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By S. A. Davis

In July of 1996, the Kroll process began production again at TIMET's Henderson, NV, manufacturing facility. This, after being shut down for several years due to low market demand for titanium. Faced with limited pond capacity and increasing costs for water and wastewater disposal and storage; process changes were made to recycle water used to wash Kroll titanium sponge back into the sponge leaching process. This idea was revisited from 1992-93, when three consecutive attempts to recycle water for this application were unsuccessful due to early pump failure. Since it was uncertain why previous attempts failed, a complete understanding of the existing system was first sought. This included reviewing piping and flow diagrams; taking field measurements for all the piping, valves, and fittings; analyzing the wastewater composition; and modeling the fluid dynamics and control of the system. The fluid dynamics of the system were modeled by breaking the piping network up into nodes and applying the Bernoulli equation to each segment. The fluid flowrate control valves were modeled for this purpose also and the models were used to help specify the required processing equipment and control ranges and tolerances. Once the project was completed, an operating procedure was prepared for operation, startup, and shutdown of the washer water recycle system.

Jan 1, 1999

By 1980, the U.S. mining community had reached a broad consensus regarding coal pillar design. The pillar load could be estimated from tributary area theory, and the pillar strength from empirical formulas and laboratory coal strength testing. Then the growth of longwall mining required new thinking. Recently, powerful design methods have emerged from analysis of large data bases of real-world pillar successes and failures. These include the Analysis of Retreat Mining Pillar Stability (ARMPS), the Analysis of Longwall Pillar Stability (ALPS), the Mark-Bieniawski rectangular pillar strength formula, and guidelines for preventing massive pillar collapses. Sophisticated numerical models have also helped transform the pillar design landscape. In the process, our understanding of pillar mechanics has been greatly enriched. A new paradigm divides pillar failure into three categories:

Jan 1, 1999

By James R. Hunter, Sandra K. Zacharias, Ursula M. Franklin

Archaeometallurgical remains can be a valuable source of information about past technological activities and, by inference, the societies that undertook them. Material traces of former metal-producing or metal-working centres can include raw materials, products, or metallurgical installations such as mines, furnaces or forges. Of these remains, the most common is slag, often left undisturbed since its original production. Physical and chemical analyses of archaeological slag and metal can often reveal the processes and materials involved in their formation. Mineral composition and softening temperature of a slag, for instance, can indicate the conditions of the metallurgical operation, such as temperature and atmosphere and, thus, help identify metallurgical processes which took place at a site(1). The present report illustrates the value of such analysis. Metal-working remains from Sainte-Marie among the Hurons, near Midland, Ontario, on the south side of Georgian Bay have been analyzed in order to determine the techniques and processes used by the 17th-century blacksmith who worked at the mission headquarters from 1642 to 1649. Samples were selected from a very large collection of blacksmith refuse which was excavated from the site by archaeologist Kenneth Kidd in 1941-42(2).

Jan 1, 1999

By T. F. Torries

Identifying high value areas of unmined coal when large quantities of coal are available relative to annual markets is difficult because of the uncertainty of when the coal is to be mined. A GIS based methodology developed to value reserve coal in a producing coal region for the purpose of ad valorem taxation also identifies high value areas for mining investment. The methodology is unique in that it accounts for most mining, environmental, and market factors to determine when specific properties are to be mined. The methodology and data base are useful for directing regional exploration and acquisition activities toward most favorable areas.

Jan 1, 1999

By I. Gaballah

Jarosite contains up to 15 % of heavy metal compounds 'HMC'. The current waste disposal methods will not be allowed in the near future due to new environmental regulations and pollution risks. For these reasons, thermal treatments of raw or decomposed jarosite, in controlled atmospheres, were investigated. The aim of these treatments is to decontaminate the jarosite and/ or to recover the HMC for recycling. According to physico-chemical characteristics of the samples, the thermal treatments in controlled atmospheres N2, CO+N2 and C12+air lead to the extraction rate that vary from 93 to 98 %. Heavy metal compounds were separated by cooling the gaseous phase. The treatments' residue was almost free from HMC. Between 700 "C and 800 "C, the chlorinating treatment was successful of eliminating more than 97 % of HMC contained in four different samples.

Jan 1, 1999

By H. Kempton

New methods for remediating metals-contaminated groundwater include in-situ emplacement of highly adsorptive substrates to permanently retard solutes. Substrates are introduced by sequential injection of soluble components that precipitate in the aquifer, forming a permanent high-retardation zone. This method overcomes the factors that limit pump-and-treat remediation; i.e, long-term source loading and slow desorption. Column tests demonstrated efficient substrate emplacement, increasing retardation coefficients of Cr(VI) by 20 and As(V) by 40. Similar effectiveness is expected for other heavy metals. Simulations using a coupled advective-geochemical model accurately matched substrate emplacement and arsenic attenuation, allowing extrapolation to other constituents and larger-scale applications.

Jan 1, 1999

By George Grandy

Kvaerner experience is being used to develop software to design or simulate crushing and screening plants. The model techniques discussed are presently being used for open-circuit plants and are being extended to closed circuit plants. The program contains a library of routines, each representing a piece of equipment or unit operation, which are assembled into one of several open-circuit plant configurations. Routines include gyratory primary crushers; standard secondary and shorthead tertiary cone crushers; single, double or triple deck screens; and stockpiles, feed bins and belt conveyors. The program uses steady-state models to simulate the performance of crushers and screens that have small residence times and quickly reach equilibrium when operating conditions and/or parameters are changed. The dynamic aspect of the total circuit model concerns the storage units within the circuit, i.e. stockpiles and bins, and, in the closed circuit configuration, circulating loads and size distributions. In many cases, just vendor's catalog data are necessary for a pre-feasibility simulation; in other cases, actual plant test data are required to obtain more accurate simulations. The entire plant is shown in a single graphic screen so the user can see all the relevant information he might want, and soft-keys are provided for the user to make on- line parameter changes and observe the effects on storage elements, equipment feed rates and the final product size distributions. The model also reports equipment utilization in percentage, power consumption, and other related operating information, and soon, will be able to report estimated capital and operating costs.

Jan 1, 1999

Water and wind erosion of toxic zinc and lead smelter waste is one of the most urgent environmental problems to be solved in the Silesia region of Poland. Over 87 x 106 Mg of various mining wastes were disposed of in uncontrolled piles leading to soil, water, and air pollution in highly populated areas. Welz and Doerschel process Pb/Zn smelter wastes were stabilized in the summer of 1994 by application of heavy loads of CaCO3 (30 Mg/ha), CaO (1.5 -15 Mg/ha), and municipal biosolids (150 -300 Mg/ha), followed by seeding with a mixture of acid-and salt-tolerant grass species selected in a pot experiment. Vegetation was successfully established on 85% of the Welz material demonstration plot area (0.5 ha), even though it was initially high in water-soluble Zn, Pb, and Cd ranging from 0.4 to 1311,0.1 to 5.8, and 0.05 to 55 mg/kg, respectively. Standing biomass averaged 3.3 Mg/ha on the stabilized Welz waste zone by the end of the third growing season (1997). The revegetation of much of the Doerschel material area failed initially because of extremely high salinity (16 dS m-1), high content of water soluble metals (Cd in particular), and heavy compaction. The area was capped (15 cm) with waste lime and retreated with bio-solids (300 Mg/ha) in 1995, and standing biomass averaged 2.9 Mg/ha in the fall of 1997. The observed plant response to bio-solids and lime indicates this approach to be an environmentally beneficial technology as compared to the traditional methods utilizing topsoil covers.

Jan 1, 1999

By F. Mucciardi

While flash smelting and converting are capturing a greater share of the market, injection through circular injectors will remain with us for the foreseeable future. The use of top lances for injection is a key feature in several processes (e.g. Mitsubishi, Ausmelt). Tuyeres, on the other hand, are incorporated into a number of processes (e.g. Noranda, Peirce-Smith). To date no lances or tuyeres are cooled by an external source. The reagent provides the bulk of the cooling. With limited cooling, it is normal to have substantial wear on the nozzles - especially in the case of lances. To overcome the issue of wear, a new patented injector (lance or tuyere) has been developed by Noranda and McGill University. This novel unit is based on heat pipe technology. It can operate for an extended period of time without wearing. Enhanced lance/tuyere life is achieved by operating the injector at a low enough temperature that promotes the formation of a thin frozen layer on the outer body of the unit. The vaporizing and condensing substance within the unit acts to cool' the high heat flux portions and dissipate the heat to areas of low heat flux outside the vessel. A fairly large number of tests have been conducted with a prototype unit. The tests have shown that the heat pipe lance is a viable unit. In this paper is detailed a test which illustrates how the lance functions when pure oxygen is injected into copper matte. In addition, the findings from a basic study of a heat pipe in high heat flux environments are also presented.

Jan 1, 1999

By S. A. Bradford

The twenty years before World War I was the Golden Age of copper smelting in British Columbia. In this short time, the smelters developed from small, primitive units to large, efficient operations. The first copper claims had been staked on Howe Sound and Knight Inlet in 1864, and there was extensive copper mining in the interior by the mid-1880s, but before 1895, all ore was shipped out of the country for smelting, converting and refining. The first interest in smelter construction was undoubtedly inspired by a Provincial bonus and Dominion land grants offered to smelter builders. The early smelters made use of small blast furnaces which were designed to smelt any kind of ore, but usually far too little ore was available. The first smelter seems to have been the McRae furnace on the Spillimacheen River (1883), followed by Vancouver (1889), Revelstoke (1891), and Golden (1891) (1). They each smelted a few tons of galena and then quickly closed down permanently for lack of ore. Only smelters that actually produced some copper matte are described in the following sections.

Jan 1, 1999

By Michael S. Wieland

"This report investigates whether it is tractable and thereupon reasonable to remove the boosterinfluences when ranking the toxic fumes of non-cap-sensitive mining explosives. The hazard potential is represented by relative fume toxicity RFT, the resultant influence computed from a formulated rule with a restricted set (tally) of fume components and multiplying constants. The RFT result is compared to the rule criterion that represents the worst case tolerable toxicity stipulated by regulations or otherwise. The typical nonstoichiometric booster composition can render notable unwanted influence on the RFT ranking results. Historically, the remedy was to shoot the booster separately and reduce the trial concentrations by the relevant subtractions. Unreal negative concentration results were noted on rare occasions, revealing the faulty nature of the reduction procedure. With thermodynamic reaction chemistry codes TDRC, on the other hand, the booster ingredients can be retained in or removed from the reactant tabulation, yielding reduction factors taken as the concentration ratios for the two circumstances. The underlying presumption regarding reduction factors is that the ratios of component concentrations with and without the booster ingredients when resolved theoretically ought to equal those rendered experimentally, when tractable. Upon rearranging the presumed relationship, the unadjusted fume concentrations divided by theoretical reduction factors yield the wanted readjusted fume concentrations, thereby removing the booster influence without generating unreal negative concentrations."

Jan 1, 1999

By Roy T. Bowles

This paper focusses on technological developments which occurred in the village of Deloro, Ontario between 1868 and 1919. These developments illustrate the manner in which improved metallurgical processes linked Ontario mineral resources to industrial expansion. Overview of Deloro The village of Deloro is in Hastings county, about 5 miles from the village of Marmora, the site of the old Marmora iron works and the more recent Marmoraton iron mine. In this area, the Canadian Shield meets the Great Lakes lowlands. The first settlement in the vicinity occurred in the 1820s and was associated with the Marmora iron works. Settlement grew around agriculture. Gold was discovered in Hastings county in 1868. Deloro - the name derives from gold - developed as a concentrated settlement in proximity to several gold mines and the related processing activities. By 1901, substantial smelting works were successfully producing gold and arsenic from local ores. The village was developing as a company town within the framework of benevolent paternalism. For reasons associated with markets and with local ore supplies, the Deloro mills were idle for a period beginning in 1902. Developments in later periods connected Deloro to world events. In 1903, silver was discovered at Cobalt, Ontario. By 1907, M.J. O'Brien, who owned mines at Cobalt, had purchased the Deloro works and was using them to process Cobalt-area ores*.

Jan 1, 1999

By George P. Demopoulos

n this study we have sought to highlight the critical linkage between individual reaction kinetic parameters (usually determined in small bench scale experiments) and large continuous reactor performance by focusing on the industrially significant zinc pressure leach process. To this end a comprehensive mathematical model previously developed for the description of this process was employed. In this paper we have examined in particular how small variations in key kinetic parameters impact on the autoclave&apos;s performance, i.e. attainment of autogenous steady-state temperature, zinc conversion and solution chemistry. The reaction parameters studied were: (i) stoichiometry of the marmatite leaching reaction; (ii) the activation energy of the same reaction, E,; (iii) the rate constant of the ferrous to ferric oxidation reaction, k,; and (iv) the apparent equilibrium constant for ferric precipitation, K,. This parameter sensitivity analysis was done under no oxygen mass transfer control limitations. Model predictions were found to be more sensitive to the kinetic parameters under certain conditions than others. The most dramatic finding was the one related to the small amount of sulfate produced during marmatite leaching. In connection to this it was found that the small percentage (< 5 %) of sulfate produced enhances the autothermal operational stability of the autoclave. The need for accurate kinetic parameter determination under conditions similar to those encountered in industrial zinc pressure leaching was demonstrated.

Jan 1, 1999

By Kenneth C. Mills

Interfacial phenomena can have a dramatic effect on the separation of phases. Furthermore, since they involve surface-active materials, concentrations at ppm levels are enough to cause dramatic effects on separation processes. The effects of (i) emulsification, (ii) contact angle and wettability and (iii) Marangoni flows on phase separation are reviewed.

Jan 1, 1999

By Stavros A. Argyropoulos, Michael Trovant, Norman J. Goudie

"Two studies were carried out to estimate the thermal resistance of various interfaces using experimental and computational techniques. Three types of interfaces were examined. The first study investigated metal-mold interfaces, and the second study focused on metal-metal and metal-oxide interfaces.For the metal-mold interface, the air gap size was measured and subsequently correlated with the interface thermal resistance. The procedural details are outlined for the development of a correlation which predicts thermal resistance as a function of air gap size.Investigation of the metal-metal and metal-oxide interfaces employed data from a series of experiments as input into a model, which solved the inverse heat conduction problem in terms of a resistance estimate. These experiments, involved dipping a cold cylindrical metal into a liquid metal or liquid oxide, respectively. Under these conditions, a shell freezes around the cylindrical addition and a thermal resistance develops during the time period which shell exists . The Heat Transfer Coefficient (HTC) at the addition shell interface differs significantly among the various types of metals and oxides used. In the case of an oxide shell, the (HTC) is about an order of magnitude lower than the (HTC) of the metal shell.INTRODUCTIONIn many metals processing operations there is a need to estimate the thermal resistance at metal-metal, metal-oxide, metal-mold interfaces. This need was further intensified with the recent proliferation of mathematical models, which predict various transport phenomena events. There are many factors which can influence the magnitude of the interfacial thermal resistance. Some of the factors, among others, are as follows: contact temperature, metal thermal conductivity, apparent contact pressure, surface roughness, interstitial gas conductivity, and interstitial gas pressure.In this paper, two studies are reported on the estimation of thermal resistance. The first involves, the development of heat transfer coefficient-air gap relationships at the metal-mold interfaces. The second includes, estimations of thermal resistance at the addition-shell interface. The former case is encountered in the metals solidification and the latter during the melting and/or dissolution of additions to liquid metals or slags."

Jan 1, 1999

By Zhijing Zhang, Ramana G. Reddy

"The viscosity of molten oxides is one of the important physical properties since viscosity has a decisive influence on fluid flow. The knowledge of the viscosity of molten oxides is essential for modeling and controlling of metallurgical process. In the present study, viscosities of high basic Na2O-B2O3 and Na2O-SiO2 binary melts and viscosities of Na2O-SiO2-B2O3 ternary melts were measured as a function of temperature and composition. Experiments were carried out using rotary viscometer and graphite components. Our experimental results were compared with those in literature. Based on the current experimental data, the previously developed viscosity model was modified. The characteristic features of viscosities of these melts have been discussed. The predicted viscosity results are in excellent agreement with the present experimental data in the temperature range with molten state samples. IntroductionThe viscosity of molten oxides is one of the important physical properties since this property has a decisive influence on fluid flow, and is one of key factors to be taken into consideration in process modeling. The manufacturing operations require the viscosity of molten oxides to be within certain ranges. Although, some viscosity measurements on borosilicate systems have been carried out [1-4], the viscosity data in literature are available only for a few temperatures and cover small composition ranges. The agreement between the results of these works is not satisfactory [I-4]. Even the viscosities of binary systems Na2O-B2O 3 and Na2O-SiO2 generally are well studied, the available viscosity data in literature are only found in the composition range of O to 0.333 mole fraction ofNa2O. The aim of the present study is to provide a base with accurate experimental data for reliable model extrapolation."

Jan 1, 1999

By L. Filip

The roast-leach-electrowinning (RLE) process for zinc was modified to treat two typical complex concentrates containing zinc, lead, copper, gold and silver. Laboratory testwork results indicated that the optimum roasting temperature ranged from 700 to 800°C, in order to produce acceptable residual sulfur levels. The calcined concentrate was subjected to a three-stage leach sequence. The resulting leach solution was purified by hematitic precipitation and directed to the recovery of copper and zinc by solvent extraction and electrolysis. Alkaline smelting and subsequent electrolytic purification recovered the lead and precious metals from the leach residue. A flowsheet was developed based on the laboratory testwork results, and demonstrated in a large-scale pilot plant. The recoveries produced during the pilot plant operation ranged from 90 to 92% for zinc and copper, 85% for lead and 90% for gold and silver, respectively.

Jan 1, 1999

By J. E. Dutrizac

Canada is currently the world&apos;s largest supplier of zinc concentrates and is also a major producer of zinc metal. This dominant position in the world&apos;s zinc market is a fairly recent circumstance and, in fact, the country&apos;s zinc industry was founded only in the early part of the twentieth century. By contrast, the American zinc industry was well established by the mid-nineteenth century, largely based on technology originally imported from the still older European practice. Initial attempts to create a viable Canadian zinc smelter were based on the traditional practice and were unsuccessful; success came only with new electrolytic technology, much of which was developed domestically. The purpose of this paper is to outline the early attempts to produce metallic zinc in Canada and to trace the gradual development of these first efforts into a viable zinc industry based on modern science and technology.

Jan 1, 1999

By A. Datta

An appropriate scale-up methodology is very useful for ball mill design and optimization of the grinding circuit. To date, the scale-up is based on the selection and breakage function model using lab mill data. However, a major drawback of that approach is that the charge motion in a lab mill is vastly different from that in a large industrial mill. Therefore, in the methodology proposed here, first the energy of individual collision in the mill is computed employing the discrete element method (DEM). Then the breakage of particles as a function of collision energy is studied in a separate experiment. Together, this information constitutes what is known as collision energy based population balance model. The appropriateness of this model is shown for different batch grinding mills.

Jan 1, 1999

By Byung-Su Kim

The reaction between calcium sulfate and hydrogen is of interest both as a means of regenerating calcium sulfide as a reductant of sulhr dioxide to elemental sulhr and for producing elemental sulhr from gypsum. This reaction was investigated using a thermogravimetric analysis technique in the absence and presence of nickel catalyst. The reaction temperature was varied between 973 and 1153 K, while the hydrogen partial pressures of 12.9 - 86.1 kPa were utilized. At 1073 K and a hydrogen partial pressure of 86.1 kPa, 60 % of the original calcium sulfate in the absence, and 95 % in the presence, of the nickel catalyst was converted to calcium sulfide in one hour.

Jan 1, 1999