Xstrata Technology Update Edition 14 – April 2013 Our First Quarter Century
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Chapter 11: Beneficiation
CHAPTER 11 Beneficiation – Comminution Sponsored by: SPONSOR PROFILE Through pioneering the introduction of modern process • project controls and reporting plants and associated technologies to remote and logistically • contract management challenging locations, Lycopodium Minerals Pty Ltd has • procurement and logistics management developed a successful track record in developing and • inspection and expediting commissioning major resource projects worldwide. • quality assurance/quality control Since its establishment in 1992, Lycopodium has become a • financial evaluations leading international engineering and project management • client representation. consultancy, with an enviable reputation for providing Engineering technically innovative and cost-effective engineering solutions. They are focused on the evaluation and development of projects • Conceptual through to detailed design in the fields of minerals processing, materials handling and • across all disciplines: earthworks, civil infrastructure. • structural, mechanical, piping • electrical, instrumentation, control Lycopodium Minerals has undertaken studies and projects across a broad range of commodities including gold (free, • systems, automation and infrastructure. gravity, refractory, preg robbing), base metals (concentrators, Process hydrometallurgy), iron ore, uranium, rare earths and industrial minerals. Their resume of projects reflects diversity in not • Metallurgical test work design only commodity, but client background, technology, scale of • management and interpretation -
Developments in Permanent Stainless Steel Cathodes Within the Copper Industry
DEVELOPMENTS IN PERMANENT STAINLESS STEEL CATHODES WITHIN THE COPPER INDUSTRY K.L. Eastwood and G.W. Whebell Xstrata Technology Hunter Street Townsville, Australia 4811 [email protected] ABSTRACT The ISA PROCESS™ cathode plate is characterised by its copper coated suspension bar, coupled with a blade employing austenitic stainless steel alloy 316L. The blade material has become the mainstay of the technology and has been closely copied by competing cathode designs. Improvement to the cathode plate design remains a key area for research, and ongoing developments by Xstrata Technology’s ISA PROCESS™ have recently been commercialised. Two such developments are the ISA Cathode BR™ and ISA 2000 AB Cathode. The ISA BR cathode is a lower resistance cathode that has proven to enhance operating efficiencies. The AB cathode was designed to improve stripping inefficiencies in the ISA 2000 technology. These developments have now had time to mature and their long term performance will be discussed. Rising material costs and the desire to extend the operating boundaries of the standard 316L cathode plate has triggered a number of significant advances. These involve the use of different stainless steels as alternatives in some operational situations. The technical aspects and results of commercial trials on this development will also be discussed in this paper. INTRODUCTION The introduction of permanent stainless steel cathode technology was pioneered in the copper industry by IJ Perry and colleagues in 1978, with the introduction of the ISA PROCESSTM in the Townsville Copper Refinery, Perry [1]. While a number of parallel processes have emerged since its introduction, ISA Process Technology (IPT) has continued to be the mainstay electrolytic copper process with consistent improvements and superior operational performance. -
Challenges Related to the Processing of Fines in the Recovery of Platinum Group Minerals (Pgms)
minerals Review Challenges Related to the Processing of Fines in the Recovery of Platinum Group Minerals (PGMs) Kirsten C. Corin 1,* , Belinda J. McFadzean 1, Natalie J. Shackleton 2 and Cyril T. O’Connor 1 1 Centre for Minerals Research, Chemical Engineering Department, University of Cape Town, P Bag X3, Rondebosch, Cape Town 7700, South Africa; [email protected] (B.J.M.); [email protected] (C.T.O.) 2 Minerals Expertise Tech Pty Ltd., Germiston 2007, South Africa; [email protected] * Correspondence: [email protected] Abstract: In order to increase the recovery of PGMs by flotation, it is necessary to optimise the liberation of the key minerals in which the platinum group elements (PGEs) are contained which include sulphides, arsenides, tellurides, and ferroalloys among others, while at the same time ensuring the optimal depression of gangue minerals. In order to achieve this, comminution circuits usually consist of two or three stages of milling, in which the first stage is autogeneous, followed by ball milling. Further liberation is achieved in subsequent stages using ultra-fine grinding. Each comminution stage is followed by flotation in the so-called MF2 or MF3 circuits. While this staged process increases overall recoveries, overgrinding may occur, hence creating problems associated with fine particle flotation. This paper presents an overview of the mineralogy of most of the more significant PGM ores processed in South Africa and the various technologies used in comminution circuits. The paper then summarises the methodology used in flotation circuits to optimise recovery Citation: Corin, K.C.; McFadzean, of fine particles in terms of the collectors, depressants, and frothers used. -
Choosing & Using a Milling Machine
CHOOSING & USING A MILLING MACHINE Bench mill vs. Knee mill? There are similarities between ALL small vertical milling Variable machines and the traditional drill press, right: speed drive 1. A vertically-movable quill which encloses the spindle. 2. A drill press lever which propels the quill downward. Head- 3. A quill clamp to lock the quill firmly in position. stock 4. A variable-speed spindle drive system. Quill 5. A headstock that can be moved up or down on a clamp vertical column. Quill Feature (5) applies only to bench mills, but check for Drill Column press this important difference: Many, but not all, bench mills lever have dovetails for headstock height adjustment, not round columns — see next page. Table Every vertical mill is a part-time drill press, but there’s more to it than that. Comparing mills with drill presses, here are the KEY DIFFERENCES: 1. Massive, rigid construction, a lot more cast iron. 4. A mill spindle is designed for both down load (axial, like a 2. Heavy T-slotted movable table on dovetail ways, with ± drill press), and also side load (radial). That is why a mill 0.0005″ position measurement capability (optional 2- or spindle runs in tapered roller bearings (or deep-groove ball 3-axis DRO). bearings) inside the quill. 3. The workpiece doesn’t slide on the mill table: instead it is 5. The spindle isn’t just for drill chucks — use any R8 com- firmly clamped to the table, which moves left-to-right and patible device — end mill holders, collets, slitting saws, etc. -
Effect of Comminution Method on Particle Damage and Breakage Energy
EFFECT OF COMMINUTION METHOD ON PARTICLE DAMAGE AND BREAKAGE ENERGY Michael Moats, Jan Miller, Chen-Lun Lin and Raj Rajamani Department of Metallurgical Engineering University of Utah Outline • Our Department • High Pressure Grinding • Particle Damage Characterization • Breakage Energy • Application to Simulant Development Department of Metallurgical Engineering • University of Utah is located in Salt Lake City along the Wasatch Mtns. • Only stand alone Metallurgical Engineering department remaining in the U.S. • Traditional curriculum with critical mass of professors – Mineral Processing – Chemical Metallurgy – Physical Metallurgy High Pressure Grinding Rolls (HPGR) HPGR consists of a pair of counter rotating rolls, one fixed and the other floating. The feed is introduced to the gap in between the rolls and they compress the bed of particles. The grinding force applied to the crushing zone is controlled by a hydro-pneumatic spring on the floating roll. Speeds of the rolls are also adjustable to obtain optimum grinding conditions. Comparison of HPGR and AG/SAG Mills Aspect HPGR AG/SAG Mill Grinding Mechanism Inter-particle compression Impact, attrition and compression Residence Time Low-single pass High (feed migrates through length of mill) Wet/Dry Grinding Dry-Low moisture Predominantly wet milling Availability >90% -2-4 change outs pa >90% -1-2 change outs pa Size regulated feed Required Yes-strongly affects stud breakage AG-No, SAG-Sometimes Critical material size Not required Required Product particle Yes (beneficial for downstream Negligible micro-cracking processes Maximum Throughput 2000tph 4000tph Footprint Small Large Specific power 1-5kWh/t 5-12kWh/t Operating cost Overall plant 20% lower Overall plant 20% higher Capital Cost 25% lower 25% higher Delivery time Substantially faster Substantially longer Variation in feed hardness Single parameter variable High losses •Reference: Koenig, R.L. -
THE NEW KEENE ROCK CRUSHERS ROLLER MILL Produc T Report
THE NEW KEENE Produc t ROCK CRUSHERS Report AND COMBINATION By AU Testing Laboratories ROLLER MILL Base Mount Trailer Mounted Electric Driven dered a competitive price on the mar- testing site because it contained an Keene Engineering has brought into ket today. THE COST IS LESS THAN abundance of fractured quartz rock view, a new ROCK CRUSHER that HALF. containing gold and silver. The rock has brought the mining industry to its When AU Testing Laboratories was also extremely harder than com- feet. A new combination rock crusher first agreed to make an evaluation on mon type ore of this nature and and roller mill that has the capacity of this product, we were needless to say should provide a good test for any crushing a four by six rock into "ultra skeptical about the manufacturer's type crushing equipment. fine powder," in one single, quick and claims, but were again impressed Although the unit weighed over efficient operation. They have com- with the performance of this beauty. 700 pounds it was surprisingly easy bined two separate processes of rock We learned that Keene had been in to tote around. We moved many crushing into a single machine. the process of engineering and test- times to different locations on the The first stage is a jaw crusher ing this unit for over 10 years and this mine site with relative ease. We that crushes aggregate to one quarter unit has evolved from some twenty understood that this machine could of an inch, that can be adjustable to previous prototypes. be provided on either a permanent larger or smaller size and the second We loaded the unit with its base or trailer mounted. -
Comminution of Copper Ores with the Use of a High-Pressure Water Jet
energies Article Comminution of Copper Ores with the Use of a High-Pressure Water Jet Przemyslaw J. Borkowski Faculty of Geo Engineering Mining and Geology, Wroclaw University of Technology, 50-370 Wroclaw, Poland; [email protected] Received: 4 November 2020; Accepted: 27 November 2020; Published: 28 November 2020 Abstract: The article presents research on the comminution of copper ore in a self-constructed mill using high-pressure water jet energy to investigate the usefulness of such a method for comminuting copper ore. As a result, ore particles are obtained that are characterized by appropriate comminution and a significant increase in their specific surface, in turn allowing for potential further processing of the mineral. A comparative analysis of the efficiency of copper ore comminution, primarily taking into account the unit energy consumption and the efficiency of the milling process, clearly indicates that the energy absorption of hydro-jet material comminuting is lower than during mechanical grinding, e.g., in a planetary ball mill. The applicability of the technique depends on the brittle nature of the host rock, e.g., it is especially appropriate for sandstone and shale ores. Keywords: copper ore comminution; hydro-jet mill; high-pressure water jet 1. Introduction Shredding processes are widely used in various fields of raw material processing. Such procedures are carried out in order to lower the costs of maintaining the cutter discs used in Tunnel Boring Machines (TBM) operating in hard rock formations [1]. They are also used to obtain fine-grained particles, sometimes even nanoparticles [2] or those that have an increased specific surface, which can be especially useful in pharmaceuticals [3]. -
Xstrata Technology Update Edition 13 – April 2012 Building Plants That Work
xstrata technology update Edition 13 – April 2012 Building plants that work You have to get a lot of things it takes another operator to get them right to build a plant that works. right. Someone who has lived through the problems, had to do the maintenance, operated during a midnight power Of course the big picture must be right – doing the right project, in the right place, failure, cleaned up the spill. Someone at the right time. who has “closed the loop” on previous designs; lived with previous decisions After that, the devil is in the detail. You and improved them, over and over. need a sound design, good execution, good commissioning, and ongoing This is why Xstrata Technology provides support after commissioning. You need a technology “package”. Just as a car to operate and maintain your plant in is more than an engine, technology is the long run, long after the construction more than a single piece of equipment. company has left. That’s when all the Technology is a system. All the elements “little” details become important – how of the system have to work with each easy is it to operate, how good is the other and with the people in the plant. maintenance access, what happens in We want our cars designed by people a power failure, where are the spillage who love cars and driving. So should points and how do we clean them our plants be designed by people with up? Are the instruments reliable and experience and passion to make each is the process control strategy robust one work better than the last. -
Improving Energy Efficiency Across Mineral Processing and Smelting Operations – a New Approach
Improving Energy Efficiency Across Mineral Processing and Smelting Operations – A New Approach C L Evans1, B L Coulter2, E Wightman3 and A S Burrows4 ABSTRACT now reporting their performance in this area using a range of sustainability indicators. Among these, energy use and its impact With their commitment to sustainable development in an increasingly carbon-constrained world, many resources companies are focused on on climate change are priorities, with many company reducing the energy required to create their final products. In particular, sustainability reports including total energy use and associated the comminution and smelting of metal-bearing ores are both highly greenhouse gas (GHG) emissions in both absolute and relative energy-intensive processes. If resource companies can optimise the terms (ie normalised to a per unit product) among their key energy efficiency across these two processing stages, they can directly environmental sustainability indicators. Companies are setting reduce their overall energy consumption per unit mass of metal produced targets to achieve improvements in these indicators, but at the and thus reduce their greenhouse gas footprint. same time there is a global trend to more complex and lower Traditional grinding and flotation models seek to improve the grade orebodies which are more energy-intensive to process. As efficiency of mineral processing, but they do not consider the energy used a result, resource companies are having to become more by downstream metal production, eg smelting and refining. Concentrators innovative to improve the environmental sustainability and the and smelters individually may be running efficiently, but are they optimising energy consumption of the overall system? A key step towards efficiency of their operations. -
Thermodynamic Efficiency of a Copper Comminution Process
PONTIFICIA UNIVERSIDAD CATOLICA DE CHILE ESCUELA DE INGENIERIA THERMODYNAMIC EFFICIENCY OF A COPPER COMMINUTION PROCESS WILHELM ALEXANDER JACOB RODRÍGUEZ Thesis submitted to the Office of Research and Graduate Studies in partial fulfillment of the requirements for the Degree of Master of Science in Engineering Advisor: PHD. JORGE RAMOS GREZ Santiago de Chile, August, 2016 MMXVI año, Wilhelm Alexander Jacob Rodríguez PONTIFICIA UNIVERSIDAD CATOLICA DE CHILE ESCUELA DE INGENIERIA THERMODYNAMIC EFFICIENCY OF A COPPER COMMINUTION PROCESS WILHELM ALEXANDER JACOB RODRIGUEZ Members of the Committee: PHD. JORGE RAMOS GREZ PHD. WOLFRAM JAHN PHD .TIMOTHY GUTOWSKI PHD. ANGEL ABUSLEME Thesis submitted to the Office of Research and Graduate Studies in partial fulfillment of the requirements for the Degree of Master of Science in Engineering Santiago de Chile, August 2016 To my parents, siblings and girlfriend whom all, in their own way, showed their support during the development of this work. To Professor Ramos whom presented this great opportunity and guided throughout its study. To Dan and Tim who patiently coached and helped during this study. ii ACKNOWLEDGEMENTS To God almighty whom I owe everything I am, his blessing for having a privileged education and health, loving family and girlfriend and good friends. May he forever guide my path and that this work be of contribution for others, for their wellbeing and his glory. To my parents, whom I owe my whole lifetime education, love and support. To my father who gave me practical counsel, to my mother who gave me all the help she could give me. To my siblings whom, in their own way, helped and supported me during this project. -
Weir: See Things Differently
WEIR: SEE THINGS DIFFERENTLY. The Weir Group PLC Annual Report and Financial Statements 2020 CONTENTS FINANCIAL & NON-FINANCIAL SUMMARY Strategic Report ORDERS2 1 Our Business at a Glance 2 £1.9bn 2.9 2.9 Our ‘We are Weir’ Strategic Framework 4 -13% Chairman’s Statement 6 2.3 2.2 150 years of Weir 8 1.9 2.1 Chief Executive’s Strategic Review 10 1.9 Our 2020 Key Performance Indicators 14 Total Group Discontinued Operations Iron Bridge Aftermarket Contract 16 Continuing Operations Our Markets 18 Our Business Model 20 2016 2017 2018 2019 2020 The Global Pandemic 22 Stakeholder Engagement 24 REVENUE Safety in Mining 26 1 Financial Review 28 £2bn 2.8 2.8 Sustainable Society 32 -4% 2.3 2.3 Operational Review 34 1.9 2.0 2.0 Risk Management 39 Principal Risks and Uncertainties 43 Total Group Our Sustainability Review 52 Discontinued Operations Continuing Operations Non-financial Reporting 64 2016 2017 2018 2019 2020 Corporate Governance Introduction from the Chairman 70 ADJUSTED PROFIT BEFORE TAX3 TOTAL STATUTORY LOSS AFTER TAX Governance at a Glance 72 1 Board of Directors 74 £255m (£149m) Group Executive 78 -5% +61% 333 299 Board Statements 79 232 247 Division of Responsibilities 80 269 255 Total Group 171 Board Meetings 81 Discontinued Operations Board Activities and Governance in Action 82 (£23m loss in 2020) Governance in Action - Meet the Board Session 83 Continuing Operations Shareholder Engagement 84 2016 2017 2018 2019 2020 Boardroom Practice 85 Board Effectiveness 86 TOTAL INCIDENT RATE4 Accountability 88 Viability Statement 89 0.37 -
Early Rejection of Gangue – How Much Energy Will It Cost to Save Energy?
Early rejection of gangue – How much energy will it cost to save energy? Grant Ballantyne 1,2 , Marko Hilden 1,2 and Malcolm Powell 1,2 1The University of Queensland, JKMRC-SMI 2Co-Operative Research Centre for Optimising Resource Extraction (CRC ORE) Contact: [email protected] ABSTRACT Comminution accounts for approximately 30 to 40% of the energy consumed on an average mine site (DOE, 2007) and somewhere from 4 to 9% of Australia’s total energy consumption (Tromans, 2008). Additionally, if one includes the energy embodied in steel grinding consumables, this may increase comminution energy by more than 50% (Musa and Morrison, 2009). Energy savings of up to 50% are theoretically possible by employing novel circuit designs and using smart separation techniques, which reject coarse liberated gangue. A range of different strategies such as selective mining, screening, ore sorting, coarse flotation and dielectrophoresis can be used to reject the coarse liberated gangue at different particle sizes. These technological advances have the potential to increase the throughput in the comminution circuit, while decreasing the energy consumed per tonne or ounce of metal produced. This paper investigates the energy consumed through sorting, and the optimum position of these technologies in the flow sheet, in terms of energy, cost and risk. The findings form the basis of a methodology that can identify the potential upgrades/changes required to obtain a positive return from these sorting and coarse separation techniques. Reference as: Ballantyne, G.R., Hilden, M., Powell, M.S., 2012. Early rejection of gangue – How much energy will it cost to save energy?, In Comminution '12, ed.