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By Jorge Alberto Soares Tenório

Household zinc based batteries contain some heavy metals such as zinc, manganese and mercury. There is a large effort from manufacturers in order to eliminate the last one. As a municipal waste, the disposal of batteries has become an increasing worry. The aim of the present work was to characterize dry batteries scraps, and establish a flowsheet for their processing. This was done using unit operations of mineral processing and parameters and yields of each stage have been defined. Such procedures have been chosen due to their low cost. The operations were hammer mill grinding, size separation, magnetic separation and specific weight separation in water. The characterization step was done through chemical analysis and x-ray difiactometry. After size classification, it was verified that 76.6% of the total amount of zinc was over 1.70mm. This fiaction was constituted basically of zinc and some coarse pieces from the steel body, paper and plastics. This fraction was submitted to magnetic separation followed by specific weight separation in water. A visual examination showed that during the grinding process, graphite was concentrated in the finer fractions. Manganese concentration in the fractions over 6,35mm was less than 2%. This means that there was low contamination by the paste in this fraction. It was due to the entrapment of the paste by steel scraps (from the body) and zinc (from the cup) during grinding.

Jan 1, 1999

By F. G. Rinker

The world demand for metallized iron continues to increase, keeping pace with steelmaking requirements for lower cost hot metal. Virgin iron ore and in-plant oxide fines can be reduced to direct reduced iron (DRI) and hot briquetted iron (RBI). MR&E has developed an improved coal-based process for cost-effective production of either DRI or HBI. Starting with dry compaction, the process combines the latest technology for material preparation, rotary hearth furnace construction and environmental control. Coarse iron ore fines are blended with pulverized non-metallurgical coal to produce a highly metallized (>90%) product. This paper presents production and installation cost data based on operating and under-construction iron oxide reduction facilities.

Jan 1, 1999

By Sandra K. Zacharias

Brass, a deliberate alloy of copper and zinc, has been known since before Roman times. There are two main methods of making brass: (1) Cementation or calamine process - crushed zinc ore (calamine, ZnC03 , or calcined calamine, ZnO), is mixed with charcoal and small pieces of metallic copper and heated to about 900°C in a closed crucible, (2) Alloying - metallic copper and zinc are melted together in a reverberatory furnace. According to most modern authorities (e.g. Smith and Forbes 1955), the calamine process was the only one used in western Europe prior to the 18th century. At that time, the alloying technique began to take over, because metallic zinc was successfully produced on a large scale for the first time. Previously, this had been a problem because zinc vapourizes at 906°C or about the same temperature at which it can be reduced from its ore. Thus, some means had to be devised to collect and condense the zinc vapour (Tylecote 1976). Metallic zinc was known, however, earlier than the 18th century A.O. Several early finds have been made, including a rolled sheet of metallic zinc found in excavations at the Athens Agora dating to the 3rd to 2nd century B. C. (Farnsworth et al. 1949). The Chinese were producing zinc by at least the 10th century A. D. and, by the 17th century, Chinese zinc ingots were being imported into Europe by the Dutch East India Company (Needham 1974). Metallic zinc is also mentioned in several European documentary sources from the 16th century (e.g. Paracelsus, Agricola). This study traces the changes in Western brass making methods from Classical to Renaissance times by examining documentary and archaeological evidence.

Jan 1, 1999

By W. M. Williams

"Although manganese is a metal virtually unknown to the layman, it is hardly necessary to point out to the engineer the importance of manganese in modern metallurgy, an importance intimately linked with iron (and steel), the basic materials of engineering construction for hundreds of years and certain to remain so for long into the future. World steel production will approach and perhaps reach 1 billion tons/year in the 1980s; with a manganese content between 0.5% and 1 % in ordinary steels, and more in specialty steels, manganese use worldwide will soon approach 15 million tons annually. Manganese was discovered and isolated in Sweden in 1774 by Karl Wilhelm Scheele (who also discovered molybdenum), but the element was only of scientific interest for several decades. By the early part of the nineteenth century, however, manganese oxide had become commercially available and was in use for colouring glass and for the production of chlorine. Commercial application in metallurgy appears to have been limited to the manufacture of crucible (or ""cast"") steel, a highquality product made by carburizing wrought iron, and melting it in small batches to make ingots which could be rolled and used for special applications, e.g. for the manufacture of fine tools or for ""steeling"" the cutting edges of implements such as wrought iron axes and chisels.* However, it was not until Bessemer's epoch-making invention of cheap steel in 1856, and the dramatic expansion of the steel industry thereafter, that manganese assumed the importance that it holds in modern steelmaking."

Jan 1, 1999

By G. Chi, M. C. Fuerstenau, R. C. Bradt, A. Ghosh

Technical Papers, Mining Engineering Vol. 49, No. 12, pp. 70-75, Discussion by McIvor, R. and Fink, R. P. We must challenge what we consider to be dubious statements in the above-mentioned article. Much of what is reported was published elsewhere over a year ago (i.e., in their reference: Chi, G., Fuerstenau, M.C., Brandt, R.C. and Ghosh, A., 1996, "Improved comminution efficiency through controlled blasting during mining," International Journal of Min¬eral Processing, Vol. 47, p. 93). There is nothing unusual or significant about a 10% or more difference in grindability between two materials of apparently similar origin and other attributes (such as chemical assays, hardness and specific gravity). Consider also that: • the materials came from different locations in the pit; • only two sets of four blastholes were considered per blast: • spatial orientation with respect to the face and other blastholes was also altered; • only two pairs of data were collected; • the impact of sampling error and bias, • both of which could be significant in this case; and • normal experimental error in parameter measurement and calculation. It is clearly inappropriate to draw any conclusions with regard to cause-and-effect relationships without first presenting a thorough error analysis. A substantial number of randomly selected test and control areas might provide meaningful statistical evidence of the claimed effect of the variables being studied. Even that appears doubtful, however, because Figures 3 and 4 show about as much variation in crushing energy for the two "regular" conditions vs. regular and altered conditions. On a separate, but also important issue, broad experience with autogenous/semiautogenous milling has shown that smaller or weaker feed material results in reduced tonnage. ? Reply Thank you for the opportunity to respond to the comments of Messrs. Mclvor ant Fink. The points raised are addressed in the order of presentation. As the commenters noted, there are parallels between this article and a previous manuscript. The reason for these complementary articles is that the audiences for the two publications are different, although there is obviously some overlap. We believe that the different audiences each profit from the technical aspects of the two manuscripts. We are not in agreement that a grindability difference of 10% is insignificant. The laboratory work is corroborated by data obtained at plant scale, which confirms that an increase in throughput of the same magnitude (between 5% and 10%) is achieved when the blasting pattern is modified, i.e., reduced from 9 to 8 m (29.5 to 26.2 ft). This increase in throughput translates into substantial power savings for ore grinding. No differences in appearance in the rock were noted between the two adjacent areas. Rock in both areas belonged to the same rock mass/block, which was quite homogeneous and without geological features in between that could create drastic differences in comminution characteristics. Given the resources, we would have sampled from all of the holes. Additional data would certainly have been desirable, as would have been additional funding to expand the study. Their comment, "spatial orientation with respect to the face and other blastholes was also altered," is not clear. Figure 1 does not show the initiation sequence. Without the initiation sequence, we do not understand how the commenters concluded that spatial orientation with respect to the face and other blastholes was altered. The commenters may be trying to make the point that the four-hole configurations with respect to the original bench face are not exactly the same. In fragmenting the

Jan 1, 1999

By R. K. Rajamani, 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 R. W. Pauls

"Many tens of thousands of hectares of forested land will be disturbed and reclaimed in the surface mineable Athabasca oil sands area during the next few decades. The surface area disturbed by Syncrude’s Mildred Lake development alone exceeds 10 000 ha to date. It is not clear that reforestation of disturbed areas will best accommodate the aspirations of all stakeholders, particularly traditional users of the land. A five-year research program by Syncrude Canada Limited and the Fort McKay First Nations has examined the feasibility of raising bison on land reclaimed after disturbance by oil sands development. Forage productivity and carrying capacity for bison was comparable to that of grasslands elsewhere in Alberta. Concerns regarding compaction of newly rebuilt soil by bison traffic proved unfounded. Bison demonstrated weight gains typical for ranched bison and calving rates averaged 90%, a value typical for ranched bison. The animal husbandry problems encountered were typical of those occurring on bison ranches elsewhere in Alberta. An economic analysis indicates that a 1000 ha bison ranch on reclaimed land has a net present value that compares very favourably with a similar area supporting commercial forest. Subject to approval by Alberta Environmental Protection, the current research project will be expanded as a pilot commercial ranching venture in order to explore its commercial viability as a business venture by the Fort McKay First Nations. At the same time, measures will be implemented to resolve various regulatory issues associated with commercial bison production in the oil sands area.BackgroundSyncrude Canada Ltd. (Syncrude) is proposing, in its land reclamation strategy, a feature that is, depending on one’s background and perspective, regarded as an innovative approach to land reclamation, a threat to the regional forest industry, a creative response to aboriginal stakeholder concerns, a reneging on reclamation commitments, an opportunity to provide an ongoing economic base for postoil sands regional economy, or an environmentally unsound use of the land. These diverse and sometimes strong reactions have been generated by the proposal to introduce bison, either free-ranging or commercial ranched, to the reclaimed landscape."

Jan 1, 1999

Electronic Detonators have made significant strides over the last few years, both in quality of product and performance in different blast applications. The precision and flexibility of the SMARTDET units provides the mines with a powerful means of controlling blast results, giving both cost and productivity improvements. The SMARTDET Electronic Detonator System, robust and easy to use, has been successfully deployed over the last 18 months in improving mine productivity and creating safer working conditions in both quarrying and long-hole stoping. The key to the improvements has been the precision and flexibility of the electronic timing, and the ability of the mine personnel to grasp the concept quickly and use it effectively.

Jan 1, 1999

Over the last ten years geological and mining software products have evolved greatly. Software companies developing such products have focussed almost exclusively on the development of technical aspects of the applications, addressing geological, ore reserve estimation and mine planning problems. These specialist applications, and the many other new technologies that are being developed by a myriad of niche developers, are an essential part of todayÆs hi-tech mining operations. Technology is also being used in many other areas to improve the mining process and there is no doubt that tremendous advances are being made in all these fields. Yet there is something missing. The manner in which the technologies are used and implemented has led to the creation of many independent and inefficient æislands of technologyÆ where a variety of products from different vendors are used to address different, but related problems. Problems occur with unreliable information, data duplication, data redundancy and transferring data between applications that may be incompatible or even run on different computer platforms. These problems impede the flow and availability of information and hamper day-to-day decision-making by mine management. A solution to this problem is to take a holistic view of all the various technical applications and incorporate them into a single information technology solution. This solution must encompass all of the information requirements of a mining operation and must provide facilities that address much of the modern thinking about mine management, including strategic mine planning, value management, key performance indicators, and maintenance of a mineral balance sheet. Gemcom is developing an Integrated Resource Asset Management System (IRAMS), which is an enterprise-wide integrated computer system that encompasses various applications typically found at a mining operation. The core component of the system is a common, open, industry standard database that can be shared by many users from each of the different departments at a mine. Around that central repository are the primary applications that provide the mine with information it needs to operate. Ensuring that the information is reliable, accurate, shareable, timely and consistent will eliminate many inefficiencies, and provide significant benefits to mining companies. In turn these benefits will lead to significant improvements in decision-making, productivity and profitability for the operation. The initial version of the IRAMS system is currently being implemented at the De Beers Venetia Mine in South Africa. The system is being built around a core repository using the Microsoft æBack OfficeÆ architecture, and incorporates key technical applications from Gemcom, Whittle, De Beers Technical Team, Wenco and JKTech. The benefits of enterprise-wide systems have long been recognised in the commercial arena and enterprise resource planning (ERP) systems such as SAP, JD Edwards and MIMS are becoming commonplace in the mining industry. The more forward looking software developers and mining companies realise the need for efficient management of the information gathered during the mining process and can see that the concepts used in ERP systems apply equally to the technical applications as they did to commercial applications. The use of IT in the mining industry has expanded tremendously over the last five years as enabling technology and management acceptance has become more prevalent, and there is considerable room for dramatic growth over the next five years. The evolution of geological and mining software has now reached the stage where mines will yield the greatest returns by integrating the applications used in each area of their operations.

Jan 1, 1999

By Bernard Scheiner

A number of wells were drilled at two phosphogypsum stacks, one at P-21 owned by IMC and the other at Agrico's South Pierce Stack. Each well was sampled, and composites representing 5-ft increments were leached with synthetic rainwater to determine the extent of metal and nonmetal migration. To simulate what was occurring in the stack, composite samples were placed in a column, so that the column represented the stack in miniature form. Leaching experiments showed that both metals and nonmetals moved down the column when water was added to the top of the column. Data obtained from P-21 showed that with time the concentration of metals and nonmetals reached equilibrium values. The concentration of Ca, SO4, F, Si, and PO4 were -600 ppm,~1,500 ppm, 32 ppm, 14 ppm, and 22 ppm, respectively. Column leaching of South Pierce material, representing 0 to 55 ft of stack, showed that after 355 in. of water, the stack was near equilibrium values down to the 33-ft level. With continued addition of water, the portion of the stack at equilibrium would continue to increase and eventually reach the values observed for P-21. The test showed that the sulfate concentration of the effluent from the stack would never reach the USEPA standard value of 250 ppm. During the leaching test, it was determined that the permeability of the phosphogypsum in the columns was 0.000103 cm/sec. This number was used in the modeling. The data obtained from the leaching experiments cast some doubt on the practice of entombment now being practiced for closure of phosphogypsum stacks. The data clearly shows that with time, the amount of material leaching from the stack is low in concentration, with only the calcium and sulfate at higher levels. When a stack is closed at an existing operating plant, allowing rainwater to fall on the stack and capturing the solution in the existing pond system would eliminate the need for covering the stack, since with time the closed stack would continue to leach and at some point reach the equilibrium values of the P-21 stack. Entombment means that the leachable material in the stack will always be there and will require monitoring forever. Allowing rainwater to decontaminate the stack may be the best environmental solution to the problem.

Jan 1, 1999

By D. Brunner

System simulation is an increasingly popular technique for analyzing and improving existing as well as newly designed underground mining operations. An engineering firm that specializes in simulation helped a major metals producer build a long-range planning model of an existing underground mine. Subsequently the team adapted this model to assess technology alternatives in the design of a new mine. The two models differ in the level of detail used for modeling the development process. This paper discusses the differences in approach between the models along with the experiences gained and challenges faced during the construction and use of the models.

Jan 1, 1999

By Joseph L. Petrillo

In July 1997, Kvaerner Environmental signed a unique contract with Echo Bay Alaska called the Transfer Risk and Accelerate Closure (TRAC). The contract called for Kvaerner to assume the responsibilities and obligations associated with closeout of the Alaska-Juneau (A-J) Mine. Kvaerner is an international engineering and construction company with global interdisciplinary experience in the mining industry and environmental remediation. Echo Bay’s requirements called for Kvaerner to: •Provide a fixed price for closure with no change orders. •Negotiate, prepare and implement a final closeout plan as outlined by Echo Bay. •Complete a closure program that exceeded current regulatory requirements. •Improve, expand and maintain a proactive public and community relations program. •Hire Echo Bay employees where possible. •Provide adequate performance guarantees and judicial relief of environmental claims.

Jan 1, 1999

By G. Goodlad

This paper describes some of the main aspects involved in implementing the European “Equipment and Protective Systems for Use in Potentially Explosive Atmospheres” (ATEX) Directive (No.94/9/EC) in the British mining industry by the year 2003. It provides a brief background to the Directive and considers its main objective of removing all barriers to trade in Europe. It outlines the need for the European Standards making bodies to write new editions of the ’explosion protection concept standards’ and for manufacturers to adopt new quality management procedures and develop new versions of equipment in conformity with the ATEX categories of “M1” or “M2.” Finally, it assesses the possible future relationship between the European enforcing authorities, manufacturers and users of explosion protected equipment.

Jan 1, 1999

At Yucca Mountain, USA, a tunnel is being built according to nuclear quality standards. It has proved possible to meet very high quality demands while at the same time achieving high advance rates. To be able to do this, routines on how to record and store quality related information have been established. This has meant that a new philosophy has entered the tunnelling industry. Especially for nuclear waste projects, of which Yucca Mountain is one of the first ones to be built, the experiences made and the quality assurance program established will be of great importance for future projects. The paper gives examples of what the Nuclear Quality Assurance system has meant in practice for the tunnelling at Yucca Mountain. And, it also explains why a non-grouted bolt, Super Swellex-, was chosen for long-term reinforcement in the tunnels which might host nuclear waste for thousands of years.

Jan 1, 1999

By A Vigar

Siliceous float sampled in the Wafi River by CRA Exploration in 1977 assayed 22 g/t Au and 89 g/t Ag. Follow up in 1979 led to the discovery of outcropping mineralisation now known as Zone A. Soil sampling in 1980 and 1982 outlined a 350 m by 400 m area of >1 g/t Au at Zone A and smaller areas at Zones B, C and D. Thirty-one diamond holes were drilled between 1983 and 1986. Elders Resources continued evaluation of Zone A under a farming agreement between 1988 and 1990. Mineralised diorite porphyry was discovered in 1990 by drilling conceptual targets 500 m to the NE of Zone A. Evaluation of this copper-gold porphyry became the main focus of exploration for the next five years and a substantial resource was outlined within a single, discrete body. A review of the paths to project development in late-1995 highlighted the need for increased resources via a second mineralised porphyry and/or an additional resource of Zone A size to make the project viable. It was concluded that the greatest immediate potential for increasing the resource inventory was at Zone A itself where the mineralisation was open in all directions. Detailed mapping and drill core logging lead to the geologic and structural models being revised in early-1996. The objectives of the 1996 drill program were to extend the Zone A resource, to test for continuity of mineralisation westwards to Zone B, to better define the controls on gold mineralisation and to delineate high-grade blocks amenable to selective mining by infill drilling and 3D orebody modelling. The last drill hole of 1996 intersected 30 m at 4.6 g/t Au from 273 m in WR147, deep in the western limit of Zone A. This intersection gave impetus to continue drill testing towards Zone B. In April 1997, hole WR154 was drilled 100 m to the west of WR147 and intersected 20 m at 8.5 g/t Au and 70 m at 11.0 g/t Au at similar depths near the diatreme contact. Drill hole WR155 was then drilled 100 m to the west of WR154 and intersected 86m at 5.7 g/t Au and WR159 drilled 100 m to the south of WR154 intersected 36 m at 9.2 and 50 m at 4.4 g/t Au. A significant zone of essentially blind, high-grade gold was discovered beneath the dipping flank of a poorly mineralised diatreme in what became known as the Link Zone. The long history of evaluation has been driven by the conviction of a dedicated team that a mineralised system of the size and complexity of Wafi with strongly anomalous gold in outcrops over the entire Mount Golpu area must contain economic mineralisation hidden within it. The keys which redefined the direction of exploration and lead to the discovery of the blind, high-grade gold Link Zone were, in our view, the critical review of the project status, detailed geological and structural studies to define clear exploration targets and the necessary funding and persistence to carry this through.

Jan 1, 1999

By M. W. Smith

Pennsylvania has 2500 miles of streams that do not meet water quality standards due to acid mine discharge (AMD), making AMD the greatest cause of water pollution in the state. The problem is mainly caused by abandoned coal mines. Pennsylvania is using a watershed-based approach to abating AMD which includes remining as a key component of a comprehensive restoration strategy. The Tangascootack Creek Watershed was targeted for AMD restoration through remining. Geologic mapping and overburden data were analyzed using Earth Vision software to identify areas of coal reserves which could be remined to improve water quality. Incentives are offered to encourage mining in these designated areas.

Jan 1, 1999

Mechanical and electrical (M&E) systems in road tunnels are constrained by the traffic envelope and the construction profile. Whilst these spatial constraints are often ælocked inÆ early in the design process, the detailed M&E design continues for some considerable time after key civil engineering issues have been resolved. Ventilation design criteria for both normal and emergency operation often involves considerable negotiation with a wide range of stakeholders. Final system performance and spatial requirements are only finally resolved when suppliers are selected following the tender process. Lighting design is dependent upon a wide range of factors including tunnel lining materials and associated colours as well as agreed maintenance regimes. Cabling systems can only be developed when the general arrangement for power distribution is agreed and a system of substation, switchrooms and equipment rooms is in place. Many other systems such as fire protection and communications facilities fill the available space beyond the traffic envelope, where physical, structural and æsight lineÆ requirements must all be accommodated. The more co-ordinated civil engineering and M&E design is and the earlier the process starts the better the outcomes for all parties.

Jan 1, 1999

By X. K. Jiang

Pneumatic, triboelectrostatic processing of physical mixtures containing fine (-200 mesh) particulate may have significant application potential in the mining and energy industries. Such dry processing methods, especially for finely comminuted materials, have not been examined in as much detail as wet processing methods nor have been part of the training or education of mining and process engineers. We have examined fundamental and applied physical and engineering factors controlling triboelectrostatic beneficiation of fine-sized physical mixtures, one of which -combustion fly ash -has size, heterogeneity and mineral concentrations typical of those expected in mined minerals. The applicability of dry processing, however, cannot be readily evaluated because of the unavailability of standard procedures for process assessment.

Jan 1, 1999

By J. E. Dutrizac

"The end of an era in zinc metallurgy took place on July 31, 1976 when the horizontal retort furnaces of the National Zinc Company in Bartlesville, Oklahoma were permanently shut down (1) . For more than a century, horizontal retorting had been the most common method of producing zinc in the United States; it was a thriving industry in many parts of that country, especially in the natural gas belts of Oklahoma and Texas. With the Bartlesville closure, yet another metallurgical process has become an object of historical interest for North American metallurgists. Although shrouded in controversy, the origins of zinc metallurgy seem to date back at least 2000 years. Pyrometallurgical methods with carbon reductants are capable of producing zinc from oxidic zinc ores, but only above the boiling point of the metal. Although slow cooling results in re-oxidation of the zinc vapour by air or carbon monoxide, quenching yields liquid zinc; some form of rapid cooling, either accidental or intentional, was likely used by ancient metallurgists to liquify the metal. Zinc metal found in Athenian objects of the Roman era was likely of accidental origin. The Romans employed brass extensively for coins and ornaments(2) , and this was intentionally produced by the calamine process whereby oxidic zinc ores were added to molten copper under strongly reducing conditions. Zinc appears to have been known in China and India as early as 1000-1300 A.D., and was probably smelted commercially in those countries from the 14th century. Although the early metallurgical procedures were probably inefficient, they were able to produce zinc metal in significant amounts. The large heaps of zinc residues with clay retorts bear testimony to an early smelting industry of impressive magnitude. It is estimated that the heaps at Zawar, India alone represent the extraction of 100 000 tons of metallic zinc(2) In the 1730s the smelting of oxidic zinc ores was developed in England using a vertical retort method. In 1788 a British patent was granted for making zinc from zinc blends (ZnS) by roasting the ore in a coalfired reverberatory furnace, mixing the calcine with charcoal and smelting the mixture with suitable zinc condensation. The English process was very energy intensive, however, and early in the 19th century the Belgians developed a horizontal retort process for the reductiondistillation of zinc that was more fuel efficient. This technique was gradually developed into what came to be known as the Belgian process, the forerunner of the ""modern"" horizontal retort furnace."

Jan 1, 1999

By C. Ottergren

A process does not have higher capacity than what can pass through its bottleneck. Acknowledging this, and with the goal to optimize production at a minimum investment, one can use existing equipment, modify the process flow and make a few strategic capital investments. Automatic setting regulation is a technology that allows balanced crusher performance matching minute changes in feed material characteristics. The system makes it possible to utilize the crushers fully at all times. It also continuously and completely compensates for manganese liner wear.

Jan 1, 1999