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By N. B. Gray, I. F. Taylor

"Gas injection to promote chemical reactions or mixing is a feature of many metallurgical processes. Often the aim of gas injection is to bring about a chemical reaction between the gas and liquid but most of the past physical and mathematical modelling work has ignored the influence of such reactions. In the work reported here, cold model studies have been conducted in which gas reacts with the liquid into which it was injected. The rate of liquid mixing has been measured as an indication of the mechanical energy transfer. It has been found that gas generated chemically within the liquid is significantly less effective at promoting mixing than the equivalent volume of inert gas. The relative ineffectiveness of chemically produced gas is thought to be due to smaller bubble sizes in comparison to the inert gas case. Small bubbles characteristic of chemically generated gas move with low slip velocities relative to the liquid and lead to different turbulence generation mechanisms.IntroductionIn processes such as steelmaking, copper conversion, bath smelting and ladle steel finishing gas is injected into liquid metal where it reacts chemically or simply serves as a source of agitation. An understanding of fluid flow phenomena in such situations is an essential pre-requisite to the calculation of process intensity and the optimisation of vessel productivity. Traditional physical cold modelling approaches to prediction of liquid flow in such situations are now often augmented by the techniques of computational fluid dynamics. Even with the availability of numerical modelling techniques cold physical models continue to have an important role for validation because it is generally difficult to obtain quantitative data from high temperature processes.Almost all previous cold modelling work has been based on the injection of an inert gas into water or some other non-reactive liquid. Such models do not include the significant increase in gas volume inherent in some processes. For example the oxidation of carbon in steelmaking leads to a twofold increase in molar gas flux through the reaction:"

Jan 1, 1996

By F. Patisson

During exothermic gas-solid reactions, heat generation makes temperature rise and modifies the rate of the various mass transfer processes, namely the chemical reaction itself, the pore diffusion and the external transfer. We have investigated this thermal effect during the oxidation of zinc sulfide porous pellets in a thermo balance furnace, between 550 and 900°C-and under O2-N2 atmosphere. The results have been' analyzed by using, firstly, the law of additive reaction times derived from the isothermal Grainy Pellet Model, and, secondly, a new numerical model taking into account non-isothermal conditions. Both the models can satisfactorily simulate conversion versus time, but the numerical model also depicts the temperature evolution within the pellet. Finally it is shown that owing to the heat generation the zinc sulfide oxidation takes place under diffusion control (3/4 internal, 114 external) in all the cases studied. During the course of reaction, the. pellet undergoes strong temperature variations, with thermal gradients confined to a shell oxide layer.

Jan 1, 1996

By C. A. Young

Cyanide is a toxic species that is found predominantly in industrial effluents generated by metallurgical operations. Cyanide's strong affinity for metals makes it favorable as an agent for metal finishing and treatment and as a lixivant for metal leaching, particularly gold. These technologies are environmentally sound but require safeguards to prevent accidental spills. Various methods of cyanide remediation by separation and oxidation, including photolytic advanced-oxidation processes, are therefore reviewed. Reaction mechanisms are presented throughout the paper. The methods are compared in regards to their effectiveness in treating various cyanide species: free cyanide, thiocyanate, weak-acid dissociables, and strong-acid dissociables.

Jan 1, 1996

By Darrell L. Beddard

Pile driving started October 29, 1993 and was completed on January 27, 1994. Field work included driving piling from ground surface at one site and at or near proposed footing elevations for the remainder. Piles were driven to specified tip elevations or the elevations directed by the Project Manager. In an attempt to address what installation technique(s) performed the best, several methods were used, including varied predrilled depths, open ended piles, closed ended piles, and the use of both impact and vibratory hammers. Piles were driven closed ended where possible to study the feasibility of this option to reduce construction costs associated with pile cleanout. Piles were driven to different depths to measure capacity variations. The 24-inch (610 mm) diameter piling were driven in one piece while the 42-inch (1.07 m) diameter piling was driven in two segments. A total of 79 piles were driven for the four sites, 74 of the 24-inch (610 mm) diameter and 5 of the 42-inch (1.07 m) diameter. Various hammers were used to determine which hammers provided viable solutions to the potential problems anticipated in the design phase. Hammer selection was based on the driveability studies. Equipment included a 175 ton (1.56 MN) crane, support crane for pile stabilization, crane mounted auger drill, offshore leads, Delmag D30-32, D46-32, and D62-22 diesel hammers, an HPSI 2005 single acting hydraulic hammer, a Foster IHC S-90 double acting hydraulic hammer and a Kencho VM2-25000AII vibratory hammer with the weights set to produce 17,500 pound-inch (1.98 kN-m) of eccentric moment.

Jan 1, 1996

By Lanny Pasternak

"This article is directed at plant production, engineering and maintenance personnel. Seldom does any industrial operation take the time to study the costs involved in the generation of what is probably their most expensive plant utility energy source.IntroductionIn the typical industrial plant in Canada, a 200 hp, 900 cfm, air compressor costs about $60,000* per year to operate (Fig. 1). In 1989 when BC Hydro embarked on their industrial energy management program Airflow Energy Ltd. were asked to spearhead the “Efficiency Compressed Air” portion of that program with a mandate to perform onsite overview surveys and physical hands-on testing of some 300 selected industrial plants throughout British Columbia for compressor efficiencies and wasteful air leaks (Fig. 2). The program duration lasted until 1995, during which time a tremendous amount of data were amassed relating to equipment types, clients’ operating habits, end-use applications and operating costs.During the past six years, Airflow Energy also performed somewhat similar surveys but on a smaller scale in Alberta, Ontario, the United States and the Republic of China. It was no surprise to find some inherent equipment concerns related to efficiency as well as neglected energy wasteful air leaks, so British Columbia was not alone and the problems appear somewhat universal."

Jan 1, 1996

By Jr. Chilson

This paper addresses the slurry pump industry as it exists today by touching on the business aspects, and by discussing research and development for material metallurgy and hydrodynamics for wear improvement which reduce operating and maintenance cost for the customer. It demonstrates why OEM parts give better value for cost.

Jan 1, 1996

By A. K. Bakshi

Slurry rheology affects autogenous grinding performance by changing the rock's breakage characteristics. In this study pilot scale batch autogenous grinding was carried out to observe the effect of viscosity on the breakage characteristics of the rocks (the media), and on the overall specific energy consumption. Clay/fines content, and temperature of the initial charge, were varied to alter the viscosity of the slurry. Results showed that at higher slurry viscosity, rocks became more difficult to break, resulting in an overall increase in the specific energy consumption of the mill. Also, it was observed that viscosity had a significant effect on the amount of critical size material present in the grinding circuit, where the critical size material is the material which is too large to be effectively ground in the mill, and too fine to act as grinding media.

Jan 1, 1996

By Jr. Wilkinson

In today's work environment a tremendous amount of data is required to provide the regulatory agencies justification to issue a mining permit. The demands for data, specifically environmental characterization data, grow and the mine plans must address the issues raised by the interpretation of that data. Computers and computer software can provide operators and consultants with the tools necessary to assimilate, digest and interpret these seemingly unmanageable data sets. This paper presents some examples of how Mincom's MineScape software can be applied to the task of developing coal mine permits in an electronic format.

Jan 1, 1996

By James M. Barker

Industrial minerals are critical to most aspects of modern society. They are pervasive in both industry and in everyone's lives (McVey, 1989; Barsotti, 1993). They are also the dominant class of minerals produced in the United States but this fact is little known outside the industry. For example, in 1993 (U.S. Bureau of Mines, 1995, table 1) industrial mineral dollar value was double that of metals ($20.86 billion vs. $10.88 billion) and employment levels were nearly so (74,000 vs. 40,000). A further difference is that transportation tends to dominate production costs (FOB end user) whereas they are much less significant in other mining ventures or other industries. Finally, metal mines are more concentrated west of the Mississippi; industrial mineral operations are more prevalent to the east (U.S. Bureau of Mines, 1995, p. 16-17). The significance of transport cost is discussed in Part 2, which is essentially Barker and Austin, 1995. Part 1 will update and expand portions of Barker and Austin (1995) and provide a more detailed discussion of import/export relationships using a China/United States reference point because of China's dramatic influence on some industrial mineral markets since the mid-1980s (barite, etc.).

Jan 1, 1996

By Michael J. Cruickshank

Marine minerals are more than an academic curiosity as they represent the most significant global source of mineral materials for economically and ecologically sustainable development for the future. Minerals research is traditionally carried out by industry and thus, in the United States at least, applied research in marine minerals may not get the share of government funding or attention that more exotic programs for space exploration or future global disasters engender. Two recent events have significantly changed the status of marine minerals. Discoveries made in the last thirty five years indicate that the potential for mineral occurrences in the oceans and seabeds, area for area, is as high as for terrestrial lands. On this basis the global mineral resource base has been recently increased by a factor of four of which three quarters is underwater. The recently enacted Law of the Sea has mandated what is probably the most far reaching re-distribution of natural resources in human history, and has resulted in a peaceful subdivision of seabed jurisdictions between the coastal nations of the world which should significantly affect future mineral markets and the balance of economic powers. Significant applied research efforts are ongoing for marine minerals as an adjunct to commercial production in southern Africa for diamonds; and in many other parts of the world for sands for beach and coastal protection. Forward planing, including research and development activities focussed on future commercial production of metalliferous oxides, continues in Korea, China, Japan, India, and with lesser activity, in the United States, United Kingdom, Germany and the CIS. Annual expenditures for this work amount to millions of dollars. In all cases the environmental aspects of commercial produc¬tion are a significant part of the research. Geologic studies on the occurence and distribution of metal sulfides at plate boundaries continue on a regional basis in the Pacific.

Jan 1, 1996

By III Boxley

Most of us realize that our nation's roadways are under ever-increasing stresses, from higher traffic counts to increased tire pressures and their resulting loads. At a time when the interstate system as originally envisioned is completed, and the National Highway System is being drawn to replace it, it is appropriate that we examine design and construction methods for the next century. The stone industry shares a common desire to produce high quality, cost-effective roadways that perform over time. The superior sub-grade and road base structure provides for the superior roadway. Since I am neither an engineer nor a contractor, I will not attempt to suggest design or construction methods. What I can do is share my company's experience in supplying road base materials by using a historical perspective in Virginia and some trends in the market that we have observed. Road building and related non-building construction are still far and away our largest markets as an industry. If we can help to improve the end product of our biggest customers, we add value to our own product. Indeed, in a time of budget constraints and competing demands for government dollars, we must show value over the life of a pavement structure to ensure their long-term funding.

Jan 1, 1996

By R. W. Bartlett

I first met Milton Wadsworth in 1951 as an eighteen year old junior taking his mineral processing course at the University of Utah. He guided my senior thesis, evaluating the then new polymer flocculants on settling uranium leached ore pulps. This was before ion exchange and solvent extraction. After my military service and a brief working stint at Kennecott he supervised my PhD work. He encouraged me to be active in AIME and its constituent societies, where both of us have been directors of AIME and presidents of TMS. He has been a consultant for research groups that I have managed. Above all, he has been my mentor and friend for nearly 45 years. Thus, I am honored and particularly pleased to receive 5MB's Wadsworth Award.

Jan 1, 1996

By J. M. Floyd

"Top submerged lance furnace developments started in CSIRO in the early 1970s and was given the name Sirosmelt. In the early work the technology was developed for tin smelting and processing tin slags but once a small pilot plant was established other slag processing applications were soon recognised and evaluated for various copper, nickel, zinc and cobalt-containing slags. The process was tried for copper smelting and converting, which was proven in the small pilot plant in 1978. In the same year the first commercial application of the technology was established for the recovery of tin from slags at Associated Tin Smelters, Sydney. Work on lead smelting was initiated by the CSIRO team in the late 1970s and laboratory work led to pilot plant trials by Mount Isa Mines.In the second decade of the technology the focus of development became commercial acceptance of the technology through marketing, development and application by Ausmelt and Mount Isa Mines; the former commercialising and developing the technology for a wide range of applications, while the latter concentrated on its own commercial needs of copper and lead smelting. This decade saw a number of commercial plants built in Australia, with considerable interest becoming evident from other parts of the world. Towards the end of this decade Mount Isa also entered into the business of marketing of the technology through rights dating to the joint work with CSIRO in the late 1970s.So far, after five years, the third decade of the technology has been characterised by diversification of applications of the technology to areas outside the non-ferrous and precious metals production industry. The waste processing and recycle industry and the iron and steel industry have recognised that the top submerged lancing system is a new type of reactor with many significant features which provide new opportunities for processing a range of materials under good environmental controls in a cost effective manner.I hope this audience will excuse my boldness in talking about the third decade of the technology when we are only half way through! I am aiming in this paper to not only talk about the past, but to try illustrate the future directions which I envision."

Jan 1, 1996

By Bror Nyman

Wide settlers are a way to decrease the linear velocities of advancing liquid phases. It has, however, been found unnecessary to risk a proper settler performance by building shallow settlers in order to avoid a so-called interface turbulence due to a too big difference between the linear velocities of the organic and the aqueous phase. This conclusion has been reached from tests using a large transparent settler model, where the behaviour of a clean interface between two advancing liquids has been investigated. Also in a more realistic case, making an organic in aqueous or an aqueous in organic dispersion to move between the liquid phases, no obstacle has been found to use a somewhat more deep and correspondingly ore slowly t10wing aqueous phase. Based on above findings, support can be given to a new trend to build the settlers slightly deeper than what has been typical for the so-called low-profile design. In this way, it is much easier to avoid an excessive air introduction and other severe difficulties, like those caused by crud moving from one stage to another. It is further shown, how gravity can be used to slow down and distribute a dispersion being fed into a settler of a VSF unit. Entrainment levels have been found to be reduced by a careful design of primary dispersion distributors and picket fences of the settler. Finally, it is demonstrated, how outlets from the side of the settler can be used to simplity interstage pumping and to decrease the rotation speed of any pumping device.

Jan 1, 1996

By Peter Bates

"HIsmelt has faced and overcome many challenges in the understanding and development of injection technologies that satisfy process and engineering requirements for further scale up to a commercial plant.An overview of the design basis of bottom and top injection systems with plant results are described in this paper.IntroductionAn appropriate way to introduce this paper is to initially reflect on the genesis of the HIsmelt Process.It is appropriate that Professor Womer is the one we are honouring as it can be claimed that by the involvement of CRA in the WORCRA process that the concepts for irijection systems in iron and steel pyrometallurgical processes achieved significant attention by the company. The development of water cooled injection lances and their application injecting solids and gases with success was certainly a pre-cursor to the development of other injection systems commonly used today in arc furnaces and for top injection at HIsmelt.HistOrically it was the work of Savard and Lee in Canada with shrouded tuyeres and the subsequent commercialisation of this technology at the Maxhiitte Steelworks spawning the suite of bottom oxygen blown process as known as QBOP; OBM and the subsequent combined blowing process such as KOBM that first commercially succeeded in injecting solids under a molten metal bath. The next progressive step from the injection of calcined lime in the technology development was the injection of coal for coal gasification as developed by Klöckner technologies being called KG, KSG and KMS and also the injection of coal for increased scrap melting.A paradigm shift in thought process to leap from steelmaking and coal gasification to direct smelting by injecting coal and iron ore into a molten metal bath in the correct stoichiometric ratio to maintain the bath at a constant temperature and carbon level was the true genesis .of HIsmelt.A good overview of the state of the art of tuyere type injection technology is given in Ref. 1."

Jan 1, 1996

By Milton Blander

A review of concepts and theories for predicting thermodynamic solution properties of multi- component high temperature liquid solutions is reviewed. During the last 50 years the ability to predict :such properties for molten salts, silicates and metals based on the generally known properties of the lower order (often binary) systems has been developed and shown to provide predictions which are quite useful in science and technology. There are many gaps in our understanding of these high temperature solutions, especially for metals, and considerably more work is needed.

Jan 1, 1996

By S. J. Taylor

The siting, grading and fill usage for leach pads are important aspects of leach pad design. A method is presented that optimizes the cut and fill quantities (i.e. minimizes the cost) required to grade a leach pad with parallel cells; given the desired pad characteristics of maximum and minimum pad slopes, maximum cut and fill depths, etc. and the cut and fill costs. The method allows the variation of the cut and fill costs with depth, which allows the accurate modeling of the cost savings practice of using cheaper fill towards the bottom of a thick fill. This optimization could be incorporated into a CAD package, enabling a designer to simply draw a desired pad shape on a site plan, input the pad and heap characteristics (required heap volume, heap height, heap sideslopes, etc.) and then have the computer report both the adequacy of the pad area and the optimum grading for the particular pad shape. Using this, a designer could quickly and accurately assess the optimum, or cheapest, grading of many shapes and positions for a leach pad. This would be especially useful for large pads that need to be sited on rough terrain.

Jan 1, 1996

By Louis J. Mittoni

"It is well known that gas injection systems can exhibit a wide range of dynamical behaviours, ranging from linear periodic bubbling through to highly complex turbulent jetting. Recently, it has been observed that an important intermediate regime exists under certain system conditions, where the dynamics are complex in nature yet predictable for short time periods. This paper reviews the evidence to support the above hypothesis, and discusses the invariant quantitative measures such as density, return maps, Lyapunov exponent and dimension which may be used as pattern recognition features in a mOnitoring and control strategy.INTRODUCTIONThere has been a great deal of research on the submerged injection of gases into liquids. This interest is primarily due to the large number of applications in the pyrometallurgical and chemical engineering industries. Gases are typically injected into liquids to achieve goals such as heat and mass transfer, or physical mixing and agitation. Only recently though has the possibility of using the evolution of the gas dynamics as a probe to internal system conditions been raised [1, 2].At very low gas injection rates and small upstream chamber volumes, gas normally disperses in the form of stable bubbles of constant volume [3]. With increases in gas flow rate, the dynamics become more complex, bifurcating into double bubbling, multiple bubbling and complex coalescence behaviour. Irregularities measured in pressuretime series acquired upstream of the injection port under these complex conditions have usually been treated as bothersome noise or contamination to be filtered from the signal and ignored in the analysis. These irregularities, however, may contain physically interesting and useful information on the system from which they were produced if the system may be classified as deterministically chaotic [4]."

Jan 1, 1996

By M. K. Rizkalla

This paper discusses the time-dependent behaviour of rock when it involves the presence of several layers of rock strata in the vicinity of mine openings, mining in sequences and the placement of backfill. The paper describes numerical techniques which proved useful when such situations are encountered in practice. The model is elastoviscoplastic. At given time stations, short term loading or changes can be made to the creep behavior of the rock. The modelling technique is first described and is followed by simulations of stresses and displacements in a potash mine with the primary objective to demonstrate the effect of such aspects as mining and fill sequences in 3-D. This involves cutting finite elements representing the strip of the mining face and simultaneously filling those elements representing the newly placed fill. The stiffness of the fill varies with the degree of compaction at each point. In this way, the effect of the time of fill placement, the gap between the top of the fill and the back as well as the degree of compaction are simulated. The second example is a 2-D problem simulating the long term effect of backfill, as a material compacting with time, on the settlement of the layers above it as well as the closure of the room.

Jan 1, 1996

By Sui Xue

A process has been developed from laboratory-scale experiments for the aqueous processing of various lead-bearing wastes. The process exploits the limited solubility of lead in sulfate-rich solutions to effectively separate lead from other metals. The lead sulfate is then completely converted to lead carbonate using sodium carbonate and ammonium carbonate. The effectiveness of this conversion was observed to be sensitive to the solution pH and carbonate concentration. The final stage of the process uses low temperature calcination of the lead carbonate to form PbO. Yellow lead oxide (massicot) is readily formed if calcination is conducted at a temperature at or iibove 50G°C, wlule red iead oxide (iitharge) is formed at temperatures near 450°?C. A complete economical analysis of the process will be discussed.

Jan 1, 1996