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By Courtney Chamberlain

The Telfer Project, Australia's newest, largest and most remote gold mine, treats 480,000 metric tonnes of ore grading 9.33 grams per tonne derived from open pit mining operations. Coarse gold is recovered by gravity concentration with jigs and further upgraded using a continuous strake, table and by amalgamation. Remaining gold is recovered in a cyanide circuit and incorporates flat bottom air agitators, CCD and stellar filters for clarification and precipitate removal. Overall recovery into bullion averages 98 percent. The mill incorporates a number of design features which allow for maximum efficiency and security using a minimum number of operating personnel.

Jan 1, 1980

The future phosphate rock deposits in South Florida contain a significant fraction of dolomite. The high MgO content of the rock is undesirable in the production of phosphoric acid. Several flotation schemes have been attempted to separate dolomite from phosphate rock. Alternately, Selective Flocculation process has been suggested to separate dolomite from apatite. A high MgO content rock was simulated by a 30:10:60 synthetic mixture of apatite, dolomite and silica. Single mineral selectivity was observed in the mixed mineral systems apatite-silica and dolomite-silica with Polyacrylic acid (PM) and Poly(ethylene oxide) (PEO) flocculants respectively but not realized in apatite-dolomite system with PEO flocculant. Heteroflocculation, suspected to be the major reason for loss in selectivity, was minimized by addition of a Site Blocking Agent (lower molecular weight fraction of PEO). Process parameters such as size reduction schemes, flocculant/SBA dosage, and pH were investigated to achieve the desired separation. The selectivity obtained in binary mixed mineral tests was translated into the ternary mixed mineral system, viz. apatite-dolomite-silica. In this presentation surface chemical characterization of the samples and their flocculation behavior will be discussed.

Jan 1, 1994

By William I. Weisman

Natural sodium sulfate is obtained from both brines and solid deposits. The brines almost always contain other salts with sodium chloride predominating. They may be obtained from surface occurrences, such as Great Salt Lake or from shallow subterranean deposits. Althought many sodium sulfate minerals are known to exist, only three are of commercial significance. These are thenardite, the anhydrous salt; mirabilite, the decahydrate; and glauberite, the double salt of sodium and calcium sulfate. The reader is referred to Weisman (1983) for details on mineralogy and geology of sodium sulfate minerals. Sodium sulfate deposits, either in the form of brine or solid minerals, are found in many parts of the world. Natural sources, by far, provide the primary supply of commercial grades in Canada, Mexico, Spain, and probably in the U.S.S.R., Chile, Argentina, and Turkey. In the United States, production of natural material and synthetic (including by-product) are about equal in volume and have been for many years.

Jan 1, 1984

By Wayne N. Marchant

Introduction The issue of coal mining safety plays an important role in the United States' growing dependence on coal to supply its future needs. This article will address the federal government's role, principally the US Bureau of Mines, in meeting this challenging growth and demand while reducing the social and economic costs attributed to injuries and fatalities in underground mining. Some interesting facts and projections with respect to the nation's energy picture will be discussed. This includes the distribution of its reserves and the projected role of coal in the energy and economics of the nation's future. Underground mining will continue to be an important means of providing this coal. The author will discuss how the Bureau of Mines' research program addresses the problems of health and safety that grow out of the demand for more coal. Future projections First, a synopsis of salient facts and projections concerning the US's situation with respect to energy and the economy. Figure 1 depicts the relative quantities of recoverable energy reserves in the United States by their type. Most people are aware of the nation's use of oil. We hear a lot about natural gas. And we are aware of the controversy over the use of nuclear energy. But, while looking at Fig. 1, the question becomes, "Where will our fuel to meet the demand for energy in the future most certainly have to come from?" With 82% of the nation's recoverable fuel reserves being coal, the answer is irrefutable. Coal will be that source. Figure 2 is the present market for coal. It shows that 77% of the coal mined goes to supply electric utilities. Therefore, the coal industry as a whole is most sensitive to the trends and demands for electricity. It is less affected by what happens in other markets, such as export and direct industrial use. In fact, the coal industry is three times more sensitive to the electric utility market than to all other markets combined. Therefore, the trend in the demand for electricity must be examined. Electricity demand is expected to increase steadily over the next 15 years. It is projected to grow from its present 2.3 trillion kWh per year to 3.5 trillion kWh per year by the year 2000. The fuel to supply this increase in demand must come from somewhere. The question is "How much of this extra fuel will be coal?" Although the demand for electricity is predicted to increase, the demand for coal does not necessarily follow. Coal must maintain its fraction of the energy sources used for electricity generation if its demand is to increase at the same or greater rate as electricity. Except for a near-term dip in demand due to a slight increase in nuclear capacity, the domestic electric generation accruing to coal will go from 56% in 1985 to more than 60% in 2005. Thus, the predicted trend is for coal to become a larger part of the fuel mix for electric power generation. Similarly, looking at the most recent forecast for total coal consumption trends, it can be seen that for electric power generation alone, the coal industry must be able to supply an additional 316 Mt/a (348.5 million stpy) by the year 2000 (Fig. 3). It must be stressed here, though, that without significant improvements in mining safety, it can also be easily predicted that injuries and fatalities will increase in proportion to the increase in coal production. Will society consider that acceptable? This author does not believe so. Figure 4 examines the effect of coal prices on the price of electricity. The projections show that the already high proportion of fuel cost will become a greater fraction of the consumer price for electricity. Specifically in 1985, 36% of the price of electricity was the cost of the fuel. In 1995, 46% of the price of electricity will be the fuel cost. That implies that the price of coal will have an increasing influence on the consumer price for electricity. Thus, as coal is used more to generate electricity and as fuel becomes a greater

Jan 4, 1987

By R. W. Fedors, S. T. Green, F. T. Dodge, D. B. Walter

Spatial and temporal temperature variations in a high-level radioactive waste repository drift can give rise to moisture transport within the drift. Knowledge of this moisture transport may be important to assessing the potential for corrosion of all metallic components in the drift. The model presented here shows one approach to simulating evaporation, transport, and condensation of water in large underground openings using a framework based on computational fluid dynamics. Simulation results that explicitly model water and latent heat transport are presented.

Jan 1, 2004

By M. U. Khan, A. D. S. Gillies

"Diesel exhaust is a major cause of large number of occupational diseases. Acute and continuous exposure to Diesel Particulate Matter (DPM) can cause numerous health issues including respiratory disease, reduced lung capacity, heart disease etc. The National Institute of Occupational Safety and Health (NIOSH) and the International Agency for Research on Cancer (IARC) consider diesel engine exhaust as carcinogenic. In large underground metal and nonmetal mining operations, regulatory compliance regarding miner’s exposure to airborne particles especially DPM is a big challenge. Complex mine networks add more difficulties in controlling DPM. MSHA relies on the NIOSH 5040 method for DPM compliance. The NIOSH 5040 method is a shift average based method which inherits some limitations. Due to these inherent limitations of the NIOSH 5040 method the concept of real-time DPM monitoring is promoted in the mining industry. Several real-time DPM monitors have been used by the researchers and efforts still continues to improve their measuring techniques and understanding. Real-time monitoring of DPM is vital to gain understanding of rapid changes in the mine atmosphere. The current study highlights the advancement in real-time DPM monitoring and mainly covers a review of several studies in which DPM concentrations were measured by utilizing real-time DPM monitors. INTRODUCTION Ventilation of underground mines is an important aspect of mining operations. Mining is a continuous activity and the ventilation networks in modern mines change with extended developments. Proper understanding of the ventilation network is a key design factor of an optimum mine ventilation plan. An important task of underground mine ventilation engineers is to provide clean air with sufficient quantity to the underground miners (Khan M. U. and Gillies A.D.S. 2015). The amount of fresh air supplied to the mine should be adequate to dilute the concentrations of contaminants present in the mine atmosphere. In the United States it is estimated that diesel powered equipment is used in thousands of mining operations (Stephenson D. J. et al. 2006). Use of diesel powered equipment is an attractive option in underground mines due to its several advantages over other available alternates. Diesel engines are rugged, dependable and fuel efficient (McKinnon 1999). It is common for diesel engines in heavy duty trucks to have a life of 1.6 million kilometers (McKinnon 1999). Looking at the developments in other energy alternatives, it can be assumed that the underground mining industry will maintain its reliance on diesel powered equipment (Anon 2001). DPM is an important source of mine air contamination in many non-gassy underground mines (Khan M. U. and Gillies A.D.S. 2015). Diesel exhaust is harmful for humans. Acute and continuous exposure to diesel exhaust concentrations can cause several health issues. Some of the health diseases caused by DPM exposure are respiratory diseases, reduced lung capacity, heart disease, and lung cancer (National Research Council. 1981, Mine Safety. 2005). In addition, NIOSH regards diesel exhaust as “potential carcinogen” (Centers for Disease Control 1988) and IARC has declared that “diesel engine exhaust is carcinogenic to humans” (IARC 2012). NIOSH has also declared that the reductions in DPM exposure would reduce cancer risks (Centers for Disease Control 1988)."

Jan 1, 2016

By N. Sahin, M. Can, Z. Ekmekçi, Y. Öztürk, Ö. Biçak, I. B. Çelik, B. Kocabiyik

"In this paper, a case study from Çayeli Bakir Isletmeleri A.S. (Rize, Turkey) about the selective flotation of copper minerals from sphalerite is discussed. Çayeli Cu-Zn Sulfide Ore contains different ore types, such as yellow ore, clastic ore, bornite-clastic ore, bornite-yellow ore, and black ore. For some of these ore types, selective flotation of copper and zinc is very difficult presumably due to presence of secondary copper minerals such as bornite, chalcocite and covellite, and also surface oxidation. These factors affect Cu-Zn selectivity due to activation of sphalerite particles in the ore during the process. The main objective of this work was to improve Cu-Zn selectivity by optimization of the pulp chemistry for different ore types of Çayeli ore. After preliminary flotation tests investigating effects of different chemical conditions, a plant survey was performed to determine the plant performance and sources of the problems when problematic bornite-clastic ore is treated in the plant. Various chemical conditions are tested in the laboratory scale test for better depression of sphalerite in copper flotation circuit. Combination of Na2S+ZnSO4+MBS was found to be the most effective depressant scheme. INTRODUCTION Ore variability is one of the most important factors affecting performance of a process plant both in short and long term planning. The geometallurgical modelling becomes a common tool to determine ore variability problems and develop the most efficient solution during life of mine (1, 2). Flowsheet design and equipment selection and sizing are usually done based on the results of ore variability test works. However, in some cases ore variability may not be foreseen during the design stage and therefore the solutions should be developed based on the existing flowsheet and equipment in the plant. In this situation, ore characterisation, problem statement and diagnostic testing should be applied step by step. The problem could be due to changing feed grade, mineralogical characteristics, grindability and surface characteristics when flotation is involved. The variability in feed grade with fixed mineralogy can be handled with relatively simple modifications (i.e. adjusting throughput or equipment capacity) in the plant. Variability in ore mineralogy is the most complex and difficult problem to tackle. Because, mineralogical variations could bring variations in mineral composition, texture and liberation. These variations can potentially lead to the variations in grindability of the ore and flotation behaviour. Variations in grindability are usually managed by optimization of operational parameters in grinding circuit, as it would be costly to replace the existing equipment in the circuit (3). The variations in flotation behaviour are mainly due to variations in mineral types and distribution, texture and surface oxidation. One or all of these factors could be observed in a flotation operation. Therefore, a comprehensive investigation both in plant and lab scale should be conducted for definition of source of the problem. The testwork to solve the problem and retrieve the performance is planned and conducted depending on the source of the problem (4, 5)."

Jan 1, 2017

By Wendy M. Brunner

A 70% excess of mesothelioma, an asbestos-related cancer, has been reported among men in northeastern Minnesota, where iron mining has been the major industry. The Minnesota Department of Health has studied iron miners who developed mesothelioma to identify possible sources of asbestos exposure. A database of all Minnesota residents diagnosed with mesothelioma between 1988 and 1996 was linked to a database of approximately 72,000 current and former Minnesota iron-mining employees to identify cases who had ever worked in the mining industry. The job histories of the cases were examined to determine if any of their jobs could have involved exposure to commercial asbestos. Seventeen individuals diagnosed with mesothelioma in Minnesota between 1988 and 1996 were found to have worked in the iron mining industry. Of the 15 for whom adequate work histories were available, 14 had identifiable sources of exposure to commercial asbestos in jobs held both inside and outside of the mining industry. The time between employment in these asbestosexposed occupations and the diagnosis of mesothelioma is consistent with the 20 or more year latency period that has been observed in other studies of this cancer. © 2007 Elsevier Inc. All rights reserved. Keywords: Mesothelioma; Asbestos; Iron miners; Taconite; Epidemiology; Case series

Jan 1, 2007

By Jack Parker

Critical width Before we go further into pillar design, we should look into the matter of "critical width," because of its effect on pillar behavior. Critical width refers to the greatest width that the rocks above the mine can span before failure or, if there are pillars, the width to which we must mine before the pillars accept the full weight of the overlying materials. There are theories to help calculate that probable width, and they usually boil down to one-quarter or one-third of the depth of cover; but they don't always fit, and it would be better for us to understand the factors that control local conditions. Critical width may be controlled by the thickness or strength of one or more of the strata above the mining horizon. In a gold mine, we might have a thick granite or basalt above us, perhaps capable of bridging across most or even all of a small ore body. In that case, pillars might have to support nothing, or perhaps just the weaker or damaged rock below the strong main roof. Obviously it would be wrong to design for tributary load on pillars based on some lab-determined rock strength. In some coal mining districts in Utah, huge steps can be seen in the mountain sides, with slopes on weathered shales and vertical cliffs 100 or 200 ft high in thick, hard sandstones. The sandstones are capable of bridging across hundreds of feet, often making mining deceptively easy at first, but it becomes more difficult as greater areas are opened. Sometimes such a mining sequence leads to violent bumps and bursts as the wide spans of sandstone sag and bear down on the working faces, like giant nutcrackers, or as bridges eventually fail, releasing much pent-up energy.

Jan 1, 1993

By Kadri Dagdelen

The classification of selective mining units (SMU) and the assignment of grades to those classified SMU are very important in open pit mining, especially for precious metal mining. When the classification is done, the true values of the SMU grades are unknown. These unknown SMU grades are mostly estimated analyzing the geologic data and blast hole assays. To classify the SMU's based on the estimate of SMU grade, without considering uncertainty associated with unknown SMU grade, yields incorrect decision in sending material to appropriate destination. In this paper, a method is developed to classify SMU's considering the uncertainty associated with unknown SMU grades. By using this method, traditional estimate of SMU grade is replaced with conditional probability distribution of SMU grade. The decisions about the destination of a given SMU are performed by minimizing the loss due to misclassification. Also, the asymmetric loss function by penalizing the overestimation and the underestimation unequally is used in assigning grades to classified SMU's. A case study is carried out to apply the traditional ore control techniques and proposed method in classification of SMU's and the assignment of the grades in a hypothetical gold mine.

Jan 1, 1999

By E. Jackson

This paper describes highlights of the Placer Dome MiniMole project - the development and testing of a robotic machine for mining narrow ore veins. A prototype hydraulically controlled robotic machine was built and tested. The machine provided a platform for testing numerous cutters in the field. Other cutters, e.g. undercutting devices, were tested in the lab. Extensive analyses were done on specific energies and cutter penetration. Three sets of quarry trials were done, then the machine was tested in an underground mine. Rock UCS values varied from 180 MPa to 230 MPa. The paper includes lessons learned and recommendations based on the project findings.

Jan 1, 2007

By J. L. Watson

n the U.S., lead has been produced via blast furnace processing for over a century, and the slags from that pyro-metallurgical process have been accumulating on industrial sites over that extended period. Lead blast furnace slags typically contain both lead and zinc compounds in an iron-silicate matrix, and it appears highly likely that such materials will have to be processed in the near future to meet with EPA regulations. Thus it is appropriate to investigate possible processing routes to render the slags non-hazardous and simultaneously to recover metal values to partially off-set the inherent high cost of processing such materials. There are two major processing alternatives: one being pyrometallurgical and the other hydrometallurgical. The research reported here investigates leaching/solution purification/recovery processes for lead and presents experimental data for the treatment of lead blast furnace slags from S.E. Missouri. The results of the research suggest that both lead and zinc can be removed effectively from the slag, and that metallic lead can be recovered directly from the organic extractant utilized for solution purification.

Jan 1, 1995

By Cary Hirner, Sarah Lothman, Chris Mueller, Savita Schlesinger, Mike Hanna, Ian Fitz-James

Loudoun Water is currently implementing a quarry to reservoir conversion that will improve water supply reliability in periods of drought and flexibility in water supply operations when turbidity in its Potomac River supplies are high. The Milestone Reservoir Project consists of an inter-tie to the existing Potomac River Pipeline; new pipeline and tunnel; and a pumped intake and outlet works. Planned construction involves significant risks due to underground conditions which includes hard, igneous rock and high groundwater at the creek crossing. In addition, the site is constrained by Goose Creek, an adjacent residence, active mining in a quarry next to the new reservoir, public use of adjacent park space, and the Washington and Old Dominion Trail. Working with these constraints will require close coordination with active mining operations and public and private property owners. Safety of personnel involved with construction also represents a concern with quarry high walls over 30 meters in height near the planned construction. In consideration of key projects risks, Loudoun Water determined that an innovative CMAR delivery approach provided the best opportunity to achieve its goals in quality, innovation, front-end cost and schedule certainty, and operational flexibility and reliability. What matters most to Loudoun Water is the value in having a builder participate in the design process where key decisions can be made based on consideration of risks, cost, schedule, quality, and operability and maintainability of the system. While a progressive design-build delivery model may have produced similar outcomes, Loudoun Water had already invested in substantial development of the design for the work, and ultimately, CMAR provided Loudoun Water the opportunity to retain the partnership with the design team while gaining valuable input from a contractor. Among the challenges with CMAR in the Commonwealth of Virginia is a substantial limitation on self-performance corresponding to 10 percent of the construction value of the work. A significant industry outreach program was initiated by Loudoun Water to encourage participation with incentives in contract terms that allowed for the CMAR Contractor to make a reasonable profit. This paper reviews the CMAR procurement process and discusses contract incentives that were adopted to promote the work within the constraints of contract law in Virginia.

Jun 13, 2021

By B. Salopek, D. Rajkovic, D. Rumenjak

In decision making support system, that are used in various fields of environmental protection (environmental impact assessment, environmental management systems, setting environmental standards and regulation, etc.), it is often important to apply various mathematical environmental engineering models. The question of linking environmetal engineering modeling to decision making support system used in environmental protection is not yet methodically solved. The reasons for that could be manifold. Decison making support systems, used in environmental protection, because they are simply taken from bussines decision making, are not often adequate for specific problems raised in environmental protection. On the other hand, there are great number of types of models in environmental engineering, what urges the problem of finding the way of their proper linking with decision making support systems. The application of fuzzy logic in that field is estimated as one of possible solution of the problem.

Jan 1, 2005

By T. L. Barone, J. R. Patts, L. D. Patts, S. J. Janisko

"Controlling float coal dust in underground coal mines before dispersal into the general airstream can reduce the risk of mine explosions while potentially achieving a more effective and efficient use of rock dust. A prototype flooded-bed scrubber was evaluated for float coal dust control in the return of a continuous miner section. The scrubber was installed inline between the face ventilation tubing and an exhausting auxiliary fan. Airborne and deposited dust mass measurements were collected over three days at set distances from the fan exhaust to assess changes in float coal dust levels in the return due to operation of the scrubber. Mass-based measurements were collected on a per-cut basis and normalized on the basis of per ton mined by the continuous miner. The results show that average float coal dust levels measured under baseline conditions were reduced by more than 90 percent when operating the scrubber. IntroductionAirborne coal dust is a byproduct of coal production, and engineering controls exist to deal with both the respirable dust health hazard as well as the float dust explosion safety hazard. Float coal dust, smaller than 75 µm (0.003 in.) in size, can deposit throughout mine entries and propagate explosions that had been initially fueled by methane gas. The inertization of float coal dust with rock dust helps prevent a potential secondary float coal dust explosion, but a preferable course of action is to significantly reduce the hazard by removing float coal dust from the airstream before it has the opportunity to deposit on the mine’s surfaces.Since 1970, disasters due to explosions in underground coal mines have caused 201 deaths in the U.S. mining industry, including 29 deaths in a single mine explosion in 2010 (Wade, 2010; U.S. Mine Safety and Health Administration, 2015). The U.S. National Institute for Occupational Safety and Health (NIOSH) had initiated a fiveyear research project that aims to investigate methods and technologies to reduce the potential for secondary coal dust explosions by the purposeful capture and/or suppression of float coal dust prior to its deposition on the mine roof, rib and floor (NIOSH, 2013). The project aims to evaluate the efficiency of methods to reduce longwall and belt airway float dust in the general airstream as well as methods to capture it at or near the source. Prioritization is given to longwall sections given the amount of coal produced relative to continuous miner sections, but the research is open to technologies that may be adapted from one method of mining to another."

Dec 1, 2016

By R. A. Franks

An evaluation of a nuisance-emissions-discriminating smart mine fire sensor system was made in an operating coal mine. These field evaluations were conducted to determine the sensor system?s ability to discern nuisance emissions, such as diesel exhaust, emissions from flame cutting and welding operations or hydrogen gas from a charging station, from real fires and to compare the number of falsely reported fire alarms generated between the sensor system and a standard carbon monoxide (CO) monitor. The sensor system?s ability to operate successfully in the working environment of an operating coal mine was also evaluated. The smart mine fire sensor system consisted of four sensors whose data outputs were fused with the use of a neural-network-type computer program. Long-term trials were conducted in a haulage way, a belt entry, and a track entry. The system functioned successfully in the belt entry, in accordance with its developmental goals, where the sensor system even discriminated events not anticipated during development. It was not totally effective in the haulage way and track entry, though, due to a combination of significant diurnal air temperature variations, dust, and mechanically induced vibrations. Also, deteriorating rib conditions contributed to operational problems in the haulage way evaluation. In general, the smart mine fire sensor provided nuisance emissions discrimination and was shown to be a viable new approach for mine atmospheric monitoring, enhancing miner safety. This paper describes the in-mine evaluation of the smart mine fire sensor system and discusses recommendations for improving the system. Disclaimer: The findings and conclusions in this report are those of the authors and do not necessarily represent the views of the National Institute for Occupational Safety and Health.

Jan 1, 2008

By Verya Nasri, Scott Thorburn

The City of Toronto and the Toronto Transit Commission (TTC) have conducted an Individual Environmental Assessment (EA) for a 6.2 km, 4-station underground extension of the Spadina Subway from Downsview Station to Steeles Avenue. This Environmental Assessment Study was performed in three phases including routes and general station locations, alignments and station concepts and detailed assessment of the effects of the undertaking. URS Canada Inc. has led the consultant team for this Study. The anticipated total duration of the project is approximately 6 years and its estimated total cost is about $1.4 billion. This paper presents the planning process of the project, the environmental and engineering challenges, and the measures taken to address them.

Jan 1, 2007

By Jacob Carr, Christopher C. Jobes, Chenming Zhou, LaTasha R. Swanson, Jennica Bellanca, Jingcheng Li

Magnetic proximity detection systems (PDSs) are used with continuous mining machines (CMMs) to protect miners from striking and pinning accidents. Generators are used in a PDS to create magnetic fields covering the space around a CMM. The PDS determines the proximity of a miner relative to the CMM based on the magnetic flux density detected by a miner-wearable component (MWC) and simultaneously alerts the miner and stops the motion of the CMM if the miner is within a proximity that creates a striking hazard. A stable magnetic field is essential to the accuracy of the proximity calculations performed by the PDS. This paper presents the results of a systematic study of the magnetic influence of two types of steel structures found near a CMM— the body of the CMM itself and the wire mesh used for roof and rib control. The results show that the steel of the CMM body can change the magnetic field distribution and also alter electrical parameters of a PDS by changing its generator current. The study also shows that, depending on the distance between the wire mesh and a generator, the magnetic field can also be altered.

A computer simulation of the automatic control of continuous mining machines has been prepared, similar to previous simulations of longwall mining systems and coal thickness sensors. The simulation allows for programmed variation of the horizon detection method, the azimuthal guidance system, the type and configuration of the miner, varying hardness in the unmined face material (leading to varying error in the machine heading), and the miner's cutting cycle. It simulates control of the miner in three axes. Use of the simulator makes it possible to anticipate problems arising from the complex character of underground mining, which include unpredictable multi-pass coupling and unpredictable variation in geological conditions.

Jan 1, 1993

By D. G. Klaren

Self-cleaning fluidized bed heat exchangers are conquering the world for reason that they are able to solve any severe fouling problem in indirect heat transfer due to the circulation of cleaning particles through the tubes of vertical shell and tube exchangers. In most cases, these particles consist of chopped metal wire. Moreover, self-cleaning fluidized bed heat exchangers perform with excellent heat transfer at very low liquid velocities, which makes completely new designs of shell and tube configurations possible. Further, self-cleaning fluidized bed heat exchangers show a strong shear thinning effect in non-Newtonian liquids. All the above characteristics make the self-cleaning fluidized bed heat exchanger an ideal tool for the indirect heating of laterite nickel slurry in High-Pressure-Acid-Leach (HPAL) plants. Preliminary tests and evaluations of these heat exchangers have shown that the performance and price of these heat exchangers used for the production of nickel and cobalt from a laterite slurry, cannot be matched by existing conventional heat exchange systems. This article explains the principle, design, lay-out and enormous advantages of the self-cleaning fluidized bed heat exchange technology in a plant suitable for an annual production of approx. 45,000 ton nickel and 4,500 ton cobalt from laterite slurry through high pressure'acid leaching.

Jan 1, 2002