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By Clodualdo C. Conde

In order for Philippines Associated Smelting and Refining Corporation (PASAR) Corporation to remain a leader in the copper smelting and refining industry, continuous improvements in plant technology are required. Reliable performance of plant equipment is essential for a competitive smelting operation. PASAR is constantly searching for the best equipment and technology to allow us to manufacture products more efficiently. When the Smelter was commissioned in 1993, the Flash Furnace off-gas treatment system was a constant source of problems. There were frequent shut-downs of the electrostatic precipitator due to material buildups on the discharge electrodes and collecting plates. In 1998, the precipitator was successfully upgraded to eliminate the buildup problems and to increase the collection efficiency. The upgrade greatly reduced down time and maintenance, and the enhanced collection efficiency also eliminated pluggage problems and material losses in the Acid Plant. This extensive precipitator upgrade was accomplished during a 30-day Smelter turnaround.

Jan 1, 1999

By A. R. House, G. W. Shepherd

Newmont USA Limited owns and operates the Phoenix Mine near Battle Mountain, Nevada, USA. The existing milling facility has operated since 2006 (House, 2010). Following the startup of the milling operation, and coupled with the upswing in the copper market, Newmont realized that Phoenix had no process option to treat transition and oxide copper ores. This meant that potentially revenue generating ore would be mined as waste. With no system in place to treat the transition and oxide copper, work began to determine the most feasible approach. After evaluating multiple options, the flow sheet was set for a runof- mine (ROM) heap leach pad and solvent extraction/ electrowinning plant (L-SX/EW). This paper will discuss the eight years of successes and challenges with developing the copper L-SX/EW plant and achieving commercial production of copper cathode.

Jan 1, 2014

By Arthur M. Miller

FROM the time of its establishment in 1933, the Tennessee Valley Authority has been active in the field of phosphates. Under the T.V.A. Act it has a broad Congressional mandate to guide a unified development of the resources of the region for the long-range benefit of the people. As one phase of this function, it is directed to co-operate with farmers in the experimental large-scale use of improved fertilizers and development of better fertilizer practices. Following careful study, it was concluded that the objectives of this phase could best be attained by soil rebuilding through the use of phosphatic fertilizer and lime in an improved farm management sys- tem. This activity was launched through a program of test and demonstration on farms and simultaneous technical investigations to develop new and improved phosphatic fertilizers. Phosphorus has since become a keystone of the Authority's resource development and conservation program. Human effort is being conserved by phosphate utilization on the farm, and mineral conservation has been promoted by technical developments in phosphate mining and manufacturing operations.

Jan 1, 1944

By R. S. Hearon

The image of the open-pit miner in the eyes or the Environmentalist has never been very outstanding. The phosphate industry, whose history in Florida reaches back to the late 1800's, can-not be credited until recently with a large number or accomplishments in terms of protection or the environment to change this image. This lack of action was not deliberate or in opposition with the desires of the public. In the formative years, there was little or no public and the companies found it necessary to build towns to house their employees and their families, towns which remained in existence until the late 50's and early 60's or formed the core of present large communities. Neither these pioneers nor most subsequent resource developers considered themselves un-thinking spoilers, nor were they so regarded by their contemporaries. Instead, they acted in a manner consistent with their environmental circumstances and intellectual heritage. Early Americans did make mistakes in using the land but the mistakes became apparent only in the opinion of later generations. Over the past five to ten years, there has been a new self-awareness in the industry with regard to environmental responsibilities brought about, in part by a continuing onslaught of new regulations with jurisdiction over our activities. Part of the new regulations are aimed at industries as a whole while many, particularly state regulations, pertain specifically to the phosphate mining industry. Why all the new regulations? The reasons are encased in a complex web of activity but stem primarily from a new public awareness of its environment. More and more of our youth have become interested in the environmental science areas such as biology and ecology. The tremendous growth rate in both the population and industry has made personal issues out of subjects such as atmospheric inversions and water shortages which previously were abstract concepts. The State has grown from a population of 1,500,000 in 1930 to approximately 9,000,000 people today. This personal impact and general lack of knowledge on the part of the public concerning economics has resulted in big business no longer being held in awe, often in contempt and generally in suspicion where environmental concerns are encountered.

Jan 1, 1978

By Ingvar Ymén, Alexandra Lundmark

"The depressive effect of dichromate on galena was evaluated with chemical experiments and small-scale depression experiments at a pH of around 12. The depressive effect was measured with Dynamic Vapor Sorption (DVS), which measures the water uptake of a sample as a function of the % relative humidity. The depression is due to PbCrO4PbO, which in the presence of Ca2+ and SO4 2- forms a more or less amorphous solid solution (Pb,Ca)(CrO4,SO4)PbO, which clogs to the surfaces of the ore. Free Pb2+- ions are needed for depression to occur and at high pH Pb2+ - hydroxide complexes, supply enough Pb2+ - ions to precipitate (Pb,Ca)(CrO4,SO4)PbO. In air CO2, precipitates CaCO3 which slowly lowers pH, precipitating more (Pb,Ca)(CrO4,SO4)PbO and CaCO3 on galena. Similar experiments where performed with five alternative depressors whereof phosphate, which forms an amorphous precipitate of approximate composition Pb3Ca13(PO4)10SO4, gave the best results. Phosphate was tested in laboratory scale flotation experiments giving encouraging results.INTRODUCTIONWithin Boliden Mines, concentrating of copper and lead from complex sulfide ores is performed by bulk flotation, meaning that copper and lead are concentrated in the same product. Downstream, copper and lead are separated by flotation of chalcopyrite, and depression of galena. Boliden has for many decades used sodium dichromate to depress galena (reference 1). Dichromate is both toxic and carcinogenic and Boliden has for many years investigated several alternatives. So far, however, the best results have been obtained with dichromate. Since Boliden has tried to substitute dichromate for a long time without finding a process as effective, Boliden decided to clarify the function of dichromate in the depression of galena and on the basis of the outcome find alternative depressors with similar function. This study was given to RISE Bioscience and Materials / Surface, Process and Formulation as a consultancy assignment. This paper presents the outcome of the combined efforts of Boliden and RISE."

Jan 1, 2018

By Jinrong (Patrick) Mang

Three of the most challenging problems in phosphate beneficiation are discussed: flotation efficiency, resource conservation and environmental impact. Some new flotation machines offer the opportunity of reducing power and reagent consumption significantly, while increasing specific capacity many fold. Efficiency might also be improved dramatically by replacing the "double float" process with a single-collector scheme. Model based software control is a powerful tool for improving overall plant efficiency. Recovery of phosphate values from the phosphatic clays could extend phosphorus reserve life significantly. phosphate recovery from the slimes might be achieved by sizing-flotation, selective flocculation and bioleaching. Reducing the volume of phosphatic clays produced is another key stop to minimizing phoephate logs. Such a reduction may be realized by floating at finer cut size. Although an ideal' dolomite separation process is yet to be developed, a cationic flotation process may prove to 'be economically feasible. Loss of phosphate in the desliming stage is the major problem with most of the flotation schemes for removing dolomite.

Jan 1, 1995

By S. M. Javad Koleini

Processing of phosphate ore sample was investigated for increasing phosphate content and reduction of its gangue minerals such as carbonates and silicates. Experimental designs were per-formed using Taguchi method. Different flotation methods were investigated for Moundon phosphate ore sample and three methods were used as follow: direct cellophane flotation, reverse calcite flotation and reverse quartz flotation. Because of the sensitivity of cellophane flotation to slime content, prior desliming was carried out before the experiments. Direct flotation experiments carried out and a concentrate contained 23.80% P2O5, 6.88% SiO2 and 72.33% recovery were produced. The achieved P2O5 content in the produced concentrate from reverse flotation of calcite was 26.44% and the recovery was 82.56%. The concentrate products obtained at optimum conditions by direct flotation of phosphate and indirect flotation of calcite were subjected to indirect flotation of calcite and direct flotation of appetite and final concentrates with P2O5 grade of the order of 24.19% and 26.96% were obtained, respectively. It was concluded that one stage direct flotation is unavoidable to achieve a product with low SiO2 content.

Jan 1, 2014

By G. M. Wilemon

The U.S. Bureau of Mines has conducted investigations on extracting phosphate values from wastes generated during the mining and beneficiation of phosphate matrix. These wastes may contain up to one third of the phosphate originally present in untreated ore. Samples of wastes were air-dried and leached using 93 pct sulfuric acid in the presence of methanol. Evidence for the formation of a calcium sulfate hemihydrate coating that hinders complete dissolution of phosphate is presented. Solid-liquid separations were enhanced when flocculation was effected using poly(ethylene oxide) (PEO) in conjunction with hydroxypropyl cellulose (HPC) or hydroxyethyl cellulose (HEC. A conceptual flowsheet for a proposed process using an acid-alcohol leaching technique is presented.

Jan 1, 1990

By L. Telfer

Summary During Palaeozoic time, there were deposited in the Canadian Rockies four beds of phosphate rock, ranging in age from Mississippian to Jurassic. Two of these beds are of probable economic importance if some means of separating the phosphate from the gangue can be devised. All the more important beds of phosphate rock so far discovered are just behind the front ranges of the Rocky mountains, within fifty miles of the prairie lands of Alberta. Mining conditions are favourable, with an abundance of timber and ample power available. The phosphate beds are all of the sedimentary type, and they all occur, apparently, at the same stratigraphic horizons over a wide area. The conditions necessary for deposition evidently occurred at several different periods in geological time, and were widespread. The most important factor appears to have been the condition of the land surface surrounding the basin of de-position. Both oolitic and nodular phosphate were laid down under nearly similar conditions. Introduction Following the discovery of phosphate rock in Idaho and Montana, search was commenced in Canada to determine whether formations of similar age in the Canadian Rockies carried similar beds of phosphate. The most widespread search has been that undertaken by the mines department of the Consolidated Mining and Smelting Company of Canada. The following paper will discuss some of the results of this exploration.

Jan 1, 1933

By H. M. Woodrooffe

In the U.S.S.R. three of the world's major-known phosphate deposits are located. These have an estimated reserve of 2,600 million short tons of contained phosphorus. The best known lies in the "Khibiny Massif', an alkalaic rock formation some 600 square miles in area with mountain peaks rising to an altitude of 3300 ft above the surrounding terrain. Location and Climate The Khibiny Massif lies north of the Arctic Circle in the Kola Penin-sula, 100 miles south southeast of Murmansk, at a latitude of 67° 30' north and a longitude of 35° 30' east. It is serviced by rail from Murmansk and Leningrad (900 rail miles south). Figure 1. The phosphate operations are centered about the two cities of Apatity and Kirovsk. The former has a population of 35,000 and is on the Leningrad¬Murmansk railway. Kirovsk, 15 miles to the east, is now a city of 85,000. The region is at the limit of the tree line with most of the ground cover typical tundra. The mean annual temperature is -4°C and, in a normal year, precipitation occurs on 240 days. Because the temperature does not exceed freezing for 300 days each year, virtually all of the precipitation is snow. The two towns are nestled between mountains and, because of the weather, extensive avalanche control systems incorporating major engineering construction have been introduced to divert snow slides away from the populated areas. General Kirovsk was first settled in 1923 and the apatite occurrences were recognized shortly after. In 1933, the first concentrator for the recovery of the mineral was completed, producing in its first year of operation 170,000 tons of concentrate. With the growth and demand for phosphate in the U.S.S.R., a second concentrator was erected at Apatity. It calve on stream in 1963. Because of the severe climate, in the early days mining was limited to 85 days per year. With the introduction of new techniques and improved mining methods, the season has been extended to 115 days.

Jan 1, 1972

By H. M. Woodrooffe

Three of the world's largest phosphate deposits are located in the USSR. These have an estimated reserve of 2,600 million short tons of elemental phosphorus. The best known lies in the Khibiny Massif, an alkalaic rock formation some 600 square miles in area with mountain peaks rising to an altitude of 3300 ft above the surrounding terrain. The Khibiny Massif is north of the Arctic Circle in the Kola Peninsula at a latitude of 67° 30' north and a longitude of 35° 30' east. It is connected by rail to Murmansk, 100 miles northwest, and Leningrad, 900 rail miles south.

Jan 12, 1972

By K. D. Jacob, W. L. Hill

THE bulk of natural phosphates is comprised of calcium phosphates, which are usually apatites;1 calcium aluminum phosphates such as pseudowavellite;2 and aluminum phosphates, which occur in extensive deposits, notably on Grand Connetable Island.3 Nearly all deposits of current commercial value are apatite, often with admixed material of other classes. In the trade coarsely crystalline material, mainly fluorapatite of igneous origin, moves as apatite, whereas the fine-grained material of sedimentary origin is marketed as phosphate rock. The latter classification includes the phosphate shales in western North America. Although several genetic varieties of phosphate rock are recognized,4 most known reserves are of marine origin. Calcium phosphate is concentrated from Florida land pebble and Florida hard rock deposits and from Tennessee brown rock deposits. Phosphate Rock as a Fluorine Carrier: More than two decades ago Reynolds and Jacob surveyed the fluorine content of commercial phosphate rock from various parts of the world.3,5 Later these samples were reanalyzed by a new and more reliable method of determining flourine.6,7 The revised results with interim additions of new samples, published a few years ago in a brief summary,' are shown in Figs. 1-3. Through the points representing the respective varieties of rock medial straight lines are drawn. In some instances the lines are well defined by the points; in others, where scattering renders the position of the best line uncertain, the greater weight is given points near the end of the covered range. Wherever distinct varieties are not recognized among regional deposits the custom is to identify the sample with the geographical location of the deposit.

Jan 10, 1954

By John V. Beall

The forecast of continued growing demand for phosphate, chiefly for fertilizer, has caused a world-wide rush for deposits by a variety of companies many of which have never before mined phosphate rock. The newcomers are diversifying into this growth industry on the strength of certain capabilities. Among these are the availability of investment capital, mining or processing know-how and marketing experience. Product tie-ins have motivated some into the search. Companies with excess sulfuric acid or potential for making it are in this category. This acid is the most commonly used for dissolving phosphate rock to make phosphoric acid. Base metal smelting companies are prime candidates in this field with by-product acid from roasting processes. Producers of "sweet" natural gas, such as those in Louisiana and Texas, have a potential for recovering low cost hydrogen from excess gas production for the manufacture of ammonia, the main source of nitrogen for fertilizer. "Sour" gas producers, such as those in the Canadian fields, are making sulfuric acid that is combined with western U.S. phosphate to make fertilizer materials. The presence of one or two steel companies in the look-see for phosphate deposits is based on by-product ammonia from coke-oven gas.

Jan 10, 1966

By N. Edmonson

An examination of the statistics of the world phosphate fertilizer industry since 1980 reveals an increasing tendency for fertilizer manufacturing activity to concentrate in phosphate rock mining areas. The economic justification for this resource-oriented strategy is clear. The choice between shipping phosphate rock, a comparatively low-value product, and shipping more valuable finished fertilizers will always be resolved in favor of the latter if cost considerations control the decision. The historical existence of substantial phosphate fertilizer manufacturing capacity oriented toward fertilizer-consuming activities and dependent on imported phosphate rock shows that narrow cost considerations have not always determined the industry's location. One is entitled to ask what conditions have changed to precipitate the observed relocations, and how permanent these changes are. These questions are the subject of this investigation.

Jan 1, 1995

By R R. Lovel, G J. Sparrow

Currently there are large reserves of good quality iron ore near to existing infrastructure that are not being developed because the phosphorous levels are above acceptable market specifications. Since the high phosphorous content is considered to be mainly associated with the goethite fractions of the ore, attempts were made to leach the phosphorous from the ore after a heat treatment to dehydroxylate the goethite. Heating the ore and leaching with 40 g/L NaOH lowered the phosphorous levels from 0.145 wt per cent P to 0.075 wt per cent P or lower, but a heating temperature over 800¦C was required to achieve this reduction in phosphorous levels. However, when sodium hydroxide was added to the iron ore before the heat treatment, similar phosphorous removal was achieved with a heating temperature of 300 - 350¦C. It was considered that dehydroxylation of the goethite in the presence of the hydroxide makes the phosphorous available for removal with a water leach. As well, 50 per cent of the silica and 60 per cent of the alumina in the ore were also removed in the leach, but some sodium remained in the leach product. Further work is required to remove the residual sodium to produce a marketable product.

Jan 1, 2009

By E. Fregeau-Wu

The major obstacle in recycling steelmaking slags to the blast furnace is their phosphorus content. Removal of the phosphorus, which is primarily associated with the silicate and phosphate phases, would allow for greater recycle of these slags for their iron, manganese, and lime contents. Calculations show that separation of the silicates from the oxide phases would remove nearly 90% of the phosphorus from the slag. The variable grain size of the as-received slag made liberation by fine grinding difficult. Therefore, slow-cooling experiments were undertaken to improve the grain size distribution. The grain size distributions were determined using in-situ image analysis. The samples were ground to their apparent liberation size and high gradient magnetic separation was used to separate the magnetic oxides from the nonmagnetic silicates and phosphates. Liberation analysis and modeling was performed on selected separation products for discussion of benefication characteristics.

Jan 1, 1995

By Tengfei Qi, Liqiang Fan, Huiqing Tang

A new method to process the oolitic high phosphorus iron ore for phosphorus removal has been proposed in this research. It is an integration of direct reduction and melting separation with carbon-containing pellets prepared using biomass char. Experiments of direct reduction were preceded using a tubular furnace and three parameters were investigated and they were reduction temperature, biomass char adding ratio(molar ratio of carbon to oxygen） and atmosphere. Results show that the optimum condition is of reduction temperature is 1373 K, biomass adding ratio 0.9, PCO2/PCO 1.0 and reduction time 15~25 min. Under this condition, the reduced briquettes with a metallization of 75.0~80.0 % and a residual carbon content of 0.69~0.11 wt% could be obtained. Subsequent melting separation experiments were conducted using a Si-Mo high temperature furnace. Results show metal with phosphorus content of about 0.4 mass% could be obtained from the reduced sample.

Jan 1, 2015

By Ewan Wingate, Ranjit Prasad, Yanjun Liu

The use of phosphorus by mankind is long established. From use in agriculture, foods, high tech electronics, and more recently in EV battery cathode production, one cannot escape its impact on today’s society. This paper will review and describe the circular journey of phosphorus through its value chain from the mining operation of phosphate ore through beneficiation into downstream chemicals production and finally into the EV battery cathode production space. This will include a review of phosphoric acid production from phosphate concentrate using wet process route and thermal route. The wet process route discussed will be via dissolution of phosphate concentrate by sulphuric acid. The thermal route will discuss thermal decomposition of phosphate concentrate using submerged arc furnace to produce yellow phosphorus followed by its combustion to produce phosphorus pentoxide and subsequent hydration to produce phosphoric acid. It will also discuss briefly other phosphate derivatives for specialty chemicals and recovery of phosphorus units from wastewater treatment plants, sewage sludge and incinerator ash. Finally, the paper will discuss the use of phosphorus in EV batteries in the form LFP cathode materials and its production. It will also briefly discuss the LFP battery recycle.

Sep 11, 2023

By Leonardo Mota, Lucas L. da Costa, Milton B. Filho, Sergio N. Monteiro, Helion Vargas, Tammy G. R. Portela da Silva

"A natural biofoam extracted from the buriti palm tree has shown characteristics for potential substitution of synthetic foams. In the present work, a photoacoustic thermal characterization was performed on buriti biofoam samples. An open photoacoustic cell technique and a photothermal rise method performed under continuous laser illumination were employed in order to determine the thermal diffusivity and the specific heat capacity of such material. In addition to their intrinsic values (finger print), these physical parameters represent the light-into-heat conversion efficiency and the amount of heat stored per unit volume, respectively. The results showed that the buriti biofoam presents thermal properties that permit its use as an effective insulation material.IntroductionSolid foams are very light materials with increasing engineering applications [1]. A natural biofoam obtained from the petiole of the buriti palm tree (Mauritia flexuosa) has been recently investigated [2-4]. The evaluation of the buriti biofoam properties and the characterization of its microstructural aspects have shown that this biofoam has a potential as a new engineering material with very low density. Additionally, its reduced open porosity and low absorbed humidity revealed a promising material for packing and floating applications. In fact, this buriti biofoam, extracted from the palm tree natural of the north region of Brazil, is being used by the low income population as a modest substitute for Styrofoam® [1].As a potential insulating material, the buriti foam needs to be characterized in terms of its thermal and acoustic properties. A preliminary investigation [3] on the thermal behavior of this natural biofoam by thermogravimetric analysis, TGA, and its derivative, DTG, as well as differential scanning calorimetry, DSC, revealed parametric conditions associated with water loss and structural decomposition. Both the surface humidity and the release of hydration water were determined. Different decomposition events were attributed to both, more rigid as well as to more flexible molecular segments. Table 1 depicts technical data obtained so far for the buriti biofoam. These data are compared to those corresponding to Styrofoam®."

Jan 1, 2011

By Vinicius Alves Gomes, Jean Igor Margem, Thallis Cordeiro, Frederico Muylaert Margem, Roberto Faria Jr., Sergio Neves Monteiro, Marina Rangel Margem

Natural fibers are attracting the interest of engineering sectors owing to specific advantages such as lightweight and lower cost as well as for their inherent condition of being renewable, biodegradable, recyclable and neutral with respect to CO2 emission. In particular, the fiber extracted from the malva plant stem is nowadays recognized as one of the strongest lignocellulosic fibers. However, the thermal properties of the malva fibers have yet not been fully investigated. The present work had as its objective to investigate, by photoacoustic spectroscopy and photothermal techniques the thermal properties of diffusivity, specific heat capacity and conductivity of a pressed malva fibers sample. The results revealed that these fibers showed a superior thermal insulation capacity.

Jan 1, 2015