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By Heinrich Hutchison, Thomas von Moltke, Roelof F. Sandenbergh, Katarina P. Cerovic

In the leaching of gold in aqueous cyanide solutions the rate of gold leaching may be decreased by the passivation of the gold, that may however be prevented or reversed in the presence of lead species in solution. In the present study potentiostatic, potentiodyanamic and XPS (X-ray photoelectron spectroscopy) analysis were used to further clarify the action of lead ions on the anodic activity of gold in alkaline cyanide solutions. It was found that lead increased the gold dissolution rate as it deposited on the gold surface at potentials more positive than its reversible Nernst potential for bulk metal deposition, i.e. by underpotential deposition mechanism, but that it decreased gold activity if present as bulk plated lead on the gold.

Jan 1, 2003

By Yoshihiko Maeda

It is said that the 21 st century will be an era of the remedy of the global environment. In order to reserve natural resources for the future and to avoid the dispersion of heavy metals after usage and to avoid pollution problems, it is extremely important to recycle heavy metals as much as possible by reasonable recovery procedures. The nonferrous metal industry is expected to play a important role in the recycling of heavy metals that are originally their products. From the depressed metal price experienced in Japan in 1980th due to the sudden change in current exchange rate between US dollar and Japanese yen, one of major nonferrous metal company, Dowa Mining, has diversified its business area not only to the so-called down stream, but also to the environmental business including metal recycling, industrial waste treatment and soil remediation by utilizing technologies and facilities once used or still used for mining and smelting of copper, zinc, lead and precious metals. In this paper some of these applications will be presented.

Jan 1, 2003

By Yasuo Ojima

The mainstream of copper smelting processes in the world today is a combination of Outokumpu type Flash smelting and PS (Pierse Smith) converting process. Presently it can be estimated that about 50% of the worldwide copper production is produced by the Flash smelting process and 80% by the PS converting process. PS converting process due to its operational flexibility and despite its batch character of operation has been widely used in many smelters for more than 100 years. However, an environmental issue has been pointed out related to this process because of the difficulty of handling the fugitive gases. Recently several copper smelters in the world have been newly constructed and others have executed major modification and modernization, The continuous converting process has been applied in many of them instead of PS converting process. This paper compares PS to the emerging continuous converting process and makes a prospect of the future of the copper converting process.

Jan 1, 2003

By Roberto Parra

The classic criteria of the preparation of the charge for the smelting of copper concentrates in at flash furnace considers the mass and energy balance from the chemical and mineralogy composition of the concentrates. The operation parameters fixed with this method don't assure the stability of the operation and the critical problems of the slag quality and dust formation occurs very often. This paper presents the results of a laboratory test that allows the prediction of the behavior of concentrates blends in the view of the minimization of the dust formation and the magnetite control in the slag. The combustion of different copper concentrates and blends were done in a drop tube furnace The results show that the magnetite and dust formation don't have a linear behavior with the weight proportion of the blend and some optimal blends of 2 or 3 types of concentrates can be identified. From the reasonable hypothesis that the qualitative behavior of blends in the drop tube represents the real behavior in the burner, the preparation of the charge with this approach could help to solve those operational problems.

Jan 1, 2003

By Harri J. Lehto, Marja I. Oja

Empirical models used for predicting the performance of screens on the basis of capacity, cut size, water split and grade efficiency curves were evaluated. This paper reports experimental results obtained with single-deck Derrick screens. The performance of the screen was tested with limestone in a separate screen set-up, in a pilot plant and in industrial scale test runs. The results of pilot plant experiments showed that the measured water split was higher than the measured bypass. This is an indication to that water flow does not entrain the same proportion of all fine particles present in the feed which is advantageous for screening. The experimental design for the industrial test runs was made on the basis of the pilot plant tests. Suitability of the existing models has been checked and accuracy compared. The tests showed that best grade efficiency model was the Rosin-Rammler model. An empirical model for the evaluation of the model parameters as a function of pulp density of the feed and the load of the screen is suggested.

Jan 1, 2003

By Scott D. Thomson

The client for this project specializes in the use of state-of-the-art technology to fabricate and assemble composites and metal-bonded structures for commercial and military aircraft programs. One of the key components for this operation at the client's plant is a highly precise computer-numerical-controlled router known as the Shoda Machine. This machine tool was installed at the plant in July 1998 for the manufacture and inspection of aircraft parts, and it is extremely sensitive to deflections. To monitor the occurrence of deflections, an internal laser system continuously checks the machine calibration. Deflections in excess of 5/1000-inch in the foundation on which the machine rests require costly periodic re-leveling and recalibration of this tool. Therefore, a significant problem arose when measured deflections during machine operation were as large as 20/1000-inch. In addition, the foundation was cracked in at least three places as a result of elastic foundation movement caused by dynamic loading as well as shrinkage and loss of base support. Deciding on a remediation procedure to alleviate or eliminate these problems involved the following important considerations: (1) achieving the client's need for reducing deflections to less than 5/1000-inch, (2) minimizing the repair cost as much as possible, and (3) reducing the time required for implementation of the foundation remediation solution. After evaluating the advantages and disadvantages of several alternatives, jet grouting was selected as the most suitable solution. The jet grouting program provided columnar elements of soilcrete to remediate the Shoda Machine foundation.

Jan 1, 2003

By G. A. Brooks

Reactive ball milling has been proposed as a new route for producing carbides from oxides through carbothermic reduction. It is claimed that through milling oxide and graphite powders to the nanoscale, amorphous materials with very high reactivity are formed, that allows for easy transformation of the starting material to another in a subsequent thermal process. Thermodynamic analysis of this proposed process suggests that unless particle sizes are reduced to below 10nm, then reduction in size alone cannot explain a change in the stability of oxides. Even with nanometer scale powders, the products formed need to have a lower total surface energy than the reactants before a chemical change will occur. A model developed by Bhattacharya and Arzt for predicting localized temperature changes based on milling conditions suggest that temperature rises less than 400 K will be achieved in laboratory conditions. The present calculations suggest that nanometer scale powders formed through high speed ball milling (> I 0 mls) may have undergone a process analogous to melting and quenching. Further work is required to fully distinguish these features.

Jan 1, 2003

By P. Trudel, É. Cabot, L. Cabot

"A modular gold processing unit (MGPU) was designed, installed and operated over an eight-month period by RSW-Béroma at the Granada mine located near Rouyn-Noranda, Quebec. A description of the project geology, plant set up, as well as exploitation results, including productivity and profitability curves, are given for a small-scale mining operation in comparison with larger ones. IntroductionSmall-scale mining (SSM) is a widespread activity in Africa, Mexico, Central America and South America, where numerous small mineral deposits are exploited manually or by semimechanized methods. On the other hand, SSM is almost absent in Canada, where the mining industry traditionally exploits large deposits, using concentration plants with capacities of many thousands of tonnes per day. However, many small gold (and other metallic or industrial mineral) deposits are known in Canada. Their reserves are too small to justify the cost related to the construction of a standard mill and, if they are remote from a custom milling facility, they remain unexploited. With this in mind, RSW-Béroma has developed the modular gold processing unit (MGPU) that allows the profitable exploitation of small mineral deposits. The MGPU is the perfect tool for SSM and its main advantages are a much lower capital cost than a standard mill and its portability, which makes it easy to transport and reinstall on another site, once the exploitation of a small deposit is terminated. The denomination MGPU will be used hereafter in the text as it was primarily designed for gold deposits, although it must be kept in mind that this portable plant can be adapted to other mineral substances."

Jan 1, 2003

By P. Somasundaran, G. Anastassakis, Z. Pan, D. R. Nagaraj

Gums are often used as depressants for talceous gangue minerals in the flotation of nickel and platinum bearing ores. However, the mechanisms of gum adsorption on talc are not clearly established. In this work, adsorption of guar gum at the talc-solution interface is investigated using spectroscopic and allied techniques. Guar gum adsorption on talc is not affected significantly by changes in solution conditions such as pH and ionic strength. Electrokinetic studies showed that guar gum decreased the negative zeta potential of talc but did not reverse the charge. Fluorescence spectroscopy studies conducted to investigate the role of hydrophobic bonding using pyrene and dansyl probes showed no evidence of the formation of hydrophobic domains at talc-aqueous interface. Urea, a hydrogen bond breaker, reduced the adsorption of guar on talc to the same extent as that for guar/alumina system, in which hydrogen bond plays an important role. All of the above results suggest that one of the main driving forces for guar adsorption on talc is hydrogen bonding rather than electrostatic or hydrophobic force.

Jan 1, 2003

By Steve Kral

When the price of gold cracked the US$9.60/g(US$300/oz) mark last year, the gold-mining industry began to crank up again. This followed several years of gold prices that had languished in the mid-200s. Existing mines increased production and mines that had lain dormant for many years were getting second looks. The United States still produces a large amount of gold. But not much of the new production is coming from that country. Instead, strict environmental regulations still have companies wary of trying to invest the millions needed to start a new mine or expand existing ones. And after years of studies and negotiations between legislators, environmental interests and the mining industry, the United States still has not crafted a new mining law.

Jan 1, 2003

By Peter N. Holtham, Mary M. Ng

"Resistivity measurements of minerals in the laboratory are commonly made with a low DC voltage source. Common test voltages specified in the ASTM Standard D257 are 100, 250, 500, 1000, 2500, 5000, 10000 and 15000 V, however 100 and 500 V are the most frequently used. Resistivity results obtained in the laboratory have been used to infer the electrical behaviour of minerals undergoing electrostatic separation. However because the voltages employed in electrostatic separation in the plant are of the order of thousands of volts, typically greater than 15000 V, whether the laboratory results are applicable as a predictor of plant performance is a critical question. It is unclear whether resistivity values taken at a low voltage are characteristic of those seen in electrostatic separation, in which the minerals are exposed to a much higher voltage. No definitive answer could be found in the literature.In this work, the resistivities of zircon, rutile and ilmenite were measured in a corona field for the first time. The measurement principle was based on a technique developed to measure fly ash resistivity in electrostatic precipitators, however the test apparatus and findings are novel.Resistivities of rutile and zircon were found to be easy to measure. The values measured in a corona field were several orders of magnitude less than those obtained with a dc voltage of 100 V. Evidence of back corona was observed with zircon. When the voltage drop was greater than the sample layer could withstand a localised electrical stress developed, resulting in a voltage breakdown, at which point a sudden surge of corona current (back corona) was detected in the sample layer. Rutile, on the other hand, exposed to the same conditions as that of zircon (i.e. same temperature and applied voltage) did not exhibit any sign of back corona. Its resistivity across the range of test voltages (14 to 33 kV) remained fairly constant."

Jan 1, 2003

By Yuexin Han, Zehong Wang, Fujia Yu, Wanzhong Yin, Xinchao Wei

Bauxite is the main raw material in alumina and refractory industries. China has plentiful bauxite resources, most of which belong to the diaspore type bauxite with characteristics of high aluminum content, high silicon content and low ratio of alumina and silica (A/S). The resources with A/S 4-7 account for more than 60% of the total resource reserves of bauxite. Therefore improving the A/S through bauxite desilication is the key task of bauxite concentration in China. Normally the grinding fineness of 80-90% - 0.074mm is required in the bauxite flotation process. Thus fine grinding of bauxite ores is necessary, which leads to the high energy consumption. In the meanwhile, bauxite ores are easy to produce slime during grinding processes. The large amount of slime produced in fine grinding greatly worsens the process environment of bauxite flotation, affects the separation performance and results in the loss of metal. Also, fine grinding makes the flotation concentrate difficult to dewater, while the water content in the flotation concentrate must be removed by distillation in the subsequent alumina dissolution process, causing the increase of energy consumption and cost in the production of alumina. In this study, the selective grinding behaviors were examined with Henan Bauxite as feed. Separation of alumina and silica at a coarser grinding fineness was achieved and new route was explored to enhance the desilication in bauxite concentration to improve the A/S of bauxite concentrate.

Jan 1, 2003

By B. Friedrich, A. Weyhe, H. Heegn

"Nickel-metal hydride batteries (Ni-MH) are storers of electrochemical energy, which have a higher specific storage capacity than lead or nickel-cadmium batteries. The demand for Nickel-metal hydride batteries is increasing rapidly since their market launch in the early 1990’s. Today there is no suitable and sustainable recycling process to recover nickel, cobalt and rare-earth metals. The discarded batteries are used today in the steel industry as alloy material because they contain nickel. Cobalt and rare-earth metals (RE) are lost; they are non-recycleable.In a German governmental funded research project, IME Aachen, ACCUREC Mühlheim and UVR-FIA Freiberg are cooperating in processing as well as in creating a feasibility study. The target of this project is the development of a new recycling process for metal recovery from Ni-MH-batteries. The proposed process described in this paper consists of a combination of mechanical, pyrometallurgical and hydrometallurgical processing steps. This process is capable of treating all types of Ni-MH-batteries. After comminution steel and organics are separated. The separated Ni-MH is smelted in an electric arc furnace. The products are a nickel-cobalt alloy and a slag phase enriched with rare-earth oxides for further treatment to ‘mischmetal’. Both the Nickel-Cobalt alloy and the ‘mischmetal’ will be directly used in battery production."

Jan 1, 2003

By Florian Kongoli

Slags and fluxes are important interchangeable dimensions of pyrometallurgical processes. They can increase the efficiency of the smelting, converting and refining processes and improve the quality of the final products. A good slag should have appropriate physicochemical properties such as low liquidus temperature, optimal viscosity, maximum ability to attract undesirable elements, minimum potential of attracting valuable elements, etc .. A good flux, on the other hand, when properly used, can considerably improve the physicochemical properties of the slag since by modifying its chemical composition it could decrease the liquidus temperature, improve viscosity etc.. Consequently, the choice of a good slag and the corresponding fluxing strategies has become indispensable in most of industrial processes. However, the properties of multicomponent slags as well as the effect of several fluxes are known only empirically and confusion exists in the literature and in the industrial practice. In today's reality of frequent changes in the composition of raw materials and that of the fluxes themselves, in the existing or new developing technologies, the quantification of the thermophysicochemical properties of multicomponent slags and the effect of fluxes becomes indispensable. This paper reviews some of the work carried out by the author's group during the last ten years on the quantification of the thermophysicochemical properties of multicomponent slags and on the effect of fluxes in several smelting and converting processes in close relation to their individual characteristics. Several examples have been given in order to demonstrate the fact that when taken outside the context some fluxes can become in fact anti-fluxes.

Jan 1, 2003

By L. H. Michaud

"Albian Sands Energy (ASE), an oil sands surface mining and extraction operation, is currently undergoing start-up and is scheduled to ramp-up to full production by mid-2003. Startup includes the selection and implementation of over 75 IT systems or computer applications which include: engineering applications; systems required to control mining activities, maintenance, the processing plant and utilities; and also systems required to run the company, such as human resources, finances and inventory/ warehousing.This paper outlines the processes used for the selection, implementation and integration of these systems in order to optimize the use of information and to meet the technical, business and IT requirements of the company. The first step in ASE’s approach to identifying system requirements is the development of a business activity model, outlining all tasks involved in running the operations. The computer applications required to accomplish each task are then identified by having the IT team work closely with each technical and business unit. Historically, at some companies, the selection of systems has been led by the IT team or by consultants, with little input from the technical or business units. Typically, this results in products that do not meet the company’s expectations. To ensure a more positive outcome, ASE believes that it is imperative that the company’s technical and business people be closely involved in the selection process.Integration of the IT systems is also key, including linking all applications through a data warehouse and EDMS. Over 120 required integrations have been identified. This ensures the storage of all data in only one location, data security, and easy data and document retrieval for all requirements throughout the company"

Jan 1, 2003

By Henry Hu

In high pressure die casting processes, proper control of temperature die yields a high casting production rate and superior quality components, Die temperature is usually influenced by various die design and process parameters such as size and location of intemal water cooling lines, flow rates of cooling lines, and pouring temperature of molten metal. Among them, the cooling water flow rate plays a major role in controlling thermal pattern of the die_ In order to develop an effective control strategy, data of local die temperature must be collected and analyzed, In this study, a PC-based data acquisition and control system (DACS) for die temperature control has been designed, and established, The developed DACS has three input channels for temperature signals and one input channel for water flow rate signals, as well as one output channel for a water pump, and is capable of displaying data in both curve format and value format. Implementation of the DACS in a laboratory setup has also been attempted, It should be pointed out that more advanced control mechanisms can be potentially integrated into this system in future,

Jan 1, 2003

By A. Kazemi, M. A. Ahmadi

Pressure tunnels are constructed nurously in related with powerhouse. In some cases, according to high internal water pressure, rock mass around tunnel can seldom suffer this pressure. So installation of concrete lining which interacts with rock mass and suffers parts of this pressure and transfers the rest of the pressure to the rock. In this paper hydromechanical interaction between rock and lining is investigated. With using empirical and numerical methods concrete lining for Symareh waterway is designed. Initial support of 10 cm reinforced shotcret with wire mesh and rock bolts pattern of 2.5*2.5 m with length of 4 m is suggested. By using FLAC package final lining with paying attention to axial force and momentum in reinforced concrete was designed. Reinforced concrete with 60 cm thickness and two rows of bars, 18 mm diameter and 20 cm spacing are designed. Also for preventing cracks in concrete which caused by the change of temperature and shrinkage, bars with 10 mm diameter and 25 cm spacing, and also bars with 8 mm diameter and 10 cm as minimum shear bars are suggested. Plusieurs galeries en pression se construisent en liaison avec les centrales électriques. Dans certaines galeries, suite à une haute pression interne de l'eau, le massif rocheux autour de la galerie ne peut pas supporter cette pression. L'installation d'une couche de béton a l'intérieur de la galerie donc réagit avec les roches et support d'une partie de cette pression et transfère le reste de la pression aux roches. Dans ce papier, l'interaction hydromécanique entre la roche et la couche en béton a été étudiée. En se basant sur les méthodes empiriques et numériques le système de support de galerie de passage d'eau de Saymareh a été conçu. Un soutènement initial d'une épaisseur de 10 cm de béton étant renforcé par un grill métallique et une maille de boulon (2.5 * 2.5 m) d'une longueur de 4 m a été proposé. En utilisant le logiciel de FlAC, la couche finale en béton selon les forces dans le béton a été conçue. Le béton renforcé d'une épaisseur de 60 cm et deux ranges d'armateurs (18 mm de diamètre) avec un intervalle de 20 cm a été conçu. De plus; pour éviter des fissures dans le béton suite au changement de la température et de l'extraction, des armateurs de 10 mm de diamètre et de 25 cm d'intervalle pour augmenter la résistance au sciesiement du béton ont été proposes Unter Druck stehende Tunnels werden hauptsaechlich im Zusammenhang mit Kraftwerken gebaut. In einigen Faellen, wo der Wasserdruck zu hoch ist, Kann selten die Felsenmasse diesen hoehen Druck allein aufnehwen. Deshalb werden sie mit Betonauskleidung versehen, die wegen guter Wechelwirkung mit der Felsenmasse einen Hauptanteil des Druckes aufnehmen Kann, wobei der Rest an die Felsenmesse weitergeleitet wird. In dieser Arbeit wird die hydromechanische Wechelwirkung zwischen der Gesteinmasse und der Auskleidung untersucht. Mit Hilfe empirischen und numerischen Verfahren sowie Kombination der beiden wurde eine Betonauskleidung fuer die Symareh Wasser Kannal koustruiert. Als erstes wurde ein 10Cm dicker armierter Beton mit einem Mashengitter von 2.5*2.5 sowie den gleichen Felsbolzenabstaenden und einer Laenge von 4 m vorgeschlagen. Mit Hilfe des FLAC Programms wurde die Hauptauskleidung unter Beruecksichtigung von Axialkraeften und Momenten im Stahlbeton koustruiert. Der 60 Cm dicke Stahlbeton wurde mit zwei Reihen von Stangen, 8 mm im Durchmesser und in Abstaenden von 20 Cm koustruiert. Ferner im Sinne der Vorbeugung gegen Rissen im Beton, die durch Temperatur aendeungen und Schrumpfungen bedingt sind, wurden Stangen mit 10 mm Durchmesser und 2.5 Cm Abstaenden zur Erhoehung vor Scherfestigkeit des Betons vorgeschlagen.

Jan 1, 2003

By Ljudmil S. Grigorov, Eric Forssberg, Hanumantha Rao Kota, Robert J. Pugh, Lidia B. Alexandrova

"We have used the microscopic thin balance developed by Scheludko at al. (1970) technique to study the stability and interactions within the thin film between the silica surface and air bubble with (i) a long chain C10 amine and (ii) a cationic/anionic surfactant systems consisting of mixtures of a long straight C10 chain amine with long straight chain C8, C10 and C12 sulfonates. It was found that the mixed surfactants caused lower contact angles, lower rates of the thin aqueous film rupture and longer film lifetime, compared to the pure amine system.This behavior was explained by the initial strong adsorption of positively charged interfacial complexes from the mixed surfactant system at the air/solution interface followed by adsorption at the silica interface. It was also shown that the chain length compatibility between the anionic and cationic surfactants controls the strength of the interfacial complex, determining an inhibition in the thin film rupture and dewetting of the film. The rupture mechanism was explained by an earlier established heterocoagulation mechanism between the positively charged air/solution interface and the solution/silica interface which remained negatively charged. The formation of the interfacial complex at the air/solution interface was confirmed by using surface tension data."

Jan 1, 2003

By Florian Kongoli

Slags and fluxes are important interchangeable dimensions of pyrometallurgical processes. They can increase the efficiency of the smelting, converting and refining processes and improve the quality of the final products. A good slag should have appropriate physicochemical properties such as low liquidus temperature, optimal viscosity, maximum ability to attract undesirable elements, minimum potential of attracting valuable elements, etc .. A good flux, on the other hand, when properly used, can considerably improve the physicochemical properties of the slag since by modifYing its chemical composition it could decrease the liquidus temperature, improve viscosity etc.. Consequently, the choice of a good slag and the corresponding fluxing strategies has become indispensable in most of industrial processes. However, the properties of multi component slags as well as the effect of several fluxes are known only empirically and confusion exists in the literature and in the industrial practice. In today's reality of frequent changes in the composition of raw materials and that of the fluxes themselves, in the existing or new developing technologies, the quantification of the thermophysicochemical properties of multicomponent slags and the effect of fluxes becomes indispensable. This paper reviews some of the work carried out by the author's group during the last ten years on the quantification of the thermophysicochemical properties of multicomponent slags and on the effect of fluxes in several smelting and converting processes in close relation to their individual characteristics. Several examples have been given in order to demonstrate the fact that when taken outside the context some fluxes can become in fact anti-fluxes.

Jan 1, 2003

By Karl J. C. Harries

"1.1. WHAT ARE AGREEMENTS AND HOW ARE THEY FORMED?In order to have an agreement, at common law, there must be an offer, acceptance of that offer, and consideration passing between the parties. In addition, the material terms (i.e. the basics or substance) of the agreement must be discernible, preferably by means of documentation. Although these concepts may appear simple and straightforward, the law relating to them is voluminous and complex. Some brief comments are worthwhile.• Offer/acceptance: Both offer and acceptance should be in writing, but they need not be. The actions, conversations, and/or correspondence of the parties may constitute either or both of them. Notwithstanding, the local law or practice of a jurisdiction will impose some specific requirements for certain types of agreements. If these requirements are not met, the agreement may be unenforceable. For example, Ontario’s Mining Act requires transfers of unpatented mining claims to be evidenced in writing and recorded.1• Consideration: Consideration is usually thought of as being money, but it can be virtually anything, even “the premises” (i.e. the mutual covenants or promises contained in the agreement itself). In addition, if one party, relying upon the offer of another, does something to his detriment, then the doing of the act can be considered to be an acceptance of the offer and, under the legal concept of “detrimental reliance”, can also be consideration. Whether or not detrimental reliance exists will depend upon the circumstances of each case.2• Material terms: The requirement that the material terms of an agreement must be discernible does not mean that all of the terms of an agreement must be documented or even have been considered, just the basic or material ones. In addition, it will be up to a judge to decide what is material – not necessarily the parties. In order to establish the material terms, a Court may look at all relevant documentation and may hear oral evidence. It will resist “writing the agreement”"

Jan 1, 2003