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By Stefan Wallner, Andreas Filzwieser, Stefan Konetschnik, Reinhard Preiss, Iris Filzwieser

"Process Safety Management for METTOP means avoiding risks as far as possible - but also dealing with the residual risk by using all existing management tools or external assistance, if required. The presented paper has two parts. The first one introduces a new and very safe cooling technology for metallurgical furnaces. The second part shows how to deal with the residual risk as well as minimize it by using the tapping area of an electric arc furnace as an example.Today more and more intense furnace operations require effective cooling in order to achieve low refractory wear and good furnace lifetime, making cooling technology an important aspect of furnace operation. However, the use of water - today’s standard cooling medium - has some disadvantages, as it can cause problems both during furnace start up and operation, namely hydration problems, corrosion, and explosion.To overcome the disadvantages of water, a new cooling technology using an alternative cooling medium, namely ISIS B (a special kind of ionic liquid) was developed. The main advantage of ISIS B is the fact that no explosion occurs when this liquid comes in contact with molten metal. The working temperature range of ISIS B of 50 to 200 °C results in other advantages as there are no corrosion problems and no risks of hydration.The fact that no explosion occurs when ISIS B contacts molten metal leads to a revolutionary solution for the metallurgical industry in terms of safety. Especially in critical areas - like tap-holes - new safety standards can be achieved.Together with the TÜV Austrian Holding AG a risk analysis was done for a water cooled tap-hole as well as for a tap-hole cooled with ionic liquids. It is shown that using the new technology the risk can be decreased dramatically and the importance of a best available technology is described."

Jan 1, 2014

By Neri Roux, Ross Gilders, Yemi Oyediran, Leo Cheung

Quest Rare Minerals Ltd. is developing their Strange Lake B Zone REE deposit located in Northern Quebec. An extensive batch bench scale testing program was launched to investigate open circuit rougher flotation performance under different conditions. The objective of the flotation study was to demonstrate the effectiveness of rejecting gangue minerals to flotation tailings while concentrating rare earth elements as well as yttrium, zirconium, and niobium into a concentrate suitable for further hydrometallurgical processing. Mineralization of interest at Strange Lake occurs within peralkaline granite-hosted pegmatites and minor aplite. The REE and high field strength element (HFSE)-bearing phases are hosted primarily in pegmatites as relatively fine-grained phases or pseudomorphs. The gangue phases comprise of quartz, feldspar, amphibole, and pyroxene. Potential ore minerals comprise predominantly of kainosite, gerenite, gadolinite, zircon, pyrochlore, and gittinsite. These complex mineralogical characteristics increase the difficulty for processing and provide a challenge for choosing the correct reagent scheme in rougher flotation. Process options including reverse flotation to reject the gangue minerals and de-sliming prior to the direct rougher flotation were investigated. Optimization trials were conducted using various reagent regimes and under different flotation conditions. Encouraging results were found using a combination of collector reagents supplied by Cytec Canada Inc.

Jan 1, 2014

By Q. Han, W. Dai

Al-Ti-B type master alloys have been widely used in the grain refinement of aluminum since 1940s. The introduction of Al3Ti and TiB2(AlB2) particles reduces the grain sizes down to about 200 micrometer level and makes cold work possible. However, the mechanism for the grain refinement is still not clear, though it is believed that TiB2 in the presence of Al3Ti nucleate a-Al grains in solidification. This paper presents our finding on the formation of (Ti,Al)B2 solid solution, which leads to a proposed theory on grain refinement by Al-Ti-B type master alloys that upon addition into aluminum melt stable TiB2 particles react with aluminum slowly and release titanium into the melt. The titanium thus released in combination with titanium in the melt through dissolution of Al3Ti maintains a transient titanium-rich layer on the surface of (Ti,Al)B2. This layer offers a low crystal mismatch with a- Al and promotes the nucleation of aluminum grains.

Jan 1, 2014

By B. Jakovljevic, M. D. Soderstrom, T. McCallum, A. J. Quilodrán

Cytec has developed a new organophosphorus based solvent extraction (SX) reagent for rare earth separations. The new product, CYANEX® 572, has been formulated to allow efficient extraction while minimizing the strip acid requirements. The optimization of formulation strength is expected to significantly reduce the operating costs of these circuits. Modeling capabilities for CYANEX® 572 (similar to those used successfully in Cu and Co/Ni SX) have also been developed to aid in the design and optimization of the SX circuits. Simulations will be shown comparing CYANEX® 572 to a traditional rare earth extractant.

Jan 1, 2014

By O. A. Ojo, D. L. Chen, N. Zhou, J. Q. Zhang, A. K. Khan

Dual phase (DP) steels are designed to consist of hard martensite dispersed in a relatively soft ferrite matrix, which offers a favorable combination of high strength with good deformability. Fiber laser welding (FLW) is becoming increasingly important for joining advanced materials due to its flexibility and deep penetration. In this study, the microstructure of a dual phase steel, DP980, welded by FLW technique was carefully analysed. Gleeble thermo-mechanical simulation coupled with analytical transmission electron microscopy (TEM) revealed that the FLW process produced significant microstructural changes in a narrow heat affected zone (HAZ) and fusion zone (FZ), which can result in dramatic changes in mechanical properties. This is reflected in the micro-hardness profile obtained across the welded material. The salient phase transitions induced by the FLW, including the formation of new martensite grains in the upper-critical HAZ and FZ, are discussed.

Jan 1, 2014

By B. Dubreuil, J. -M. Lalancette, D. Lemieux

A gold bearing pyrite concentrate was treated at the pilot scale for the extraction of gold. Mineralogical analysis of the concentrates identified gold to be mainly present in the form of a solid solution in pyrite. Gold distribution resulted in a poor extraction yield of 55 % by direct cyanidation. A piloting campaign including an oxidative pre-treatment by roasting in a fluid bed was followed by treatment with halogens for gold extraction and has led to a gold extraction yield of 94%. Sulphur removal during the oxidation was very efficient at >99.5% and gold extraction by the halogens was completed within a 1 hour contact time. The piloting was performed on a 300 kg sample and used a diluted solution of hypohalites as the oxidizing agent for gold extraction. Sulphuric acid was injected in the reactor during the halogens treatment to lower pH to 2. The diluted solution of hypohalites (1-3%) was generated by electrolysis during the piloting campaign in a diaphragm-less electrolysis cell. The extracted gold was recovered via adsorption over silica and the gold depleted brine was treated for impurities removal. This brine was recycled for further gold extraction. With the recycling of water and brine, the regeneration of hypohalites and with a barren solid that is inert and stable, the Nichromet Extraction technology is a green process where the protection of the environment does not preclude profitability.

Jan 1, 2014

By K. Tsuchihashi, A. Kishimoto, T. Uda, Y. Kado, S. Maruyama

We recently proposed a continuous production process for titanium metal with some experimental results. In the process, titanium tetrachloride is reduced by Mg in the presences of Bi to form a Bi-Ti alloy at 900ºC. At this temperature, the obtained alloy is liquid and allows for the continuous removal of product and heat from the reaction vessel. The obtained Bi-Ti alloy was vacuum-distilled at 1000ºC for 24 hr, and 98 at % (92 wt %) titanium, which was easily crashed to powder, was obtained. Bi solvent was selected because of the highest titanium solubility at 900ºC and the moderate vapor pressure among the candidate metals (Bi, Sn, Pb, Zn, and Sb).

Jan 1, 2014

By Guadalupe Sanchez, Roel Cruz, Sergio Castro, Claudia Beltrán, Isabel Lázaro

The recovery of zinc in refineries is strongly affected by the formation of zinc ferrites during the roasting of zinc concentrates. To achieve the highest zinc recovery most of these plants operate under high acidity and high temperature conditions in their leaching circuits. However, under these conditions high iron dissolution occurs. For iron control the common practice is to precipitate it as jarosite, and calcine is normally used as neutralizing agent. This practice causes a significant loss of metal values associated with the calcine, such as zinc ferrites and silver insoluble phases. These metal values are carried by the jarosite into confined waste in many plants. In order to diminish such losses, it is necessary to use a neutralizing agent that could substitute the use of calcine. An alternative neutralizing could be the basic zinc sulfate (BZnS). This work presents the results of a laboratory analysis on the required conditions for the BZnS production from process streams of a zinc refinery plant. Neutralizing behavior of BZnS was evaluated in iron precipitation as jarosite, in order to establish the feasibility of replacing the calcine and decrease the loss of zinc and other metals values during the iron removing step of the hydrometallurgical circuit of the zinc refinery under study.

Jan 1, 2014

By L. Gonzalez-Sardi, W. McCombe, M. Pearson

Pressure oxidation is increasingly being used for processing refractory sulphide ores and concentrates because it offers highly effective base metal and precious metal extraction while minimizing elemental sulphur, arsenic & mercury emissions. Yet pressure oxidation processes introduce new safety concerns and process risks as demonstrated by a number of safety incidents over the last 20 years, including overfilling, oxygen-metal fires, nozzle/sparger failures, and uncontrolled pressure relief events. Chemical Process Safety regulations in the United States and Canada mandate that companies constructing or operating chemical process facilities perform a rigorous hazard and risk analysis based on either ANSI/ISA-84.00.01 or IEC 61511 safety standards to determine the level of protection required for each hazard in the plant. This paper describes the application and implementation of three (3) unique safety instrumented systems developed by Hatch for ensuring the safe operation of three different pressure oxidation processes.

Jan 1, 2014

By X. Cao, X. -G. Chen, K. Liu

Due to the detrimental effect of platelet iron-rich intermetallics on mechanical properties (particularly ductility) in cast alloys, it has been essential to transform these phases into Chinese script morphology. In the present work, the effects of Mn and/or Si addition and cooling rate on the phase transformation of the iron-rich intermetallics in 206 cast alloys with different Fe contents ranging from 0.15 % to 0.5 % were systematically investigated. The results obtained showed that platelet ß-Fe and Al3(FeMn), Chinese script a-Fe, Alm(FeMn) and Al6(FeMn) can be observed in the 206 cast alloys, depending on the Fe, Mn and Si contents as well as the cooling rate. It was found that the addition of either Mn or Si favors the formation of Chinese script iron-rich intermetallics but inhibits the precipitation of the platelet phases. In addition, the combined addition of both Mn and Si has a synergistic effect on the phase transformation. Furthermore, there exists a critical cooling rate to effectively suppress the formation of platelet iron-rich intermetallics for a given alloy. The threshold cooling rate decreases with increasing Fe, Mn and Si contents. Casting process maps are established to correlate the intermetallics precipitated with alloy chemistry and cooling rate for 206 cast alloys containing various Fe levels.

Jan 1, 2014

By A. R. Barnes, R. Pandher, T. Shannon, P. Gover

Following the closure of the Glencore Zinc Brunswick mine, the Glencore Brunswick Smelter has transitioned to treating external feeds, and currently treats a number of secondary Pb-Zn concentrates. Processing these concentrates has in some cases been challenging due to the diverse mineralogy of the feeds. Certain feeds are difficult to ignite or show inadequate sulphur removal during oxidation on the sinter strand, while in other cases, combinations of feeds produce a sinter with unsuitable properties for further handling. This paper discusses two methods developed in collaboration with XPS Consulting & Testwork Services to characterize these feeds prior to processing them and to identify which ones are most likely to pose challenges during processing.

Jan 1, 2014

By K. C. Viveros, R. R. Ambriz, C. García, F. De Villèle, A. Talha, D. Jaramillo

Cold hole expansion on base metal, weld metal and heat affected zone of 6061-T6 aluminum alloy welds was simulated by means of finite element method. Three dimensional compact test models with a previous fatigue crack length with a relation of ??= a/W = 0.3, were used to analyze the hole expansion process. Considering the local mechanical properties for each zone of the welded joint, the optimal expansion degree (1.64 to 2.46 %) was determined. The residual stress field, through thickness, after the expansion process in all welding zones, were correlated with the crack opening displacement obtained by finite element analysis. It was observed, that compressive residual stress fields for a post-expansion, in different crack lengths, provided a crack closure mechanism for base metal, weld metal and heat affected zone. Contrary, the crack remained open when residual stresses are positive. The results are given as tangential stresses versus distance from the edge of the cold expansion and crack opening displacement as a function of applied load.

Jan 1, 2014

ABSTRACT Understanding process histories and worker exposures in nickel production operations is critical in determining the role nickel compounds play in respiratory cancer incidence. As part of a series on Vale Canada’s (previously known as Inco) nickel processing operations, this paper includes descriptions of Ni electrolytic operations at refineries in Port Colborne, Ontario (1922–1984), and Thompson, Manitoba (1961–present). Industrial hygiene measurements, by area and personal sampling, of workplace aerosols at these operations are reported.

Jan 1, 2014

By T. Hadley, E. Catovic

"Northern Minerals Limited’s (ASX: NTU) flagship project is the Browns Range Rare Earth Project (the Project) located in Western Australia, consisting of a number of deposits with high value, heavy rare earth elements, in particular yttrium, terbium, and dysprosium. The deposits are dominated by xenotime mineralisation, which occurs within hydrothermal silicified and hematitic breccias. The Company delivered an initial JORC compliant resource estimate for the Project at the end of 2012 of 10,500 t of contained total rare earth oxides (TREO), which was increased to 28,084t of contained TREO in October 2013 and further enlarged to 47,997 t of contained TREO in February 2014. Concurrent with the growth of the Project resource base, significant progress has been made in developing the metallurgical process for the beneficiation and extraction of rare earth elements (REE’s) from the xenotime mineralisation. Development of the beneficiation circuit evaluated several process options and selected whole-ore flotation and magnetic separation, followed by flotation (hybrid circuit) as the two preferred flowsheets to pilot, following encouraging results on the bench of 83% and 86% recovery to a 20% TREO mineral concentrate respectively. Several downstream hydrometallurgical extraction flowsheets were evaluated. However, the following two preferred process flowsheets were ultimately selected for further detailed investigation during the prefeasibility study: 1. Sulphation bake, water leach, purification, oxalate precipitation, and/or calcination to produce a mixed RE oxide; 2. Sulphation bake, water leach, phosphate precipitation, caustic conversion, HCl leach, and oxalate precipitation to produce a mixed RE oxalate. Excellent heavy rare earth oxide (HREO) extractions (~ 90%) from beneficiation concentrates were achieved on the bench for both circuits, however flowsheet 1 was ultimately selected as the preferred flowsheet to pilot due to lower capital and operating cost. A mixed rare earth oxalate (42% TREO) or oxide (92% TREO) can be produced with low levels of Th and U of 3 ppm and 6 ppm respectively."

Jan 1, 2014

By B. Yu, N. Verbaan, A. Mezei

The recent 20 years witnessed a boom and bust in the nickel laterite industry. Most notoriously is the story of the first three Western Australian nickel laterite projects which all suffered major ramp-up issues. Many hard lessons were learned by the industry and it has been widely reported that the major contributing factors included insufficient testing as well as a limited understanding of the materials handling characteristics at the front-end stage of the flowsheet. This paper compares the current "race to production" in the REE industry to the laterite industry 20 years ago and addresses the fundamental question: ‘Have mining and exploration companies with rare earth projects learned from past lessons and are they doing sufficient and appropriate testwork to prevent failure’? The authors will provide the perspective of a commercial metallurgical laboratory that has gone through the laterite cycle and is active in the present REE cycle.

Jan 1, 2014

By T. Krumins, L. Zunti, R. Frischmuth

Titanium and titanium alloys are commonly selected for pressure oxidation autoclave vent piping and pressure control valve components, as well as autoclave internals, in high-temperature operations. In a vent application, titanium ignition risk is reduced by limiting oxygen concentration, and preventing high gas velocity gas impingement on surfaces. Oxygen concentration is dependent on the autoclave pressure and temperature conditions and therefore titanium ignition risk is dependent on standard operating procedures, and process control interlocks and permissive conditions. It is not uncommon for standard controls to be deficient during atypical operating conditions, or for operations to deviate from the operating procedures, increasing the potential for titanium ignition incident. Titanium ignition risk caused by elevated oxygen concentration in autoclave vent systems can be reduced with the introduction of an online autoclave overpressure calculation and the configuration of associated interlocks and permissive conditions.

Jan 1, 2014

By Chris Harris, Kamal Adham

The use of HCl acid is gaining momentum among hydrometallurgical processes. However, the issue of environmentally efficient and economically viable ways to regenerate HCl acid (from various metal chloride intermediate products) remains a technology and operational challenge. The authors provide a state-of-technology review based on Hatch’s years of testing, design and commissioning experience with high-temperature units (fluid bed and spray roasters), plus the recent efforts in the area of low-temperature HCl regeneration.

Jan 1, 2014

By P. A. Gonzalez Contreras

Scorodite is considered as a secondary mineral formed from the product of weathering of primary minerals by chemical or biological reactions. In the case of biological scorodite formation, microorganisms mimic and accelerate what in nature takes a very long time, i.e. biocrystallisation. The goal of the biological scorodite formation is to form very stable arsenic crystals suitable for long-term and safe disposal. The biological formation of scorodite is a novel combination of biological oxidation, biocrystallisation, and proper bioreactor design to achieve the biological formation of scorodite crystals in one step. We have explored simultaneous biological arsenic and iron oxidation at 30ºC and at 70ºC leading to arsenic-jarosite phases and scorodite, respectively. As biologically formed scorodite crystals are very stable (TCLP < 1 mg/L As (V)), the risk of arsenic toxicity is minimized when leaching takes place. This process is suitable for arsenic concentrations above 0.5 g/l As achieving up to 20 mg/l As in the effluent. This biological scorodite formation system is a selfsufficient bio-oxidation system and therefore many new applications can be explored such as reprocessing of arsenic trioxide, orpiment or calcium arsenate to scorodite crystals for a stable and safe disposal.

Jan 1, 2014

By K. Peake, A. Dalvi, V. Hernandez, S. Chang, M. Oliazadeh

"Ironstone Resources Ltd. is developing the Clear Hills oolitic iron ore deposit in northwest Alberta, Canada. Sources of oolitic iron ore worldwide are abundant and ubiquitous, but there is currently no commercial technology to extract iron from oolitic iron ores. Mineral processing of the ore to generate a commercial iron ore concentrate is very challenging due to the nature of these ores. Accordingly, Hatch and Ironstone are developing a new pyrometallurgical process (Hatch Ironstone Chloride Segregation) to produce metallic iron from high silica and high phosphorus oolitic iron ores. Following the chloride segregation process, the treated ore is subjected to fine grinding. The iron is then separated by magnetic separation. The iron grade and phosphorus content of the final product shows a strong dependence on the separation methodology and the grind size. The pyrometallurgical process has been developed and tested at a lab-scale pilot plant. The commercialization of this technology could provide an opportunity for the development of a new alternate iron making technology. This paper presents the results of test work done on the raw iron ore to create a concentrate and also on the products of the pyrometallurgical process for the production of a high grade 90% metallic iron product.INTRODUCTION Oolite is a sedimentary rock formed from ooids – spherical particles with concentric layers. There are a number of large oolitic iron deposits where the mineralogical form features a low iron content and high concentration of impurities making them presently impossible to exploit on either a technical or economic basis. The fifteen largest oolitic iron ore deposits in the world are estimated to contain approximately 337 billion tonnes of iron ore, which would be a significant source of supply for worldwide steel production. A viable process that can economically recover iron from these oolitic iron ore deposits could become an important new technology to meet future demand in the steel industry. Hatch and Ironstone have demonstrated that oolitic iron ores can be exploited to produce direct reduced iron (DRI). Direct reduction ironmaking is a method for producing solid metallic iron using different techniques compared to the blast furnace process, which is the more conventional ironmaking route. The demand for the construction of direct reduction ironmaking plants has increased in response to the increasing demand for crude steel. It is viewed as a method of providing low-residual iron sources to scrap-based steelmaking in electric arc furnaces."

Jan 1, 2014

By George P. Demopoulos

In this paper the author will provide an overview of over 20 years of research & developments in the area of hydrometallurgical arsenic immobilization that culminated recently in the industrial implementation of the atmospheric scorodite process. The paper will consider various aspects of arsenic fixation in the non-ferrous metal industry from the iron-arsenic co-precipitation process employed to arsenic-bearing effluent solutions; to autoclave processing of arsenical copper and gold feedstocks and the fate of the in-situ formed iron sulphato-arsenate precipitate phases; the precipitation and stability of scorodite; the possible stabilizing role of mineral phases like yukonite, and the development of "scoroditeplus" processes employing novel encapsulation strategies. Emphasis is placed on the characterization and long-term stability of the various forms of arsenic-immobilized phases under either oxic or anoxic conditions over a wide pH range and the establishment of critical links between process parameters and hazardous material stability, contributing thus to advancement of new generation safe and sustainable waste management technologies.

Jan 1, 2014