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Hazardous waste has often very complicated chemical compositions in a variety of physical forms and is normally processed in rotary kiln incinerators. Due to large variations in waste types and difficulties in feed characterization, the complex transport processes within the incinerator are not well understood, and the incineration process meets challenges in a smooth operation, and expects various uncertainties in the process chemistry and emission control. For better understanding of the incineration process, simulation was carried out by using Computational Fluid-dynamics (CFD) to characterize temperature and species distribution in the incinerator. In order to catch certain aspects of thermal and chemical behavior, a novel approach is proposed to represent approximately the waste streams and the subsequent combustion process. Hazardous waste in various forms from an industrial-rotary-kiln waste incinerator is firstly converted to a hydrocarbon-based virtual fuel mixture with approximately the same HIC molar ratio and calorific value. The simulation of the combustion process of the simplified hazardous waste was proceeded with a combustion model. The distribution of temperature and chemical species especially the remaining CO in the system is preliminarily investigated. Distribution of CO concentration, as a good indicator of emission level for the incineration process, could be used to evaluate the emission control. The predicted temperature distribution has been compared with available measurement data from an operating rotary kiln waste incinerator at AVR-Chieme, in the Netherlands. Reasonable agreement has been reached between the measured and predicted temperature data. In the next step, measurement of species distribution in the system is planned to further validate the combustion model.

Jan 1, 2003

Hazardous waste has often very complicated chemical compositions in a variety of physical forms and is normally processed in rotary kiln incinerators. Due to large variations in waste types and difficulties in feed characterization, the complex transport processes within the incinerator are not well understood, and the incineration process meets challenges in a smooth operation, and expects various uncertainties in the process chemistry and emission control. For better understanding of the incineration process, simulation was carried out by using Computational Fluid-dynamics (CFD) to characterize temperature and species distribution in the incinerator. In order to catch certain aspects of thermal and chemical behavior, a novel approach is proposed to represent approximately the waste streams and the subsequent combustion process. Hazardous waste in various forms from an industrial-rotary-kiln waste incinerator is firstly converted to a hydrocarbon-based virtual fuel mixture with approximately the same HIC molar ratio and calorific value. The simulation of the combustion process of the simplified hazardous waste was proceeded with a combustion model. The distribution of temperature and chemical species especially the remaining CO in the system is preliminarily investigated. Distribution of CO concentration, as a good indicator of emission level for the incineration process, could be used to evaluate the emission control. The predicted temperature distribution has been compared with available measurement data from an operating rotary kiln waste incinerator at A VR-Chieme, in the Netherlands. Reasonable agreement has been reached between the measured and predicted temperature data. [n the next step, measurement of species distribution in the system is planned to further validate the combustion model.

Jan 1, 2003

By E. T. de Groot, D. L. Verhelst

With the successful start-up of Cominco's new KIVCET smelter, the final key component is now in place for Trail Operations to operate efficiently as a modern integrated zinc-lead facility. Unique metallurgical, operational, planning and management issues apply to this operation. Along with presenting the current flowsheet for Trail Operations, this paper discusses issues such as the impact of recycles, operational re-stabilization following significant process changes, plant operation with just-in-time inventories, real-time process optimization, and management philosophy.

Jan 1, 2000

By W. A. Jankola, M. T. Martin

"The world's first zinc pressure leaching plant at Cominco's Trail operations started production in 1981. Sullivan zinc concentrate is leached at the rate of 190 tpd in a four-compartment autoclave at elevated temperatures and oxygen pressures to produce a zinc sulphate solution and elemental sulphur. Zinc extraction exceeds 98% and sulphide to elemental sulphur conversion exceeds 95%.The sulphur is recovered from the discharged slurry in the underflow of a hydrocyclone, and is upgraded as a flotation concentrate. The concentrate is dewatered, melted and filtered to produce a polished sulphur product of better than 99% purity. An alternative sulphur recovery process employs an unique sulphur separation method that recovers over 90% of the sulphur in the molten state. The remaining sulphur is recovered by flotation following flash discharge of the slurry. The product slurry containing the zinc sulphate solution and the iron-lead residue joins the existing roast-leach zinc plant for purification and zinc electrowinning.IntroductionIn 1981, Cominco Ltd. commissioned the world's first commercial zinc pressure leaching plant at their Trail operations in British Columbia. As part of a $700 million modernization and expansion program for lead and zinc started in 1977, the company installed the first o f two autoclave trains.Prior to pressure leaching, zinc production was closely tied to acid and fertilizer production. Sulphur dioxide produced from roasting the concentrates had to be converted to sulphuric acid. Thus, any expansion of zinc operations with the roast-leach technology would have required extensive modifications to the acid and fertilizer plants as well as to the roasters. Zinc pressure leaching, on the other hand, offered a one-step dissolution of zinc from the concentrates with high extraction, and production of elemental sulphur. The associated dust and sulphur dioxide generated in the roasting process are both eliminated from the working environment of the pressure leach facility. The flexibility allowed by producing elemental sulphur, and the opportunity to break the sulphuric acid link for about 25 per cent of the targeted 272,000 tonnes per year zinc production was very appealing. The process was successfully demonstrated at a pilot plant in 1977(1-6)."

Jan 1, 1985

By C. B. E. Douglas

In an interesting article on evaluation of the water problem at Eureka, Nev., W. T. Stuart describes how a difficult water problem, or one phase of it, may be evaluated by means of a small scale test. Test data are plotted by a method rendering, under certain conditions, a straight-line graph that can be projected to show how much the water table will be lowered by pumping at any specified rate for a given time. A formula is then used to determine the size of opening, or extent of workings, necessary to provide sufficient inflow to enable pumping to be maintained at that rate. At first glance this might seem the answer to a miner's prayer, but a word of caution is in order. It may not be the whole answer. Moreover, results obtained by the method described are reliable only for conditions approximating those assumed. Even where conditions do not meet this requirement, however, it may be possible to draw helpful inferences from the results, perhaps enough to facilitate another approach to evaluation of a problem.

Nov 1, 1955

J. H. HEGINBOTHAM, a, metallurgist of the General Engineering Co., talked on "Current Milling Practice at Kirkland Lake," at the December meeting of the Utah Section. The ore is enough alike through the whole district so that some generalizations and comparisons may be made. The question as to whether or not the flotation process should be used in the flowsheet for extracting gold by cyanide solutions is still being vigorously debated, and it will seemingly need some years for a definite answer to be given. Most of the gold is either free, though much of it is finely dispersed in quartz, or occurs with pyrite. At times there may be 2 per cent of telluride compounds in the ore, but the amount of gold telluride present is small and has not been definitely established. It has been shown by Dr. Haultain and others that though gold tellurides may be so finely disseminated that it is necessary to grind the ore exceedingly fine, the compounds themselves are not difficultly soluble. (An increase in temperature helps to dissolve tellurides, and also to settle pulps.) It is likely that if the ore were ground through 400 mesh, practically all of the gold would be soluble. As it is, with 96 to 98 per cent of the ore ground to minus 200 mesh, and some 70 per cent minus 325, the cost of

Jan 1, 1934

By B. G. Thomas

"Mathematical process models can be applied in several different ways to serve industry by inducing beneficial changes to process operation. This paper attempts to summarize the different uses, types, and attributes of these models, and to offer some ideas to consider when developing, using, and reporting on them. Process models range from empirical to mechanistic in nature and vary in complexity from simple analytical solutions to coupled, 3-D transient numerical simulations. They are classified here according to the way in which they are implemented in practice, viz. fully-online models, semi-online models, off-line models, and literature models. The purpose of the model should dictate how choices are made during its development. Ways to validate and compare the model with experiments are suggested. Examples are taken in the context of the author's experience in modeling the continuous casting of steel.IntroductionThe objective of this paper is to provide a partial introduction for this symposium by discussing some basic aspects of the application of mathematical process models in industry. Essentially, the aim is to explore how process models are used to benefit industry, and to offer some general comments and suggestions, based on the experience of the author, on how models can best meet this goal.This work is concerned with process models, which consist of systems of mathematical equations and constants that are solved on a computer to make quantitative predictions about some aspect(s) of the process. The specific variables required as input data and generated as output data are important features of the model. The equations often derive from a numerical solution to one or more differential equations and their boundary conditions. The model also includes the constants, which represent material properties, empirical relationships, and other knowledge about the process, and usually require considerable effort to obtain. Thus, general purpose commercial software packages, (ie. finite-element or finite-difference based codes), are not models in this context. They are useful tools, however, serving as frameworks for the development of process models."

Jan 1, 1994

By Edwin Ludlow

THE responses to the request of the Finance Committee have been coming in with gratifying results, .but there have also been about a dozen letters received objecting in various ways to the voluntary subscription. These can be summarized as: First.-That the dues should have been increased, and thus impose the same burden on everyone. This would not have met the present situation, as under the constitution no increase could be effective until 1922. Second.-The Institute should 'live within its means, and reduce its expenses to correspond with its income. As far -as possible this was done by deferring the publication of Volume LXIV until 1921, although the papers published in that volume, were presented at the meeting in February, 1920. It is to avoid being obliged to do this again that the subscription is asked, as we feel that it is, a duty we owe to our membership_ to give them the papers presented at as early a date as possible.. Our financial situation is due to the very large increase in the cost of publication; owing to the high price of paper and printing. The cost of paper is now decreasing, and we hope that there will be' wage adjustments that will permit a lower cost for printing. Under present conditions each volume of our TRANSACTIONS costs three times as much as it did in 1917 and we would be able to publish only one' volume per year. Third.-That there are too many papers published that are 'of no interest to the writer of them .complaint.-This is undoubtedly true, but it must be remembered that the membership of the Institute includes all branches of mining and metallurgy and that all these branches are entitled to be' represented in our TRANSACTIONS by papers.

Jan 1, 1921

By D. W. Leyshon

The fluidized solids technique for the calcination of phosphate rock has been well established for over 10 years. This paper is intended to review the recent performance of many of the Dorr-Oliver FluoSolids* calciners. In addition, design features of these three compartment refrac¬tory construction reactors will be described and a comparison made with fuel requirements for single compartment calcination. Also presented will be certain, aspects of the use of the rock including a discussion of non sulfate sulfur in the rock. A system is described for producing a blended mixture of calcined and uncalcined rock.

Jan 1, 1972

By R. J. McClincy

The potential techniques for the direct smelting of copper sulfide concentrates to blister copper were evaluated from the standpoint of commercial application. Many existing smelters are adaptable to direct smelting practice but only with improved control of metallurgical performance. Modified and innovative procedures for slag cleaning and metal refining, prerequisites to direct smelting, are presented and discussed. The ability to smelt directly to blister copper using existing equipment and eliminating the need to convert matte offers ,significant advantages to traditional smelting practice from the viewpoint of cost, 'S02 control, and process simplicity.

Jan 1, 1983

By Gil Bourcier

A process has been developed for detoxifying spent potliner (SPL) in which the SPL is blended with limestone and an anti-agglomeration agent and thermally treated in a rotary kiln. The process has been proven and a commercial plant is in operation at Gum Springs, Arkansas. The treated by-product material has been delisted by the U.S. EPA and is now a potential raw material for many commercial applications. Finding uses for a non-hazardous material has many advantages over finding uses for a hazardous material like SPL. Complete usage of the by-product will complete the life cycle and eliminate any landfilling of non-hazardous SPL by-products or residues. Being non-hazardous and containing compounds used in the ceramic and numerous other industries assures many potential uses for the spent potliner by-product.

Jan 1, 1994

By Ausenco Engineering Canada

"This paper demonstrates the selection of grinding circuit technology for a number of recent projects including discussion of the key drivers and the role of energy efficiency. Decreasing head grades combined with a strong and sustained increase in operating costs has forced miners to examine increased project size, increased equipment capacity and efficiency improvements in order to reduce their unit operating costs and improve overall project economics. Comminution energy consumption, safety and capital cost considerations play a critical role in the success of projects. This paper presents some key guidelines for a successful and cost effective comminution circuit design and includes a case study on three projects, outlining the issues and the drivers which led to the ultimate circuit selection and the critical role that energy efficiency played.INTRODUCTIONComminution circuits for minerals processing are selected based on their suitability and efficiency in reducing run-of-mine ore to the desired feed size for the downstream process. The input material (ore) properties and downstream process requirements are the key determinants and there are standard approaches for each circumstance.The minerals processing industry has been a fast adaptor of efficiency improvements based on increasing capacity of equipment (e.g. trucks, crushers, mills, pumps) but less successful in adapting radically new technologies that disrupt incumbent flowsheets or processes.The installed power of grinding mills has increased linearly over the past 25 years (Meka & Lane, 2010) and pumps and classification equipment have kept pace. The autogenous grinding (AG) and semiautogenous grinding (SAG) mills displaced stage crushing as a dominant method of coarse rock breakage in many applications causing crusher manufactures to increase the capacity of cone crushers to meet the competitive demand.Examples of new comminution technology in the 20th and 21st centuries are the development and adoption of cyclone classification in the 1940s (Newtech, 2016), AG milling in the late 1950s, vertical grinding mills in the 1980s, high pressure grinding rolls (HPGRs) also in the 1980s and ultrafine milling technology in the 1990s (Meka & Lane, 2010)."

Jan 1, 2016

Commissioning is one of the many phases of a project, it has inter-dependencies with the other phases, as they have amongst themselves, and has its own terminology and distinctive features. Commissioning time and cost can severely affect project economics, especially through unrealistic estimating, and requires a separate management team to ensure full control is. maintained. Targets to be achieved in commissioning are identified, together with the necessary policies to achieve them. Factors which have to be taken into account in applying these policies are Discussed.

Jan 1, 1986

By M. Gorman

The Mineral Park Mine is an open pit copper-molybdenum mine located in northwestern Arizona, approximately 74 miles southeast of Las Vegas, Nevada. The property has been owned by the Duval Corporation, Cyprus Mining Company and Equatorial Mining of Australia. Mercator purchased Mineral Park from Equatorial in 2003. Mineral Park commissioned a 25,000 tpd copper and molybdenum concentrator in November and December of 2008. The process includes two stage milling (SAG and Two Ball Mills) fed by primary crushed ore. Metals are recovered in a copper-molybdenum flotation circuit consisting of mechanically agitated roughers and cleaners. The copper- molybdenum flotation concentrate is thickened and further processed in the molybdenum flotation circuit which separates the copper and molybdenum minerals into salable concentrates. The molybdenum circuit also uses mechanically agitated cells. This paper describes the plant and some of the highlights of the commissioning process.

Jan 1, 2010

By Steven Hart

In September 2009, Newmont began the commissioning of a 3 stage crushing and milling circuit at its Boddington Gold Operation in Western Australia. The Boddington ore has been recognized as one of the hardest and most abrasive ores treated to date and this played a pivotal role in the selection of crushing and HPGR technology for this operation as opposed to the more conventional SABC circuit. This paper will examine the scale up from laboratory to pilot plant and full scale operation of the crushing circuit. There have been many challenges to overcome in the first 18 months of operation; however, the HPGRs have in general met design expectations and performance is expected to improve further with ongoing design changes

Jan 1, 2012

By N. Romani, R. Provost

"Commissioning of a circulating dry scrubber plant was recently completed at an existing facility, in order to treat the sulphur dioxide off-gas emitted from rotary kilns. Proper planning of the different commissioning stages and staffing an integrated team are the most important factors required for a successful plant start-up. A strong operational readiness plan must be in place as early as the start of construction in order to ensure a smooth transition from commissioning to operations. Plant performance can meet or exceed performance criteria within the required timeframe if the proper group dynamic and good communication is established between construction, commissioning and operations teams.INTRODUCTIONCommissioning of a circulating dry scrubber (CDS) plant was recently completed at an existing facility in Quebec, Canada. The CDS plant treats the sulphur dioxide off-gas emitted from rotary kilns in order to meet increasingly stringent environmental requirements. This installation enables the existing facility to reduce their sulphur emissions by over 90%.The CDS ProcessA general overview of the CDS process is presented in Figure 1 below. The combined, de-dusted off-gas from multiple kilns is sent to the CDS, which acts as an entrained fluid bed, where the gas is contacted with a water mist, re-circulated solids and hydrated lime. The SO2 from the gas stream and the available calcium hydroxide (Ca(OH)2) from the hydrated lime dissolve in the water and react to ultimately form calcium sulphites and gypsum. The solid residue (referred to as CDS residue), is the primary byproductof the process.Fresh hydrated lime and CDS residue is captured by the dust collection system and is re-circulated to the CDS via a fluidised transport system. Clean off-gas passes through the dust-collection system and is then sent to the atmosphere by a single exhaust fan.The CDS residue purged from the system is combined with the dust collected from the kiln offgas system and this mixture is wetted in the already exiting agglomeration system, to minimize dust generation during handling, and then sent to disposal."

Jan 1, 2016

By Niels Verbaan, Ernesto Bourricaudy, Ronald Molnar, James Brown, Sunil Jayasekera

"SGS Minerals commissioned an internal R&D program to develop in-house expertise to design, set up and operate REE separation pilot campaigns at its Lakefield, Canada site. A team approach was used that included expert consultants in the field of REE separation as well as in-house expertise supported by the on-site Analytical Laboratories.A mini pilot scale SX circuit was designed and constructed consisting of several modular banks of 30 stages each. About 80 stages of mixer-settlers were used to separate Pr and Nd from La and Ce contained in a synthetic REE chloride stream simulating the raffinate from an initial La-Nd|Sm-Lu+Y separation.Two pilot campaigns were operated totalling 25 days of 24/7 operation with 99.4% plant availability in the final 20 day campaign. Purities of > 99.9% in the Pr-Nd strip liquor and > 99% in the La- Ce raffinate were achieved and simultaneously sustained in the second campaign for prolonged operating periods. Key to controlling and adjusting the circuit was the rapid assay turnaround (as low as 2 hours) provided by the on-site SGS analytical lab. This permitted the operating team to modify conditions and observe the effect of changes relatively quickly considering the large number of stages. A portable XRF analyser was also used to track evolving assay trends in the circuit. The small physical size of the circuit enabled longer operation with a limited amount of sample.This paper discusses the design of the circuit, operating conditions, some of the key operating factors and controls and results obtained.INTRODUCTIONSGS Minerals commissioned the design of and built a solvent extraction (SX) pilot plant for the separation of rare earth elements (REE). The plant consists of a battery of 120 mixer-settlers set up in a dedicated piloting facility.The purpose of the programme was to develop capabilities and in-house expertise in REE SX separation technology. The program aimed to establish operating procedures, sampling regimes, and analytical methodologies and protocols for this type of process/plant. A team comprised of SGS personnel and several external consultants with prior industrial and REE separation piloting experience was assembled to achieve these objectives."

Jan 1, 2016

By M. Savella

The Runruno Gold Project is located on the island of Luzon, approximately 200 km north of Manilla in the Philippines. The mine is a surface mine operation and use the proven BIOX® and carbon in leach processes to recover gold, and the ASTER™ process for detoxification of the CIL residue prior to discharge to the Residue Storage Impoundment (RSI). Work to date has defined a mineral resource of 1.39 million ounces of gold, and the operation will produce 96,700 ounces of gold per annum over a mine life of 10.4 years. The BIOX® circuit is designed to treat 140,000 tpa of concentrate with a design capacity of 404 tpd of concentrate at a design sulphide sulphur grade of 17% S2-. The Runruno project is the first BIOX® plant to implement the Generation III BIOX® design principles. As part of the Generation III BIOX® program Outotec supplied a turnkey, containerised metallurgical laboratory to facilitate the first four stages of the BIOX® and ASTER™ inoculum build up requirements. BIOX® inoculum build-up was started during early January 2015 with 5 litres of stock cultures shipped from South Africa. The BIOX® culture was successfully adapted to concentrate produced from the mini plant during March 2015. The ASTER™ inoculum build-up commenced during early August 2015 utilising 27 litres of ASTER™ bacterial inoculum already adapted to similar process conditions expected during commercial operation. This paper will detail the various stages of inoculum build-up through to commissioning and ramp-up of the BIOX® and ASTER™ Processes at the Runruno Gold Project. The paper will highlight some of the factors affecting the commissioning process as well as the improvements seen through the introduction of the Generation III BIOX® design principles.

Jan 1, 2017

This paper outlines the role of commissioning in the project cycle, shows how to get organised for commissioning and describes the principal commissioning activities. Emphasis is placed on appointing key commissioning staff early in the project to coordinate the preparations for commissioning and on detailed planning and tracking to ensure that the required commissioning activities are performed satisfactorily. The management of safety during commissioning is reviewed.

Jan 1, 2005

1. Domestic Production and Use: Twelve companies operated 31 primary aluminum reduction plants, three firms accounting for 66% of production. Washington, Oregon, and Montana accounted for 32% of the total production; Gulf Coast States, 25%; Northern States, 29%; and other Southern States, 14%. Output of primary metal in 1973 was valued at $2.2 billion. About 80% of the secondary recovery was from new aluminum base scrap and 20% was from old scrap. Aluminum consumption by 25,000 firms was centered in the East Central United States. Of aluminum consuming industries in 1972, building accounted for 28%; transportation 19%; electrical, 13%; packaging, 16%; and consumer durab1es, 10%.

Jan 1, 1974