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By Steven J. Van Kauwenbergh, Talaat A. B. Lawendy

Batch laboratory-scale beneficiation tests were conducted on four high-iron phosphate samples. These samples included sedimentary ores (Tilemsi Valley, Mali and Tahoua, Niger), a sample from an igneous phosphate deposit (Matongo, Burundi), and a fine-grained phosphatic iron ore processing residue from Chile. The Matongo phosphate deposit occurs as a thick (up to 80 m) residual blanket of P205-enriched soil over solid parent rock (carbonatite and associated rock types). Although the Matongo deposit is an igneous deposit, ore from the deposit can be subjected to beneficiation treatments commonly used to treat sedimentary rocks. The beneficiation flowsheets designed to process these diverse ore types involve attrition scrubbing, size classification, and flotation. At the best flotation conditions tested, phosphate concentrates assaying 32.0%-39.0% P205 and 1.0%-1.5% Fe2O3, were obtained at 64.2%-82.2% overall P2O5 recoveries from run-of-mine (ROM) ores containing 9.2%-28.6% P205 and 5.9%-16.1% F,20,. A cleaner phosphate concentrate assaying 33.1% P205, 1.8% A1203, and 3.3% Fe2O3 at 53.4% overall P205 recovery was obtained from the phosphatic iron ore residue that originally contained 4.5% P205, 8.0% A1203, and 17.6% Fe2O3.

Jan 1, 1993

By Ann M. Hagni

Microscopic and sub-microscopic gold commonly occurs in the sulfides pyrite (FeS2) and arsenopyrite (FeAsS). To recover refractory gold from pyrite and arsenopyrite, these sulfides are roasted to create porosity and permeability prior to cyanide leaching. A new technique of adding Ca(OH)2 and roasting, lime roasting, is being tested fro retention of contaminant sulfur and arsenic and effectiveness of gold extraction. The lime roasting of pyrite at 500°C contains anhydrite (CaS04), oldhamite (CaS), calcium sulfite (CaS03), hematite (FenOs), magnetite (Fe304), and minor amoupts of pyrrhotite (Fel.,S) and pyrite. At 600°C, 650°C and 700°C the main constituents are anhydrite, oldhamite, and hematite. At 750°C, 800°C, and 850°C anhydrite and hematite are the predominant phases with minor oldhamite. The roasted arsenopyrite at 450°C contains arsenic sulfides, calcium sulfite, hematite, and minor oldhamite, magnetite, and pyrrhotite. At 650°C 700°C 750°C and 800°C, anhydrite, oldhamite, arsenic sulfides, and hematite are present. At 850°C, the same minerals are present with only minor oldhamite. The textures indicate excellent porosity and permeability at high temperatures. At lower temperatures, rims of low porosity and permeability surround many of the pyrite and arsenopyrite particles, and the complete oxidation process from pyrite to pyrrhotite to magnetite to hematite can be observed in individual particles. Additional process mineralogy techniques employed in this study are electron spectroscopy for chemical analysis (ESCA) and cathodoluminescence microscopy (CLM) in the determination of the calcium-sulfur- oxygen phases. Automated scanning electron microscopy-energy dispersive spectroscopy was utilized to analyze particles for gold content. Reflected light microscopy (RLM) revealed arsenopyrite and pyrite encapsulated in quartz particles of the gold-bearing concentrate, gold roast calcine, and cyanide leach residue.

Jan 1, 1993

By B. M. McKay

The Walnut Creek Mine was developed in 1989 to supply lignite to the Texas-New Mexico Power TNP-ONE power plant. Being new, we had the opportunity to start from scratch and rethink many of the traditional methods of managing a mine operation. We had the opportunity to create a team environment, encouraging people to get involved and make decisions. The founding philosophy of the mine, "A Quality Product by Quality People", acknowledged that the key to a productive, quality operation was the people. This paper will explore methods employed by Walnut Creek in selection of team members, building the team and the relative success of these methods.

Jan 1, 1993

By D. A. Smith

The successful integration of overburden casting techniques into the mine production cycle can be an extremely cost effective use of explosives. The entire mining cycle revolves around the cast blasting and to be successful requires a great deal of planning and cooperation. Several operations of Cyprus Coal Company in the Appalachian coal fields have successfully integrated blast casting into their mine plan. This paper will detail the parameters and necessary controls to integrate an overburden casting program into a surface coal operation.

Jan 1, 1993

By G. A. Kosick, L. Kuehn

The design of an information management system (IMS) for a mineral processing plant requires prior consideration of many factors, which can be broadly categorized into two domains, process plant considerations and IMS considerations. The process plant considerations include: plant characteristics, management and personnel issues, existing organizational standards and policies, and the level of existing hardware and software systems. The IMS considerations include: system functionality, system sizing and desired performance, hardware components, software components, and system support issues. All of these aspects must be addressed in order to achieve a functionally successful and cost effective system. The purpose of this paper is to lay out these design issues and, in doing so, to provide process engineers with a guideline with which to tailor a system that is best suited to their specific application. The paper is completed by presenting an approach that has been used in two Canadian concentrators. Both of these plants have incorporated MillEX, a software system designed specifically as the central component of a mineral processing IMS.

Jan 1, 1993

By R. H. Sergent

The interest in using halogens for extracting precious metals from ores has increased due to changes In ore characteristics, environmental concerns and regulations. The rediscovery of halogen leaching capability has been the topic of these and other writers1-30. Much work has been done on the performance of bromine, chlorine and iodine5-29. Of these, bromine and chlorine look most promising. Iodine is quite expensive and sometimes forms an Insoluble film on a precious metal surface22,23. Little experimental work has been published on the relative performance of bromine versus chlorine. The Pourbaix diagrams for the halide leach system (see Fig. 1-4) Indicates a significant stability advantage for bromine In forming complex ions with gold. This should result In greater extraction of gold under similar leach conditions and Is evaluated In this work. The regeneration of halogen from a spent leech solution is a critical requirement for an environmentally acceptable halogen leach process. Bromide can be oxidized In-situ to bromine ~ adding chlorine or ozone2,31. Bromide like chloride can be oxidized In an electrochemical cell to produce halogen on demand 13,15,17. Bromine clearly offers a number of possible regeneration pathways. This work strives to compare the relative ability of chlorine and bromine to extract gold from partially and fully oxidized ores. A commercially pressure oxidized sample was evaluated under a number of experimental conditions. The autoclave feed ore from the same mill was also evaluated after complete oxidation In a laboratory autoclave.

Jan 1, 1993

By R. J. Kuczynski

The U.S. Bureau of Mines operated a 2,000-9 (4.4-lb) batch process development unit for recovering platinum-group metals (PGM) from automobile catalysts. Virgin monolith, used pellet and used monolith catalyst samples were tested. Leaching twice with 1-pct sodium cyanide (NaCN) solution at 160' C for 1 h in a pressure vessel dissolved over 95 pct of the PGM from virgin catalysts and over 90 pct from used pellet catalysts. Over 85 pct of the PGM was dissolved from used monolith catalysts when a third leaching step was added. PGM concentrates as metallic powder containing over 99.8 pct of the dissolved PGM and analyzing greater than 70 pct PGM were recovered by heating the pregnant leach solutions from virgin catalysts to 250' C and used catalyst to 275" C for 1 h. The solution after heating contained primarily sodium carbonate from cyanide decomposition and less than 0.2 ppm total cyanide.

Jan 1, 1993

By M. Labrie, H. L. Gibson, G. Doiron, J. J. Watkins, D. H. Watkinson

Abstract -The Corbet deposit is one of 17 proximal Cu-Zn massive sulfide deposits located. within the Noranda Cauldron which occurs within the core of the Noranda Volcanic Complex. The deposit is located at the top of the F1avrian Formation, the lowermost formation of the 3000 m thick Mine Sequence; the deposit has yielded 2.75 M tonnes of ore grading 30Jo Cu, 0.96% Zn, 2.06 g/t Ag and 1.0 g/t Au. The multi-lens Corbet deposit formed within a 250 m wide crater that occurs within a localized breccia pile. The Corbet breccia pile was constructed by explosive magmatic and hydrovolcanic eruptions localized along the south flank of a larger andesitic shield volcano that formed during the waning stages of F1avrian volcanism. The breccia footwall of the deposit allowed unfocused and widespread hydrothermal discharge that resulted in the development of a large area of chlorite and fringing sericite alteration that exceeds, by six times, the size of the sulfide lenses and represents a significant exploration target.

Jan 1, 1993

By Richard Komarek

When limestone (Ca03) is calcined in rotary kilns to produce quicklime (CaO), it is not unusual for 10% to 20% of the stone to abrade and emerge from the kiln as quicklime fines (-6.3 mm or -0.25 in.). While there are various industrial processes that can use fines, handling and shipping is tricky and dangerous. Due to the highly caustic nature of quicklime, airborne dust easily bums eyes and skin. On the other hand, money has already been invested in mining (or buying) the raw material and in the equipment and energy needed for calcining. Discarding the fines will not only waste that investment, but add even more cost in transportation and possibly dumping charges. So the question becomes, how can fines best be turned into a revenue-generating asset? Some plants convert leftover quick-lime fines into calcium hydroxide - Ca(OH)2, also known as hydrated or water-slaked lime - for sale into agricultural applications. For farm uses, hydrated lime fines are preferred over quicklime because they are easier to handle. And they are favored over raw limestone fines for their higher concentration of calcium and greater solubil¬ity. From the producer's viewpoint, quicklime fines are ideal for this use because they go through hydration faster than the larger chunks of quicklime. Those larger chunks, or "pebble lime," are more readily salable and more easily handled, for such uses as steel, copper, aluminum and magnesium production, water waste treatment, chemical, paper, glassmaking and flue gas desulfurization in coal- fired boilers.

Jan 1, 1993

By Filippos Patsiogiannis

Laboratory size (5 kg) aluminum killed low carbon steel melts were desulfurized with synthetic fluxes in zirconia crucibles. The sulfur, oxygen, aluminum, silicon, and manganese contents in the melt were determined as a function of refining time and temperature. With a good argon shield and synthetic flux cover, melt reoxidation was not observed. Sulfur removal followed first order reaction kinetics. The effectiveness of calcia saturated calcium-aluminate (12CaO.7Al2O3) based fluxes in desulfurizing the steel melts was evaluated. The effects of initial sulfur level of the melt, weight of the flux (slag), and additions of tellurium, fluorspar, and barium oxide to the melt on the kinetics of desulfurization were also studied.

Jan 1, 1993

By R. S. Saunders

Congress, under the Nuclear Waste Policy Act of 1982, as amended, charged the U.S. Department of Energy (DOE) with the responsibility for safe and permanent disposal of high-level radioactive waste in a geologic repository. The waste will consist of spent fuel from commercial nuclear generating plants and reprocessing activities. Under direction of this law DOE is currently evaluating Yucca Mountain in Southern Nevada as the candidate site for a potential high-level radioactive waste repository. Presidential, Congressional and State of Nevada approval are needed for repository construction to proceed after successful completion of site characterization and recommendation of the site to Congress. The DOE will submit a license application to the Nuclear Regulatory Commission (NRC) to construct the geologic repository. Following successful construction DOE will update its license application to operate the repository.

Jan 1, 1993

By W. Ellison

Worldwide development of commercial markets for FGD (flue gas desulfurization) gypsum is described and used as a basis for assessing potential overall market growth and regional demand foreseen in the U.S. during the 1990s. Diverse strategies are outlined for cost-effective substitution of this major supply from acid rain control retrofits (power plant scrubbers) for natural gypsum in the principal, existing markets: gypsum board and portland cement. Another focus of utilization forecasting is a key group of related. new-product advancements including floor screeds, mining mortars and various types of innovative construction products.

Jan 1, 1993

By J. R. Evans

Mining claims must have a discovery of a valuable mineral deposit to be valid. When required, a Federal government mineral examiner makes a determination of validity and recommendations thereof to authorized management officials. The examiner should show whether or not an existing mining operation, or a proposed operation have economic viability. This is accomplished through an analysis of legal entities, land status and use, geologic and mineralogic relationships, and mining, milling and processing techniques considered in an appropriate economic evaluation framework. A framework involves market and market entry studies, reserve analyses, all costs analysis, royalty buyouts, tax structure, discount rate of return, and escalation and risk factors. An income approach to value is then used by means of a simple or complex discounted cash flow (DCF) analysis to certify validity. Whether one claim is owned by a single miner, or hundreds of claims are owned by a large corporation, thorough, fair, consistent, and appropriate economic concepts should be applied by the mineral examiner.

Jan 1, 1993

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 David K. Ingram

Research performed by the U.S. insurance industry has determined that mine subsidence is uninsurable. Consequently, the insurance industry has decided not to voluntarily offer mine subsidence insurance. The U.S. Department of the Interior has long been investigating the effects of mine subsidence. These investigations have resulted in Federal regulations and controls of mine subsidence. This U.S. Bureau of Mines report generally describes mine subsidence, the development of mine subsidence insurance programs, and the eight current mine subsidence insurance programs in the United States. The States that have these subsidence programs include Colorado, Illinois, Indiana, Kentucky, Ohio, Pennsylvania, West Virginia, and Wyoming. Major aspects of the programs include history, administrative and operational procedures, insurable structures, recognition of mine subsidence, major exclusions, claims, insurance premiums, and the economic health of each program. Addresses of agencies involved with mine subsidence insurance are also given. Information within this report can be useful for residential and commercial property owners and mine operators. States that are considering starting or have an existing mine subsidence insurance program can also use this report as a model for initiating or modifying their programs.

Jan 1, 1993

By William F. Riggs

The basic theme of this symposium and panel Is Rotation Pads: Are They Optimized? There Is a. reason for phrasing the title In the form of a question. There Is not only the technical competency which we must address; there Is the operating philosophy that must be evaluated on the part of both the customer and the supplier. Customers desire reagents which are trouble-free and capable of providing that extra amount of selectivity or recovery. When they receive ft, after the supplier has provided several years of Internal research, one of the first concerns/complaints Is the price of the product. This has a tendency to rapidly reduce a supplier's support level In the future. Suppliers are equally guilty from another perspective. When they approach a customer to Introduce a product, they often attempt to market by offering only a price Incentive. They then wonder why a customer doesn't respond Immediately to the incentive. They are often oblivious to the fact that the reagent cost is such a minor aspect of the operating budget, and the customer has many more pressing problems on a day-to-day basis In comparison to the reagent cost. We need to establish the understanding that reagent cost Is an Inconsequential cost of operation, and yet has such a disproportionately high Impact on the success of the entire operation. This understanding Is required by both the customer and the supplier. We say to each other,' why are we discussing this since this has been obvious for some time?' The reason is relatively simple in that we talk about it, acknowledge it, and yet we do not adhere to it. The supplier provides a product along with test data containing statistics, analysis, recovery, grade and cost calculations while most of the time ignoring the operating technique which must be applicable In the plant In order to optimize the product. He expects the reagent to be substituted In the plant for the existing reagent and ft works or does not work after trying several variables. The operating management Is equally guilty, In order to best explain this to both the customer and the supplier, ft becomes necessary to review the basic purpose of the major reagents utilized In flotation. A collector is basically to Impact selective, maximum water repellency on the surface of a particular mineral, The frother has the purpose of providing a chemically stabilized membrane on the surface of the bubble at the air-water interphase. This, then, provides a host environment for the attachment of the collector-coated mineral to a bubble. The depressant functions In the reverse of the collector and must demonstrate the same or greater degree of selectivity than expected of a collector. The key area which has been Ignored Is the rate by which these reactions occur and Interrelate. This has a very specific effect on the operating technique and the compatibility of the chemistry, equipment, and the operator himself. Researchers, suppliers, and customers provide reams of data to demonstrate how their products or design produce, for example, higher kinetics, more selectivity, or more recovery. The Information is often true. After all, we are all learned men and laboratory and actual plant data do not lie. However, we must remember the theme of this symposium and panel: Flotation Plants: Are They Optimized? and Optimizing of Flotation Reagents? The direct, honest comment to the two titles is very simple. OF COURSE THEY ARE NOT The plants, equipment, and reagents had better not be optimized or else we are in trouble. The Issue of this panel discussion is to approach this subject from a slightly different or perhaps mainly Ignored aspects of optimizing reagents in flotation. When we have reagents which provide higher kinetics, more selectivity, and better recovery, how do we use them? Since each reagent has a different physical characteristics of froth, rate of recovery, volume effect on the compatibility of equipment, and many more aspects too numerous to mention, the question which has been severely Ignored Is, 'What degree of study and cooperation by both the supplier and the operating management has been conducted In order to prepare the operator for maximizing the performance of a reagent In relation to the rest of the system?" Prior to testing a new reagent, how much time Is spent to bring the actual operator(s) Into the program to make them feel part of the program? How much time is spent explaining to the operator on the float floor how to possibly take advantage of a reagent with faster kinetics or one which Is Inherently more selective? What

Jan 1, 1993

By Orlando C. Rojas

The Potrerillos Smelter commissioned a new El Teniente converter in 1985. As a result of the use of this technology, the Peirce-Smith converters have been processing only high grade matte or white metal. These operational changes resulted in damages to the converter shells, excessive splashing and cold dope generation and very short refractory campaigns. The paper shows the modifications to the tuyere angle, mouth design changes and new techniques for mouth cleaning and gas handling. Operational results up to 1991 are also shown.

Jan 1, 1993

By Zhang Hengzhong

Based on thermodynamics of surfaces and a proposed two-dimensional state equation for surfaces, the relationship between the surface tension (Y) of a solution and the activity (a1) of its component (i) was derived: (1/Y)r2-.¬E (ai/Yl) The derived equation was verified with reported experimental data of water-alcohol systems and water-acetone system, the calculated results showed astonishing coincidence with experimental. Applications of the equation to the five matte systems Cu2S-FeS, Ni3S2-FeS, FeS-PbS, Cu2S-PbS and FeS-Cu22S-PbS also demonstrated that at given matte compositions the calculated surface tensions agreed with experimental fairy well.

Jan 1, 1993

By R. D. Hagni

Pyrometallurgical products from lime roasting of refractory gold ores, pyrite, and arsenopyrite have been examined for their mineralogy, porosity, permeability, retention of contaminant sulfur and arsenic, and potential effectiveness of gold extraction. Cathodoluminescence microscopy, supplemented by X-ray diffraction and scanning electron microscopy-energy dispersive analysis study, has shown that the products phases have characteristic cathodoluminescence properties as follows: anhydrite (CaS04), deep blue; unreacted portlandite (Ca(OH)2), deep purple; oldhamite (CaS), light yellow to rarely pink or orange; a sulfur-rich, arsenic-poor phase, violet; an arsenic-rich, sulfur-poor phase, non-CL. Within the temperature range examined (400-850°C), hematite exhibits greater porosity and permeability at the intermediate roast temperatures of 600-650°C.

Jan 1, 1993

By P. R. Taylor

Three refractory gold concentrates have been tested to evaluate the effect of roasting with hydrated lime followed by cyanidation. The results indicate that it may be possible to roast in such a manner as to contain nearly all of the sulfur, arsenic and antimony in the roaster calcine. Cyanidation results indicate that the gold recoveries are greater than 80% for all three concentrates.

Jan 1, 1993