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By Masanori Abe, Yoshitaka Kitamoto, Kazuhiro Nishimura

"Ferrite plating is a chemical processing which utilizes Fe2+ - Fe3+ oxidation to synthesizing polycrystalline films of ferromagnetic spinels (MFe20 4, M = Fe, Co, Ni, Zn, Al, Cr, TI, etc:) directly from an aqueous solution at 24 - 100°C. This low temperature process allows us to fabricate new ferrite film devices on · substrates of such non-heat-resistant materials as plastics, GaAs integrated circuits, and biomaterials. Synthesized from an aqueous solution the ferrite plated ·films are highly biocompatible. Thus various magnetic device and biomedical applications have been proposed and realized using ferrite-plated films. Ferrite-encapsulated polymer microspheres are applied to antibody carries for enzyme immunoassay, and also to toners/carriers for photocopying. Perpendicular magnetic recording media utilizing plated CoNi ferrite films are proposed. The low-temperature synthesized films of NiZn and Co ferrites are potentially used as soft-magnetic and/or insulating layers, respectively at high/microwave frequencies.IntroductionFerrite plating is a processing which facilitates the formation of crystalline spinel ferrite films with various compositions, (Fe, M)30 4 (M = Fe, Co, Ni, Zn, Al, Cr, TI, etc.), directly from an aqueous solution at 60 - 100°C [1]. This opened the door to fabricating novel ferrite-film devices using substrates of such non-heat-resistant materials as plastics and GaAs integrated circuits [2-4]; conventional ferrite film preparation techniques such as sputtering, vacuum evaporation, MBE, LPE, etc., require high temperatures(> -600°C) for crystallization of ferrites, which deteriorates the non-heat-resistant substrates. Recently we extended ferrite plating to be preformed at room temperature [5, 6]. This enables us to use as substrates such organic materials as biomaterials (e.g. enzymes) having very low heat-resistance."

Jan 1, 2000

By J. Pesl, U. Kemey, F. Sauert

"The CONTOP® smelting cyclone is a water-cooled, upright, high-intensity smelting reactor. The technology for the reactor was initially developed and brought into industrial-scale operation in the area of non-ferrous metallurgy. The two largest smelting cyclones were built with a capacity of 32 tons per hour of copper concentrate mix.The newest industrial CONTOP® plant treats up to five tons per hour of zinc-bearing residues including EAF dust. The highly concentrated zinc-lead oxide produced is sold to the zinc industry. The slag fulfills the leaching criteria and is used in waterway construction. The heat transferred to the cyclone cooling system and the off-gas boiler produces steam from which power is generated in a turbine.V AI has erected a new CONTOP® demonstration plant at MEFOS, Lulea, Sweden. A zinc volatilization rate of 90% was achieved during hot commissioning with Swedish EAF dust.Treatment costs in the range of 85 to 100 EUR per ton were estimated in a feasibility study on the treatment of 73,000 and 57 ,000 tons EAF dust for a group of steelmaking mills in Southern Europe."

Jan 1, 2000

By Bruno Bussière, Michael Aubertin, Robert P. Chapuis

Covers with capillary barrier effects (CCBE) have been used in recent years as gas barriers for the isolation of wastes, including reactive mine tailings. Capillary barrier effects help to maintain a high degree of saturation in the moisture retaining layer, which then reduces gas flux. Various factors affect the degree of saturation of the moisture retaining layer in a CCBE, such as the material water retention characteristics and layer thickness. Slope geometry can also influence the hydrogeological behaviour of a CCBE, but this factor has frequently been ignored in the past. In this paper, the authors show some results of a numerical study that illustrates the influence of slope on the behavior of capillary barriers made of different types of material. The numerical model calculations are based on an actual case of a CCBE constructed in northern Quebec. This investigation shows that the water content profile is greatly affected by the position along the slope. Thus, it is necessary to evaluate the influence of the geometry to properly establish the performance of a cover system.

Jan 1, 2000

By J. W. Merks

Spreadsheet software is an effective tool for simulating dynamic stochastic systems such as mineral processing plants. The two-product formula is used to show how to set up a Monte Carlo simulation in a spreadsheet template and how to calculate variances of dependent variables. The key to a reliable and realistic simulation model is to obtain unbiased estimates for all independent variables and variances in the set that defines the stochastic system. Monte Carlo simulation is also a powerful tool for optimizing sampling procedures, for applying sensitivity analysis and for designing and evaluating experiments.

Jan 1, 2000

By Eiichi Kuzuno, Atsushi Shibayama, Toyohisa Fujita, Kazuo Koike, Toshio Miyazaki, Hitoshi Masuda

"A solid sulfur is more useful to recover and store than a sulfuric acid as a by-product in the zinc hydrometallurgy. In this experiment a zin concentrate (sphalerite) was leached with ferric sulfate at about 373 K for 3 to 6 hours. Zinc was leached more than 95%. After a solid-liquid separation, the leached residue contained solid sulfur was obtained. The particles in the residue were dispersed by lignin and the solid sulfur of approximately 85% was recovered as float product by a flotation with frother in the pH 4. The dried float product was heated at 413K for 2 hours. The pure solid sulfur was recovered. On the other hand in the leached liquid a zinc oxide was ·added and ferrous .iron was oxidized to ferric iron by blowing oxygen. This ferric iron was returned to the zinc leached process after solid-liquid separation.IntroductionZinc concentrate is usually roasted as pretreatment in zinc hydrometallurgy and the produced S02 is changed to sulfuric acid. However, recently in Japan the utilization of sulfuric acid has been limited and it is more costly to store. Instead of producing sulfutic acid the solid sulfur recovery has been examined by direct leaching of zinc_ concentrate in this experiment.In the direct leaching, several kinds of effects have been studied for leaching of sphalerite in ferric sulfate solution. The addition of lignine siilfonate1 • 2) and fine· grinding3) increases the · speed arid leaching fraction of sphalerite. The leaching ratio depends on impurities in sphalerite ores4 • 5). Here, the zinc concentrate is leached ferric sulfate solution under atmospheric pressure at 373K. The solid sulfur in leached residue is separated as float products from other solids by sink-float separation and flotation. The sulfur in float products is purified by evaporation at 413K and recovered."

Jan 1, 2000

By Cadia Geology Team

The Cadia Hill Gold Mine, located near Orange in Central Western New South Wales, is owned and operated by Cadia Holdings Pty Ltd, a wholly owned subsidiary of Newcrest Mining Limited. Construction including pre-strip mining occurred from 1996 to 1998. The mine was officially opened in October 1998 following commissioning of the concentrator and mine fleet in June of that year. The Cadia Hill orebody is a porphyry related gold and copper system. The final pit has a strip ratio of approximately 1.3:1.0. Mining is undertaken on 15 metre benches using large capacity diesel hydraulic face shovels at an annualised rate of up to 70 Mtpa. The concentrator is currently rated at 17Mtpa and includes the worldÆs largest single line grinding circuit. The feasibility Mineral Resource was estimated at 352 Mt at 0.63 g/t Au and 0.17 per cent Cu. Initial reserves totalled 200 Mt at 0.74 g/t Au and 0.17 per cent Cu yielding a mine life of approximately 12 years. During the pre-production period mine geology systems were developed to support the operation. By design these systems were intended to add value to the business through minimisation of material miss-classification, provision of accurate and timely production information and mapping and reconciliation as a continuous model improvement tool. Variances that would prove to be material to the life of mine plan were recognised during the first year of production. These included identification of additional ore tonnes, higher copper grades and higher gold recoveries relative to the model. Gold grades and copper recoveries also reconciled favourably. Testwork was undertaken to determine the underlying causes of each variance. Re-modelling was then undertaken to capitalise on those variances. The Cadia Hill Gold Mine life of mine plan was re-evaluated with updated geology, grade, geotechnical, metallurgical and environmental inputs. Operating strategies were also reviewed and revised. Despite application of reduced metal prices in the evaluation, the outcome was one of extended mine life with more metal produced at lower cost. Development of robust mine geology systems, including a pro-active reconciliation process contributed to tangible improvement of the Cadia Hill Gold Mine operation. On-going system development and improvement initiatives are planned to add further value for the future.

Jan 1, 2000

By Mark R. Stanton

Geochemical and mineralogical analyses of 46 samples from six drill cores in the Mayday mine pile near Silverton, Colorado, demonstrate wide variability in trace metal contents with spatial location. This variability results from the original geochemical composition of mined rocks, mixing of ore and non- ore rocks during emplacement of the pile, and weathering since rocks were placed in the pile. Weathering reactions are controlled by factors such as pile thickness (depth), water availability, microbial activity, and mineral dissolution and formation kinetics. These factors result in variable redistributions of trace metals from primary (ore) to secondary (weathering products) minerals within each core.

Jan 1, 2000

By Osamu Taki

This paper presents the system, the strength of column, the design concept, and the applications with four case histories from the past project as the general aspect of Geo-Column (trade mark of single soil-cement column by SCC Technology, Inc.). In the system, it shows the installation process and drilling/mixing tool with the mixing process. In the design concept, it shows how to design Geo-Column against the vertical and horizontal load. Finally, it shows the applications with four case histories, (1) building mat foundation, (2) isolated foundation on the pedestrian bridge, (3) bridge spread footing and slope erosion control wall in the channel, and (4) cut-off wall and shoring wall in the underpass roadway to the railroad.

Jan 1, 2000

By Andre Vervoort

The roof in coal room and pillar panels is normally stratified and can be thought of as beams or plates supported by the pillar sides in the roadways and by pillar corners in the intersections Underground measurements showed the effect of the face advance on the additional total movement of the roof skin and on the relative movement between various layers in the roof. The latter consists of the opening of bedding planes and of the lateral sliding of layers over one another. Both phenomena increase locally the axial load along full column anchors. Four models have been used to come to a better understanding of the roof behavior: a beam either clamped above the pillar side or laying on the pillar sides and a three-dimensional boundary clement model with and without bedding planes. The shape ref the curvature of the roof deflection is host approached by a clamped beam: the other models overestimate the movement at the sides. The largest roof deflection for a given Young's modulus is estimated by the model incorporating bedding planes. This model estimates that the bed separation occurs close to the face (within the first meter) and within 0.2 m of the sidewalk. In some simulations, openings are even recorded just ahead of the face. Further underground measurements should focus on these findings, as the effectiveness of the support is directly related to the amount of bed separation and sliding, which have occurred prior to the support installation and which still cart occur abler installation.

Jan 1, 2000

By D. C. Foguel, J. L. R. Bravo

For several years, Caraiba Metais S.A. (CMSA) had to stock the arsenic sludge generated from the electrolyte purification process of its tankhouse. The amount stocked · reached approximately 3,500 tonnes, as the effects of its recycling during the smelting process and consequently in the sulfuric acid plant were unknown. Besides, it had as limiting factors the high content of arsenic in the copper concentrates supplied by foreign countries as well as the reduced capacity of the tankhouse's purification plant. The choice for selling the mentioned residue, which generally contains more than 50% of Cu, was attractive, but the environmental policies and regulations had not allowed this option. Other alternatives, such as the production of bicupric arsenic by means of a solvent extraction process or arsenic trioxide, were considered but the economic feasibility was not attractive due to the absence of a domestic market and a poor international market. After a study of the arsenic partition in the metallurgical process, it was verified that the residue could be recycled without causing any operational problems or damage to the environment. To make this possible, the capacity of the purification plant was increased and the way of removing the arsenic sludge from the cells was modified from manual to mechanical, therefore avoiding the direct contact of the workers with this poisonous substance. Moreover, procedures for recycling in the smelter were established and tolerance limits were set for both the smelter and the sulfuric acid plant. The main amount of arsenic to be recycled is released with the smelting furnace off-gas, which is washed during the purification stage of the sulfuric acid plant. The acid water, rich in arsenic, is then treated in the waste plant and the arsenic, in its stabilized condition, is confined in an appropriate area.

Jan 1, 2000

By D Ryan

Following a long period of increase, there has been a reduction in exploration expenditure and activity in Australia over the past two years. During the post Second World War period, exploration was largely driven by mining companies seeking resources to satisfy an increase in world demand, while increasing their asset base as a result of mineral discoveries. In general, return on investment to shareholders was not the major driving force. With the exception of gold the mining industry has been faced with a long-term fall of metal prices in real terms. As a result the net profit return on average shareholderÆs funds in the Australian minerals industry has fallen from over 20 per cent in 1990 to less than five per cent today. Mining is now competing for funds with communication and finance based industries yielding high returns on shareholder investment. Shareholders and superannuation fund managers seeking a high return on short-term investments have indirectly reduced the funds available to the mining industry. Globalisation of the mining industry is leading to the rationalisation of the Australian mining industry as witnessed by mergers and acquisitions of local companies by foreign investors. The return on capital invested in the Australian mineral exploration industry must improve if the industry is to be competitive on a worldwide basis. Failure to achieve this will result in capital flowing overseas or to other industries. Relatively short-term upswings in metal prices which are generally driven by threats to the supply base (eg strikes, mine closures, increases in country risk) often lead to increased capital raisings for exploration funding. As a consequence of the time taken to raise the capital and increase exploration activity, measured exploration activity lags the metal price increases. There are also lags between commencement of exploration and discovery and ore production. In the case of gold exploration expenditure peaked six years after the price rise of 1980 Companies persevering with exploration in the current difficult period will be rewarded because they will be able to capitalise on future metal price rises and a minimised time lag.

Jan 1, 2000

By J. D. Zhu, T. Ohmichi, H. Yasuda, S. Kashiwai, I. Ohnaka

"Since the casting process affects the properties of castings, its computer simulation has been greatly developed in the last decades. This paper presents our recent works, especially on mold filling simulation, because most casting defects such as porosities and inclusions that greatly affect the properties originate during mold filling. The first topic is the mold filling simulation with consideration of cavity pressure change during mold filling, including direct observation of flow phenomena with X-ray and pressure measurement. The second .one is the mold filling simulation in the lost foam process, in which gasification of polystyrene pattern and gas outflow through the coating and mold have been considered. The simulation can predict not only the mold filling sequences but also periodical vibration of the gas layer between the melt and pattern. The third one is the comparison of simulation of Al melt flow in a metallic runner and direct observation through a transparent mold, showing that the entrapped gas or inclusions is expelled ahead through the melt and its simulation needs very fine meshes. These examples show that the comparison of simulation and observation is very important to develop the numerical simulation further.IntroductionThe mechanical properties of castings are greatly affected by casting defects such as porosities and inclusions, and solidification structure. Although recently the structure simulation has greatly progressed [1-4 ], the application in plants is very limited, because the structure is mostly determined by chemical compositions and cooling rate, enabling us to estimate it from the structure of past similar castings without simulation.On the other hand, the casting defects often vary with each casting or time. Among the defects, porosities and inclusions are main causes to deteriorate the properties and mostly originate during mold filling. Therefore, a lot of efforts to simulate the mold filling and estimate those defects have been made in the last decades [l,5,6]. These efforts have been mostly to develop numerical techniques to solve the Navier-Stokes equation. However, the flow phenomena in molds have not been well understood, because the direct observation of the flow phenomena in mold is not easy. This means the accuracy of the simulation is still not clear."

Jan 1, 2000

At Bulong, the mineralised (>0.8 per cent nickel) ore exists within numerous lithologies, which can and do occur coincidently. It is very important to discriminate between the different host units for estimation purposes, stockpiling and scheduling. This allocation of host unit has relied upon visual interpretation by the geologist recording the information, which can be very subjective by its nature. By using quantified constraints, such as assayed magnesium oxide and iron, the subjectivity of describing the host material of nickel laterite ore is reduced. The constraints permit consistent identification of the various host units, which improves the confidence in the overall estimation and scheduling of the ore.

Jan 1, 2000

By Manqiu Xu, Glen Robertson, Steve Wilson, Pete Quinn

"The middlings circuit, once called the pyrrhotite rejection circuit, at Inco’s Clarabelle mill was a single flotation stage. It used to process a combined feed consisting of the main flotation scavenger concentrate and the non-magnetic portion of the magnetics flotation circuit tails. The typical circuit metallurgy was 55% nickel recovery at 6.5% Cu+Ni concentrate grade. In the past few years, a research project with the objective of improving the circuit metallurgy was initiated between Inco’s research laboratory and the Mill’s Process Technology group. This project has gone through three steps: a) initial laboratory studies, b) on-site pilot plant investigation, and finally c) full plant implementation.The present paper describes the initial laboratory test work. The development of a two-stage circuit consisting of separate rock and pyrrhotite rejection stages to replace the simultaneous rejection of both rock and pyrrhotite in a single stage is discussed. A two-stage circuit simulation based on batch laboratory flotation data is also presented. Further development work, including the on-site pilot plant test work and the plant implementation of the new circuit design, will be described in a later publication.INTRODUCTIONThe milling operation at Inco’s Clarabelle mill, Copper Cliff, Ontario processes a rich complex sulfide ore from several large production mines around the Sudbury basin (Agar, 199 1). The sulfide mineralization is simple, consisting of chalcopyrite (Cp), pentlandite (Pn) and pyrrhotite (Po). The main gangue minerals are pyroxene, feldspar and quartz with minor amphibole and talc. Estimates of mineral composition are routinely calculated from Cu, Ni and S assays. In the mineralogical calculations, all gangue minerals are conveniently grouped and treated as rock (Rk)."

Jan 1, 2000

By Paolo Heiniger

The aim of this paper is to present the operative solutions devised and then adopted to implement the underexcavation (soil extraction) of the Tower of Pisa, by means of soil extraction. The intervention has been performed by the Consorzio Progetto Torre di Pisa, a joint venture made of five qualified Italian companies (Trevi S.p.A. , Rodio S.p.A., Italsonda S.p.A., Ismes -Enel Hydro S.p.A., Bonifica S.p.A.), selected for their experience in the field of monitoring and restoration of monuments, structural design, foundation engineering and specialised works in underground conditions. Since 1991 the Consorzio has been charged with the specific task of implementing, within the contractual frame of a Concession, all the decisions made by the International Multidisciplinary Commission appointed by the Italian Government the previous year, with the aim at solving the «problem» of the Tower, strengthening the structure and stabilising its foundation. The Trevi Group, which is represented by Trevi S.p.A. in the above mentioned Consorzio, has given and is giving its direct and constant contribution and is engaged in supplying the special equipment to the operation and the drilling technology which has been successfully adopted to date.

Jan 1, 2000

By Brad Bjornson, Geoff Stevens, Mike Ashar, Cliff Britch

"LocationThe facilities are located 30 km north of Fort McMurray, Alberta (or 470 km northeast of Edmonton, Alberta).Brief Description of OperationThe operation includes the mining of oil sands, extraction of bitumen from the oil sands, and upgrading of the hydrocarbon fraction prior to shipment via pipelines to refineries.HistorySuncor was initially called Great Canadian Oil Sands. It was started by Sun Oil of Philadelphia. Construction began in 1965, with the first production coming on September 1967.Details of Present Milling Practice (Plant 3)Plant 3 recovers bitumen from the oil sand using the Clark hot water process. The basic steps in the process are conditioning, primary recovery, secondary recovery and tailings oil recovery.Oil Sand Feed SystemThe oil sand feed from the mine is transferred to the feed bin in extraction by two conveyor systems. Oil sand analyzers on each conveyor system measure the amount of bitumen and fines in the ore. Cones at the bottom of the feed bin distribute the oil sand to five process lines. Feed flow from each cone is regulated by an apron feeder which transfers the oil sand to conveyors that discharge into the conditioning drums. Weightometers on each of these five conveyors measure the rate at which the oil sand is delivered into the drums. The oil sand feed rate to each drum can be adjusted by varying the speed of the apron feeders."

Jan 1, 2000

By K. Biswas, F. C. Felipe

Paste backfill, because of its colloidal or water-holding properties, does not produce run-off water when placed underground. Paste backfill is generally, prepared from relatively low water content, full mill tailings with a certain proportion of ultra-fine particles and mixed with cement, thus producing early and better strength. Mill plant discharge tailings and other materials available at or near the mine site such as sand, aggregates or waste rock are used as blending materials in the mix design. This study investigates the influence of the above-mentioned blending materials on the mechanical characteristics of paste backfill, as well as the grading, shape, specific surface area, mineralogy and workability of the different mix design.

Jan 1, 2000

By Hideharu Fukunaga, Jin Pan

"The recognition of Metal Matrix Composites (MMCs) as a means of providing high specific strength, high specific stiffness, excellent wear resistance, low thermal expansion and improved high temperature properties has led to a number of new processing, not previously used for plastic and ceramic matrix composites. As a primary fabricating process, the liquid methods are the major ones, which are reviewed briefly from the view of processing terminology. One of them, squeeze casting process is the most traditional and well-developed, because it is rapid, versatile and near-net shape production of materials. Two of new squeeze casting processes are presented to offer the hardness· controlled MMC and the· functionally graded MMCs as well as a newly developed whisker preform.I .IntroductionA large number of liquid processes and techniques including semi-solid liquid process are proposed. The most primitive process is ''pressure infiltration casting” of liquid metal into the fiber preform. It is called as follows depending on pressure and its source squeeze casting (1-4) by hydraulic ram, gas pressure infiltration casting (5, 6), vacuum infiltration, centrifugal casting (7), Lorentz-force-driven infiltration (8). The pressurizing on the liquid metal requests a large and stiff equipment, so pressureless infiltration technique has been developed using K2ZrF6 flux (9,10) while the mechanical properties are not high enough, and using H2 gas with Mg alloying element called pressureless infiltration casting (11-13), spontaneous infiltration process (14) and PRIMEX (15). In those processes, no severe reaction occurred between the reinforcement and matrix molten metal. In early l 990's, the reactive processing with pressure or without pressure, in which one material is totally transformed into another of the required shape, eq. assisted oxidation, has been developed, called reaction squeeze casting (16,17), DIMOX (18) reactive infiltration casting (19,20), and in-situ process (21,22). Die casting of SiCp/Al alloy (23,24) and thixocasting of SiCp/Mg alloy (25) are also applied to produce the machine component of MMCs."

Jan 1, 2000

By M. Furuta, M. Hasimoto, Y. Komoda, K. Haiki

"Tamano Smelter & Refinery started its operation in 1972 with high current density electrolysis (350Nm2 of maximum) applying PRC technology. After the start up, four times of expansion have been done, the cathode production capacity has increased from- 84,000 t/y to 191,000 t/y. However, recent refining technology with permanent stainless steel cathode enabled to increase current density up to 300 Nm2 or more without PRC method. In order to increase current density more than 350 A/m2 , experimental work using commercial size cell has been carried out at several conditions, such as current density, PRC conditions, electrolyte composition and electrode condition. As a result, it was found that high quality (LME A grade) cathode can be produced at such a high current density as 405 A/m2•IntroductionWhen considering the production increase of electrolytic copper, what becomes important is the improvement of productivity per unit of production facility. Conventionally, production had been expanded by increasing the number of cells but a huge investment required for this had a influence to the business profitability. Because of this, increase of current density, which is one of the methods to improve unit productivity, 'was expected and this method at the same time has another advantage of shortening the retention time of copper and other precious metals in the cells. At present, the average current density at Tamano during full capacity production is around 350 A/m2 and this used to be the limit throughout the world (1)."

Jan 1, 2000

By F. Garcia-Carcedo

This research aimed to develop a clean technology for the production of ZnO from residues generated by the steel making industry. Scientific and technologic parameters were both investigated in order to define an industrial methodology allowing the integral recycling of EAF dusts. A reengineering of the Waelz process was perform,~d, aiming to produce a clean fraction of ZnO, fluorine free, as well as a slag enriched in metallic iron, which can be recycled in electric arc furnaces. The technical conditions used to produce the ultra pure fraction of ZnO are described. The magnetic separation of the EAF dust allowing the production of a phase high in iron and recyclable to the electric arc furnace is also discussed. Thermodynamic of the volatilization of all the elements contained in the EAF dust was performed in order to better control the thermal process in the rotary kiln. Tests were run using different reducing agents, weakly or highly reactive, aiming to determine their specific efficiency.

Jan 1, 2000