at high acidity the cobalt is extracted preferentially to nickel. Typically, minimum pH for efficient extraction of Ni is 1.5, to compare with pH 0.8 for cobalt. In stripping, unlike many other extractant systems, the opposite is true-while the cobalt may be fully stripped with mild concentration of HCl, the nickel stripping requires high concentration of acid.


Overall, cobalt is much easier to be both extracted and stripped. An average pregnant leach solution, that contains both nickel and cobalt, arrives from upstream at pH well above 2. Therefore, for relatively low concentration of both metals, as is the case for laterite leach solutions, they are extracted efficiently without the need for base addition for pH control. For other metal-containing solutions, containing nickel and higher levels of cobalt, the use of Cyanex® 301 presents some interesting opportunities for separating the two metals. Cobalt extraction from more concentrated cobalt solutions, without pH control, will yield an acidic raffinate with pH that may be sufficiently low to suppress the extraction of nickel thus providing an opportunity for separation of cobalt from nickel during extraction. Following acid neutralization of the cobalt-depleted acidic raffinate, nickel can then be extracted with Cyanex® 301. The extraction of Ni and Co from feed solutions as a function of the pH and their mutual concentration in the aqueous phase, and various schemes for separation of Ni and Co from the feed as a function of the concentration of both metals in the feed will be presented in the paper. Abstract ID: 1661 An update on the Application of Molecular Recognition Technology (MRT) to Cobalt Separation and Purification in Primary and Secondary Process Streams S. R. Izatt1, N. E. Izatt2, J. Dale2 and R. L. Bruening2. 1IBC Advanced Technologies, Inc, 2IBC Advanced Technologies, Inc. Presenting from 16:50:00 To 17:15:00 - Tuesday IBC Advanced Technologies’ Molecular Recognition Technology (MRT) SuperLig® products selectively and rapidly bind with target metal ions to remove them from solution. The MRT process can produce high purity separation products of maximum added value at low cost. This paper provides a review of some examples of applications for MRT related to purification of cobalt bearing streams containing contaminants such as copper, nickel, iron, cadmium, and others. In some cases, cobalt is also extracted and purified, producing a high value, high purity cobalt salt.

HYDROMETALLURGY of Nickel and Cobalt Symposium including the Processing of Valuable By-Products Containing Materials Presentations from 2:00:00 PM to 5:30:00 PM - Room F441 LATERITES Abstract ID: 1770 Development of the Anglo Research Nickel Process M. Pelser1, J. T. Smit1 and J. D. Steyl1. 1Anglo Research Presenting from 14:00:00 To 14:25:00 - Tuesday Anglo Base, via its partner Anglo Research, is developing a new technology for the treatment of nickel laterite ores. It is a closed-circuit combination of a hydrometallurgical brine section, operating under atmospheric conditions, and a pyrometallurgical, high temperature decomposition section. The reagents required for the hydrometallurgical section are regenerated within the pyrometallurgical section. The technology is developed through an iterative approach, pursuing economic optimisation utilising mass/energy balance modelling, batch test work and continuous mini-plant test work. This paper will


explore the development of this novel technology as illustrated through the procession of the continuous mini-plant campaigns. Abstract ID: 1774 The Effect of Magnesium on HPAL-Comparison of Sherritt Laboratory Studies and Moa Plant Operating Data M. Collins1, M. Chalkley2 and N. Tuffrey2. 1Sherritt International Corp., 2Sherritt Technologies Presenting from 14:25:00 To 14:50:00 - Tuesday The magnesium content of laterite ore has a significant impact on the quantity of acid required to achieve target nickel extraction by the high pressure acid leach (HPAL) process, both through direct consumption of acid when magnesium-bearing minerals are dissolved, and through buffering effects via the bisulphate ion equilibrium at temperature in the leach reactor. This paper presents the results of HPAL batch tests conducted in Fort Saskatchewan with ore samples from Moa Nickel's Pedro Sotto Alba plant at Moa Bay, Cuba, along with a comparison of the lab results with operating data from Moa. A significant variation in the acid requirement was demonstrated over a relatively narrow range of feed magnesium content. Further, the quantitative results of the tests allow a model to be formulated for the most economic consumption of acid at Moa. Abstract ID: 1716 Ammoniacal Ammonium Leaching of Nickel Alloys - With a Twist D. Dixon1 and A. J. Fischmann1. 1University of British Columbia Presenting from 14:50:00 To 15:15:00 - Tuesday Naturally occurring nickel alloys such as awaruite (Ni3Fe), commonly found in ultramafic rocks, are a potentially significant nickel resource, although an effective extraction process has so far proved elusive. We have developed a hydrometallurgical process using ammonia that operates at modest temperature and atmospheric pressure. Certain additives to the leach have overcome the passivation of the alloys in aerated alkaline solution. The process could also find application in the post-reduction leaching stage of the Caron process. Abstract ID: 1753 Evaluation of Nickel Extraction Kinetics Per Mineral Phase in Laterite Ore F. P. Castro1, P. C. Macieira1, I. Araujo1, O. Gobbo1, G. Pereira1 and F. R. Faulstich1. 1Vale Presenting from 15:35:00 To 16:00:00 - Tuesday An exploratory approach was applied to semi-quantitatively evaluate the extraction of nickel and other metals from the main nickel-bearing minerals commonly found in laterite ores. By interrupting column leaching tests at different times and mineralogically analyzing corresponding leach residues to determine mineralogical composition and nickel distribution throughout the minerals, nickel extraction kinetic curves were obtained for different minerals. Results indicate that different nickel-bearing minerals are leached at particular rates and intermediate phases can be formed and destroyed during the leaching cycle. This study can be considered a starting point for advances in ore behavior prediction and process modeling for nickel laterite heap leaching.


Abstract ID: 2039 Reduction of Limonitic Laterite in Ammoniacal Solution Using Metallic Iron M. Zuniga1 and E. Asselin1. 1University of British Columbia Presenting from 16:00:00 To 16:25:00 - Tuesday The reductive leaching of a limonitic laterite (containing approximately 1% Ni, 0.1% Co and 50% Fe) was studied in ammoniacal solution. The laterite was leached in the presence of metallic iron which acted as a reductant. The kinetic parameters studied included the effect of temperature, agitation speed, iron concentration, pulp density and total ammonia initial concentration. Tests were performed in a batch cell with temperatures ranging from 50 to 80°C at atmospheric pressure. The kinetic behaviour for nickel and cobalt extraction was observed to be different. Cobalt extraction was initially faster than nickel, however, after reaching a maximum value of approximately 70%, extractions decayed by as much as 50%. This was likely due to cobalt adsorption onto iron hydroxides which were formed during the process. Cobalt losses tended to increase with leach temperature and pulp density. Nickel extraction was increased by higher temperatures up to a maximum of roughly 60% after 48 hours at 80°C. Abstract ID: 1926 Selective Reduction - Mixed Chloride Leach Process for Laterites R. Sridhar1, R. R. Roy1 and V. I. Lakshmanan1. 1Process Research Ortech Inc. Presenting from 16:25:00 To 16:50:00 - Tuesday Laterite ores can be classified as low iron, medium iron, and high iron. The low iron (< 10 % Fe) laterites, which are mostly saprolytic, contain > 2% Ni and are treated by pyrometallurgical smelting processes to produce ferronickel. More recently, the medium iron deposits (15-30 % Fe) are treated by mini blast furnaces in China to produce nickeloferrous iron or matte. High pressure leach using sulfuric acid has been considered the best option for high iron (> 35 % Fe) limonitic ores. However, with the world demand for sulfur increasing due to requirements in the fertilizer industry in growth economies, these processes are becoming uneconomical. Selective reduction process provides an alternative option. Novel reduction and leaching process steps are described to make this alternative more economically attractive in current market conditions. Abstract ID: 1739 The Importance of Mineralogy to the High Pressure Acid Leaching of Nickel Laterites R. McDonald1. 1Commonwealth Scientific and Industrial Research Organisation Presenting from 16:50:00 To 17:15:00 - Tuesday The mineralogy of nickel laterite ores determines their process flow sheet. It is widely accepted that limonitic ores are best suited to high pressure acid leaching (HPAL) while ores from the clay and saprolite zones of the laterite profile can also be treated under atmospheric and heap leaching conditions. Accurately predicting sulphuric acid requirements for leaching requires knowledge of the ore mineralogy and for HPAL, an understanding of the impact of the leaching conditions upon the residue composition. This information can be fed into a simple method for predicting HPAL acid requirements for a wide range of ore types.


Applied MINERALOGY Presentations from 2:00:00 PM to 5:30:00 PM - Room F337 Abstract ID: 1711 Quantitative Characterization of Spodumene Ore by Automated Mineralogy from the Moblan Rare Metals Pegmatite Deposit, Quebec, Canada T. Grammatikopoulos1, G. Pearse2, S. Gelcich3 and C. Gunning1. 1SGS Mineral Services, 2Equapolar Resource Consultants, 3GlobeStar Mining Presenting from 14:00:00 To 14:25:00 - Tuesday The Moblan spodumene deposit is located in Quebec, Canada. Globestar Mining Corporation is now evaluating processing techniques for recovery of spodumene to be used in the Li industry. To determine the purity of the processed ore, XRD and QEMSCANTM coupled with whole rock and Li analyses were utilised to identify and quantify the mineralogy of the deposit, and define the Li distribution among minerals. Six composite samples covering a wide area of the deposit were examined. The Li-bearing minerals include primarily spodumene and Li-bearing muscovite, and impurities including microcline, Na-feldspar, quartz and trace amounts of sulphides, biotite, chlorite, Fe-Ti-oxides, Ta-minerals, spessartine and other minerals. Samples were prepared and analyzed in a manner to decrease or eliminate preferred orientation of muscovite to provide accurate quantitative results. The results show that spodumene is the main Li mineral. It is well liberated (>80%). The main associations of spodumene are with Na-feldspars, quartz, microcline, and a combination of these. Muscovite is the main mica and it also carries Li. The value of the QEMSCANTM mineralogical data is extremely valuable in assessing the mineralogy of o the ore. The data have been implemented in defining the mineralogy of the ore body, support metallurgical test work, predict recoveries and grades, and finally calculate reserves of the deposit. Abstract ID: 1992 Preparation of Polyhydroxy-Titanium Ion Pillaring Agent and Ti-Pillared Montmorillonite Complex Material T. Liu1, Y. Zhang1 and J. Huang1. 1Wuhan University of Technology Presenting from 14:25:00 To 14:50:00 - Tuesday In this work, a polyhydroxy-titanium ion pillaring agent has been prepared by using Ti(n-C4H9O)4 as a titanium resource. In the preparation of polyhydroxy-titanium ion, several parameters such as preparation temperature, aging temperature and aging time, were tested in order to elucidate their effects on polymerization. The prepared polyhydroxy-titanium ion pillaring agent was intercalated into interlayers of a host clay, Na-montmorillonite, to produce a Ti-pillared montmorillonite complex material. The formation of the Ti-pillared montmorillonite has been confirmed by X-ray diffraction, scanning electron microscopy and specific surface area measurement. Abstract ID: 1917 Process Mineralogy and Applications in Flowsheet Design and Plant Optimization: Overview and Case Studies J. Zhou1. 1Jktech Pty Ltd Presenting from 14:50:00 To 15:15:00 - Tuesday


As a predicting and trouble-shooting tool, process mineralogy helps address issues and problems related to flowsheet design and plant optimization. It provides useful information on process selection, flowsheet development, recovery improvement and/or cost reduction. The information acquired from a process mineralogical study is often used as a guide for a metallurgical testwork program for process design or optimization. This paper reviews the principles and objectives of process mineralogy, advances in and applications of commonly used mineralogical techniques, and comments on how the process mineralogy can help with flowsheet design and plant optimization through case studies. Abstract ID: 1983 Speciation and Quantification of Surface Gold in Carbonaceous Matter from AC POX Stream Products by TOF-SIMS S. Dimov1, B. Hart1 and A. Chattopadhyay2. 1University of Western Ontario, 2SGS Mineral Services Presenting from 15:35:00 To 16:00:00 - Tuesday Gold recovery can be adversely affected by preg-robbing on inherent carbonaceous material during autoclave pressure oxidation. Gold complexes with thiosulfates and thiocyanide radicals or with halogen ions are sorbed on the surface of carbonaceous matter and eventually reduced to metallic gold. The Time of Flight Secondary Ion Mass Spectrometry (TOF-SIMS) technique has been applied for direct determination of gold species on individual carbonaceous particulates from AC POX stream samples. The speciation of the gold preg-robbed on carbonaceous matter from CIL tail sample showed presence of both metallic gold and Au(CN)2 compound. Direct quantification of the metallic and compound gold provided an estimate for the fraction of gold losses due to preg-robbing in carbonaceous matter. Abstract ID: 1986 The Chemical Reactivity of an Ore: A Predictive and Diagnostic Tool for Flotation Behaviour Using TOF-SIMS Analyses B. Hart1, S. Dimov1, C. Martin2 and J. Lang3. 1University of Western Ontario, 2SGS, 3SGS Mineral Services Presenting from 16:00:00 To 16:25:00 - Tuesday The Time of Flight Secondary Ion Mass Spectrometer (ToF-SIMS) is unique in that it measures the outermost atomic layers of any material. In this regard, the technique is particularly suited for the determination of surface chemical composition on mineral particles. In this paper we will present evidence showing how mineral surface chemical analyses by ToF-SIMS can be used to predict the chemical reactivity of the ore. The preliminary experimental study investigated the potential for Cu transfer between the ore minerals pyrite and sphalerite during the grinding process. The data revealed a number of interesting and significant features: the variability of Cu transfer on sphalerite and pyrite for the entire ore data set extends over a dynamic range of several orders of magnitude the degree of Cu transfer is better indicated by pyrite surface loading. the surface loading of Cu on pyrite, can in some, but not all, cases be reconciled by mineralogy. In testing the chemical reactivity test of samples composed of skarn, hypogene, supergene material, the Cu content on pyrite surfaces follows a distinct trend: increasing from the skarn to the supergene samples. The data can be correlated to an increase in secondary minerals in the hypogene and supergene samples, whose solubility is greater than the primary minerals found in the


skarn. We believe this shows the value of the chemical reactivity test in that it can potentially predict the behaviour of minerals in a flotation test in response to chemical transfer during the grind.

PROCESS CONTROL Applications in Mining and Metallurgical Plants Presentations from 2:00:00 PM to 5:30:00 PM - Room A226 METALLURGY, MODELLING Abstract ID: 1861 Modeling in a Metallurgical Process Development R. Kandepu1 and A. Grovlen1. 1Elkem AS Research Presenting from 14:00:00 To 14:25:00 - Tuesday This paper focuses on role of modeling in a metallurgical Research and Development (R&D) centre, specifically in a stage gate framework for product and process development. Modeling assists in the design of the equipment and to understand, optimize and control the process. This work presents an overview of modeling work in a stage gate framework and identifies the tasks to be solved by the models at each stage gate. Modeling also involves inter-disciplinary understanding and cooperation; metallurgical, mechanical, control and operational groups. The paper also tries to identify the modeling tasks from each group’s view and tries to list the kind of models (for example, zero-dimensional or multidimensional, static or dynamic, mathematical or empirical etc) that may be needed in a typical process development. Abstract ID: 2051 Integrated Modeling of an Smelter Off-Gas Cleaning System H. Shang1, P. Nelson2, B. Salt3 and J. Scott1. 1Laurentian University, 2Xstrata Process Support, 3Xstrata Nickel Sudbury Smelter Presenting from 14:25:00 To 14:50:00 - Tuesday In a Nickel smelting process, a large amount of off-gas emission is often generated, which can cause serious environmental and plant hygiene problems if not properly treated. With increasingly stringent environmental regulations, an enhanced understanding of and well controlled off-gas cleaning systems are vital for Nickel smelter production. In this paper, the dynamic models for an industrial smelter off-gas system, tackling hazardous sulfur dioxide (SO2), carbon monoxide (CO) and carbon dioxide (CO2), are developed using mass continuity, momentum and energy conservation laws. Interactions of the off-gas systems from roaster and furnace are investigated. Effects of air in-leakage are explored under different operating conditions. The developed models provide an enhanced process understanding and a necessary basis for high performance control analysis of smelter off-gas systems. Abstract ID: 2026 Control of Copper Teniente Smelting Units Using Integrated Advanced Control Technologies A. Morrow1 and M. Gajardo2. 1Invensys Ips, 2Codelco Chile Presenting from 14:50:00 To 15:15:00 - Tuesday


Copper flash smelting units are very difficult to control and optimize. The units are semi-continuous, and they experience frequent large unmeasured disturbances, variable process delays, and noisy measurements. Shutdowns and feed interruptions are common. The unit’s key controlled variables always include discontinuous measurements and laboratory analyses. This paper describes Advanced Process Control (APC) applications on two copper smelting units of Teniente design at Codelco smelters in Chuquicamata and Teniente, Chile. Integrated applications that combined model predictive control (MPC), expert rules, embedded stoichiometric relationships, and economic optimizers were successfully implemented to control and optimize these units. Abstract ID: 1775 High Fidelity Dynamic Simulation for the Mining and Metallurgical Industry M. Delisle1 and J. Alamo1. 1Honeywell Process Solutions Presenting from 15:35:00 To 16:00:00 - Tuesday The mining a metallurgical industry is facing structural and cyclical challenges. Structural challenges include declining levels of reserves, increasing costs, and environmental regulations. Cyclical challenges include lower demand, declining prices, and the current financial credit crunch. These challenges force operating companies to improve their operation and become more efficient. New techniques have been used successfully in the oil sands industry to characterize physical properties of solids and to simulate solid handling equipment. The same approach can be applied to the mining and metallurgical processes to reduce cost and increase productivity. This paper will present: - Modeling concepts used to represent process streams, and equipment such as conveyers, crushers, screens, floatation cells and clarifiers. -Benefits of using dynamic process simulation in de-bottlenecking, control system design and checkout, HAZOP reviews and initial and ongoing operator training programs. Abstract ID: 1967 Modeling Bubble Size Distribution for Control Purposes M. Maldonado1, A. Desbiens1, R. del Villar1 and R. Aguilera 2. 1Universite Laval, 2University of Concepcion Presenting from 16:00:00 To 16:25:00 - Tuesday Although bubble surface area flux (Sb) has been found to be related to flotation performance, important information related to the shape of the bubble size distribution, such as multi-model behavior is completely neglected in the calculation of the Sauter bubble mean diameter usually used to calculate Sb . In this work, a Gaussian mixture model (GMM) is used to represent the underlying bubble size distribution. A recursive version of the expectation maximization algorithm is implemented to estimate the GMM parameters. Three “frit and sleeve” spargers were implemented to generate diverse distributions by changing gas rate, water rate and frother concentration. Abstract ID: 1679 Improving Accuracy, Transparency and Audibility by Moving From Spreadsheets to an Integrated Metal Accounting Application P. Cooper1. 1Schneider Electric Presenting from 16:25:00 To 16:50:00 - Tuesday


Improving accuracy, transparency and audibility by moving from spreadsheets to an integrated metal accounting application Many organisations in the minerals processing industry are focused on improving the accuracy, transparency and audibility of their primary metal accounting process. The AMIRA P754 code and guidelines for Metal Accounting provide excellent guidance to those organisations undertaking this challenge. The P754 code states that efficient, secure and reliable data management adds value to the Metal Accounting System and highlights some of the issues encountered when using spreadsheets for primary metal accounting. The organisation must then face the issue of moving from spreadsheets to something else. What is that something else? This paper provides a case study of the approach and the product used by a Base Metal Refinery. This paper will demonstrate an easy to use operations management solution providing real-time information for both primary and secondary accounting. The outcome is a solution that significantly improves the organisations compliance to the AMIRA P754 code but also a platform for continuous improvement of recoveries. To assist other organisations that are considering a similar path, this paper will also discuss the practical lessons learnt through the implementation and the maintenance phases of the project.

MATERIALS - Materials Development and Performance of Sulphur Capture Plants Presentations from 2:00:00 PM to 5:30:00 PM - Room F336 PROCESSING AND PROPERTIES Abstract ID: 1859 Optimization of Reactants Ratio in Aluminothermic Reaction of Aluminum and Zinc Oxide A. Maleki1, B. Niroumand1, M. Meratian1 and M. Panjepour1. 1Isfahan University of Technology Presenting from 14:00:00 To 14:25:00 - Tuesday In this study pure aluminum and zinc oxide powder mixtures containing 20, 40 and 60 percent of aluminum were milled in a planetary ball milling machine for 60 minutes. These mechanically activated powders were reacted in a differentials thermal analyzer system under argon atmosphere. The activated powders were tested using X-ray diffraction method. The DTA test results were analyzed to determine the reaction mechanism and activation energy. Based on kinetical analysis, the reaction mechanism was found to be interface controlled. The results revealed that the activation energy was minimum for the mixture containing 40% of aluminum. Abstract ID: 1733 Using Artificial Neural Network to Optimize the Aging Behaviors and Bake Hardening of Al2024 and Al7075 N. Kamkar-Zehmatkesh1, K. Dehghani1 and S. S. Tayarani-Bathaie1. 1Iran Amirkabir University of Technology Presenting from 14:25:00 To 14:50:00 - Tuesday In the present work, the response of two aluminum alloys (Al2024 and Al7075) to strain aging and bake hardening (BH) was investigated. After the primary heat treatments, the direct chilled ingots were subjected to laboratory cold rolling. Various treatments and different testing conditions were used to evaluate the aging and baking behaviors of the mentioned alloys. The different strains were applied so as


to attain different dislocation densities required for attaining various aging and baking values. The results show that the higher the strain, the greater the strain aging and BH amounts will be. Experimental data was used for the training of ANN and a multilayer cascade forward back-propagation neural network was designed. The optimization was achieved by minimizing the errors between the predicted values and the ones that were obtained experimentally. The predicted values obtained from the trained ANN are found to be in close agreement with the experimental results. Abstract ID: 1823 Studies and Experimental Research on Structural Modifications of an Al-Cu-Li Alloy During Plastic Deformation Through Warm Extrusion I. Butnariu1, I. Butnariu2 and D. Butnariu3. 1University Politehnica of Bucharest, 2Socesit Bucharest, 3Tudor Vianu College Presenting from 14:50:00 To 15:15:00 - Tuesday The paper presents studies and experimental research work on warm plastic deformation of the aluminium alloy (AA) 2090 (AlCuLi alloy). The plastic deformation processes that can be applied to AA2090 are rolling, forging and extrusion. For each plastic deformation process, the possibility of warm and cold deformation was examined, including analysis of the deformation equipment. The research work performed on the AA2090, which included microscopic examination and micro-hardness measurements in longitudinal and transversal directions, indicated good workability of the alloy. Abstract ID: 1799 Determining of Residual Stresses in the Nitrocarburized Layers with X-Ray Diffraction Techniques A. P. Zumbilev1 and I. Zumbilev1. 1Technical University of Sofia, Plovdiv branch Presenting from 15:35:00 To 16:00:00 - Tuesday The aim of the present investigation is to examine the influence of nitrocarburizing of low temperature plasma over forming surface macroresidual stresses of the steel. Particular modes of ionic nitrocarburizing are revealed in which layers with different depth and surface microhardness are obtained. The residual stresses in the nitrocarburized layers are determined with the method of "sin2ψ". The results show that at different modes of ionic nitrocarburizing residual macrostresses are obtained, which are with different size and depend on the mode of treatment (pressure of ammonia, temperature of nitriding, duration of treatment) and the depth of the nitrided zone. Abstract ID: 1880 Sonochemical Deposition of Silver Nanorods by Nanobubbles in Laser Techniques I. Farahbakhsh1. 1Islamic Azad University of Qouchan Presenting from 16:00:00 To 16:25:00 - Tuesday Sonochemical irradiation of silver acetate aqueous solution resulted in deposition of on silver nanocrystals and imparted it with electrical properties. The silver nanorods are well product by ultrasonic method. The characterization of the product by X-ray diffraction (XRD), transmission electron microscopy (TEM), high resolution transmission electron microscopy (HR TEM), energy-dispersive X-ray analysis (EDX), and X-ray photoelectron spectroscopy (XPS) reveal the presence of two phases of the silver and the oxide, but no chemical interaction between them has been found. The strong anchoring of oxide to


the nanosilver surface was explained as a result of local melting of silver when the oxide nucleus is thrown at the silver surface by high speed sonochemical microjets.

MANAGEMENT - Current Management and Human Resource Issues Presentations from 2:00:00 PM to 5:30:00 PM - Governor Lounge Abstract ID: 1884 How to Deal with Changing Demands in Engineering Resources H. De Ruiter1 and W. Dalmijn2. 1Delft University of Technology, 2Federation of European Mineral Programs Presenting from 14:00:00 To 14:25:00 - Tuesday Partnership and cooperation in metallurgical and mineral engineering education is essential to maintain programs in this field and cater to the changing demands from the industry. Since thirteen years 6 European universities offer jointly education in mineral and mining engineering in order to continue high quality education in times of low demand. A total of 60 students from North and South America participated. About 35 companies support this program through the Federation of European Mineral Programs (FEMP). Without this internationalization of the education, it is impossible to maintain good quality education and to increase the enrolment when needed. Abstract ID: 1876 Case Study: A Latin American Project Example for Strengthening Community Relations and Promoting Local Employment and Training O. Gamache1. 1Hatch Presenting from 14:25:00 To 14:50:00 - Tuesday Using a rural Latin American case study, this presentation highlights the lessons learned in building and maintaining effective relations between project teams and local communities. Project challenges will be discussed, such as overcoming language barriers, achieving effective consultation, ensuring respect for local culture, managing community expectations, and maximizing employment and small business opportunities for local Indigenous communities. Key successful strategies used will then be shared, including creating a local employment office, strengthening communications with the Community Relations team, promoting employment and training strategies for rural/indigenous populations, building culturally sensitive approaches to hiring, training, and consultation, and managing population influx. Abstract ID: 1804 The Best of Both Worlds-Building a Competent Workforce with Global Rigour and Local Context A. Kitchen1 and P. B. Maclaren1. 1AMEC Presenting from 14:50:00 To 15:15:00 - Tuesday Today the resource sector faces significant challenges to develop and maintain a competent workforce. These challenges include increased technical and logistical operational demands, and the imperative to promote local content. There is an increasingly unpredictable labour pool which can be aging, or have skill shortages, or non-aligned skills. As globalisation continues, companies also require efficiencies during operation across locations. Often, companies are also required to implement a competence


management system that satisfies increasingly rigorous regulatory requirements. We will describe a process that meets these challenges. We will present examples of its implementation in oil and gas projects in the UK and Azerbaijan, and downstream projects in the USA, which are globally applicable. The process is a competence determination and management system that provides global consistency while allowing localisation. The process covers the full lifecycle of development activities-from local capability assessment and candidate selection, training that integrates blended learning technologies, task-based competency assessment and performance review against applicable standards, to succession management and organisational development. The process provides a dynamic framework which supports simultaneous consistency and flexibility by making the task the base unit of competence. This allows reuse and recombination of tasks, which have globally defined standards plus local customisation of suitable assessment evidence, to provide role profiles which fit local contexts. Combined with web-based technology, this system enables the management of high volume workforces, while retaining individual learning plans and progression, aiding job satisfaction, and employee retention. Global companies are demanding a competent and safe work force to maintain consistent production, and deliver the required financial returns within the frame work of a regulated industry. A well designed competence management system helps in that process. Abstract ID: 1705 Supervisory Effectiveness - Bridging the Gap Between Expected and Delivered Results B. Chertow1 and K. Kelton1. 1Kelton, Chertow and Boyd Inc. Presenting from 15:35:00 To 16:00:00 - Tuesday Most business leaders admit that creating a strategy is easier than executing it. That’s because organizations don’t know how to bridge the gap that exists between executives, managers and employees. Results suffer when “a company” tries to execute its strategy despite its “people”, rather than co-operating with them. This paper describes: - The roots of supervisory engagement and effectiveness - The reasons workers, including supervisors, consider themselves disengaged - What managers and supervisors can do to increase the level of effective engagement with their employees - A framework and range of valuable tools enabling supervisors and their employees to speak the same language, see from a common viewpoint, and connect their individual actions to the success of the company. Abstract ID: 1924 Modeling for Real-time Performance Measurement: A Strategic Approach R. Cook1. 1Invensys Process Systems Presenting from 16:00:00 To 16:25:00 - Tuesday As mining companies look to improve their operations in the face of increasing global pressure and competition, continuous improvement programs, have been undertaken by companies in an effort to remain competitive and improve their position. To ensure that continuous improvement projects and initiatives are adding value to the company, a real-time performance measurement system must be coupled with continuous improvement programs. Real-time business intelligence can also be applied to greenfield projects that provide all layers with unprecedented view in to the business performance in the mineral processing operation. With this business intelligence, people can make better decisions to


improve performance. By improving performance with this system, performance can be expected to improve 2 to 3 percent. This enables operations to earn project payback in a shorter timeframe. Abstract ID: 2016 Filling the Baby Boomer Vacuum: Millions of People Are Retiring from the Workforce in the Next Two Decades D. Evans1. 1Kepner-Tregoe Presenting from 16:25:00 To 16:50:00 - Tuesday How organizations choose to identify their highest priority talent and knowledge management concerns today, and focus on the greatest potential problems will play a significant role in their long-term survival and growth. A critical component in facilitating this transition is the deployment and support of a common language for issue resolution across the business. Only by embracing a shared platform for addressing open issues, bridging gaps between levels of subject matter expertise, will organizations be able to ride the wave of this workplace transformation. This paper is intended to raise awareness of the three critical building blocks necessary for achieving - and sustaining - improved business performance through the transfer of critical thinking skills to the next generation of workers.


com 2009: technical program - tuesday, august 25,...

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