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By Steven M. Puricelli

Sulfuric acid plants associated with smelters, have historically been an overworked and often neglected pollution control device. They could do little more than manage the wide fluctuations in gas flow and SO2 strength from the smelter. With the introduction of flash smelting, the picture began to change, but the fluctuating batch converters continued to dictate acid plant design. More recently, the commercial use of continuous converting processes utilizing high levels of oxygen enrichment has dramatically upgraded the SO2 strength and stabilized the gas flow to the acid plant. The SO2 gas now issues continuously and at concentrations that allow for compact and, cost effective acid plants. Relieved of the burden of excessive dilution air, the heats of reaction can also be recovered as medium pressure steam and used to drive a generator, making the acid plant a net producer of power and a valuable asset to balance sheets. This concept was put into practice at the Kennecott Utah Copper Corporation smelter modernization project, located in Salt Lake City, Utah. The new acid plant, which was commissioned in June of 1995, is a sophisticated, low environmental impact, energy producing plant, worthy of review. This paper examines the key features of this acid plant, such as controlling its tail gas, by catalysis alone, to an environmentally friendly, 100 ppm of SO2, while feeding the acid plant converter with an efficient 14% SO2. The acid plant is also a prudent steward of energy resources, recovering 220,000 lb/hr of 140 psig steam from process heat which is used to generate a substantial 20 MW of gross power. Also discussed will be some of the ongoing issues, such as handling of selenium and fluorine in the gas cleaning sections, as well as a review of some. of the problems that were identified and resolved. Today's modem acid plants, by necessity, are becoming a producer of quality, valuable products, making the acid plant an asset and not a liability. Plants like Kennecott are already gaining wider acceptance and are expected to be the vision of the future.

Jan 1, 1998

By M. Nichols

Where am I? Where are they? Where is it? These are the fundamental questions that need to be answered in managing people and resources. This paper explains how GPS positioning technologies answer those fundamental questions and provide better information management from initial exploration work through daily mine operations to reclamation work and environmental monitoring.

Jan 1, 1998

By Karlson R, Rispin M

Chemical admixtures are not commonly included in the variety of backfill mixes used in the mining industry. This may be attributed to several reasons including, but not limited to: the perceived high added cost, 2. the lack of awareness about their proper use, and 3. the lack of knowledge about their features and benefits. In the construction industry today, however, chemical admixtures are used in the majority of the concrete produced, enabling concrete to become a more cost-effective building material. They also enable construction crews to meet demands for year-round construction, quicker completion of construction projects, and improved concrete properties. The high demand for chemical admixtures in the construction industry has led to numerous innovations in admixture technology in recent years. Some of these chemical admixtures have been found to enhance the production, transport, placement, and in situ properties of backfill mixes. Others have been found to reduce the cost of such mixes while maintaining, and in some cases improving, their physical properties. In this paper, a few of such innovative admixture technologies are discussed. The benefits, imparted by these technologies to backfill mixes as well as performance data on their use in several backfill applications at various mines, are presented.

Jan 1, 1998

By W. M. Husslage

The permeability in the blast furnace shaft is adversely affected by low temperature reduction degradation of sinters. The fundamental cause is an expansion of the iron oxide phase resulting from reduction of hematite to magnetite. The present study showed that expansion behavior during the hematite / magnetite reduction step and the resulting microstructure are strongly influenced by the reduction temperature (viz. partial oxygen pressure), the reducing agent and the nature of the hematite. The reduction rate is of minor importance. A reduction mechanism is proposed, explaining the dilation behavior and the magnetite microstructure. The results can provide better insight into reduction degradation behavior.

Jan 1, 1998

By W. Stark

Many developing countries with little or no previous environmental regulation are now promulgating air quality regulations which require facilities to demonstrate compliance with both process parameter based emission limits and ambient air quality standards. For many companies with operations in developing countries, an air quality compliance program at the facility level is lacking and these companies have very little background information to work with in developing a program for assessing and maintaining compliance. This paper will present a methodology for development of a comprehensive air quality compliance program for operations located in developing countries with new environmental regulations. The experiences of the authors in developing an air quality compliance program for a mining operation located in South America will be used as a basis. A program for meeting new air quality requirements can be developed in seven steps. The seven steps are: (1) regulatory review and project scope; (2) design and implementation of a baseline air quality monitoring program; (3) site visit, (4) development of a complete air emission inventory; (5) dispersion modeling; (6) compliance analysis and compliance plan; and (7) project completion.

Jan 1, 1998

By F. Nelson

RJB Mining is the largest coal producer in the UK. In January 1995 the Company acquired the Central North and Central South Regions of British Coal consisting of: ? 15 operating collieries -including capital equipment ? 2 care and maintenance mines ? 16 operating Opencast sites ? Interest in 26 prospective and 46 potential Opencast sites ? Approximately 417 million tonnes of proven and probable reserves and considerable mineral resource ? 9 million tonnes of coal stocks ? Long term contracts to supply approximately 90 million tonnes of coal to National Power and PowerGen to the period of 3 March 1998 ?Approximately 7,600 employees and 4,500 mining contractual labour. Up to the acquisition RJB Mining had the capacity to produce 14 million tonnes of saleable output with an approximate 1,500 strong workforce.

Jan 1, 1998

By A. B. Holland-Batt

Following a relatively static period in the 1960s and 1970s when incremental development rather than innovation was the norm for gravity separation, the last 15 years has seen a number of new developments in this area. The paper briefly reviews the traditional gravity separation techniques and then examines the newer developments such as centrifugal separators. Particular emphasis has been placed on novel devices or improvements that offer either better control or improved performance.

Jan 1, 1998

By D. C. Yang

A practical and economical flowsheet has been developed and demonstrated by integrating the packed column flotation with the GranuFlow process for fine coal recovery. Orimulsion, which was used as an additive, served a dual purpose: first in the flotation and second in the dewatering and granulation steps. The test results on the coal preparation effluent sample show that Orimulsion is flexible and compatible with fuel oil and various frothers used in the packed column. Clean coal with ash contents of 3.0, 3.7, 4.3 and 5.1% were produced from a head sample of 33% ash at combustible matter recoveries of 72.4, 81.1, 87.5, and 89.2%, respectively. Other advantages include high throughput, low moisture, improved handleability, and reduced dustiness of the dewatered coal, thus providing a very significant economic Incentive for the integrated process.

Jan 1, 1998

By Zenjiro Asaki, Teruo Tanabe

"To clarify the formation of light rare earth (R =Ce, Pr, Nd or Sm) -Fe compounds in the reduction-diffusion (RD) process, two kinds of experiments were carried out: (a) RD experiment in which briquettes composed of R oxide powder, Fe (particles or wire) and CaH2 were reacted, and (b) immersion experiment, where an Fe plate was immersed into R-Fe melt having the composition of Fe-side liquidus line in Fe crucible. The compound formation was examined by using XRD, SEM and EPMA. The formation rates of RzFe17 measured by the RD experiment were compared with those obtained by the immersion experiment. The growth rates of compounds obtained in the RD experiment for Pr-Fe and Nd-Fe systems were much lower than those obtained in the immersion experiment. This result was explained by the difference of the reduction rates of R oxides by Ca. The parabolic rate constants for the formation of RzFe17 were separated in two groups of (a) Pr-Fe and Nd-Fe systems and (b) Ce-Fe and Sm-Fe systems. This was discussed in connection with the difference of their crystal structures and the driving force of diffusion. The parabolic rate constants for the formation of compounds in Ce-Fe and Sm-Fe systems decreased in the order of RFez, RFe3 and RzFe17.IntroductionTo understand reaction behaviors in the production of rare earth (R) -iron intermetallic compounds, which have excellent magnetic properties, is very important from engineering point of view. And the reduction-diffusion (RD) process<O has recently attracted attention as one of the promising processes to economically produce R-related materials. A few fundamental studies on the compounds formation in the RD process have previously been reported. Qi, Hino and Yazawa(2) observed the formation of R(Nd, Sm)-Fe and R-Co compounds in the process from various view points. Song and Ogawa(3) measured the growth rates of Nd-Fe and Sm-Fe compounds by using Nd or Sm vapor supplied from Nd-Ca or Sm-Ca melts. The authors have also carried out fundamental studies (4)-(8) to clarify the rate and mechanism in the production of R-Fe intermetallic compounds."

Jan 1, 1998

By Tingkan Lu

To understand the reinforcing mechanisms of the fully grouted resin bolt and clarify its performance in weak roof strata, the field monitoring investigation using instrumented bolts has been conducted in a coal mine. The total time of monitoring was around ten months. In the first 8 month period, the rock bolt performance relates to the initial development of the gateroad and subsequent time dependent strata response. After 8 months, the rock bolt performance relates to the effect of the approaching longwall mining operation, up to the point where the measuring station was destroyed due to the mining operation.

Jan 1, 1998

By Yuan Zeping

This paper describes the distribution and removal of the main impurities in the pyrometallurgical process ?at the Guixi Smelter. The paper discusses in detail our converting schedule?of3S-SB and injecting deeply a mixture ofNa2CO) and CaO flux into the converters to enhance impurity removal.

Jan 1, 1998

By P. McGrath

From the mid-1980s through 1997, Echo Bay Alaska evaluated reopening the historic Alaska-Juneau (AJ) gold mine. Their original proposed project underwent numerous modifications in order to minimize the potential for significant environmental impacts. One of the major modifications involved changing .the tailings disposal method from a conventional tailings impoundment to submarine tailings disposal (STD). In 1995, the U.S. EPA began work on a Supplemental Environmental Impact Statement (SEIS) to assess the impacts of the STD proposal. Key features of the STD impact assessment included fate and transport modeling to determine the extent of tailings deposition and the use of ecological risk assessment to predict marine impacts during deposition and ecosystem recovery following STD. A key feature of the SEIS regulatory process included a rulemaking proposed by EPA to exempt the AJ tailings from effluent regulations. Critical to success in moving the project forward was early development of an interactive working relationship with other regulatory agencies and the public.

Jan 1, 1998

By Antti Roine

HSC Chemistry is a widely-used therniochemical tool in the chemical and metallurgical industries and in universities. The main reasons for it&apos;s popularity is the easy user interface and the large integrated thermochemical database. This paper summarizes the main properties of the new HSC Chemistry version 3.0, and gives a short review of the new features: Some metallurgical applications with the new features are also presented. HSC Chemistry 3:0 contains seven calculation modules and a thermochemical database with more than 11 ,000 chemical compounds. The new spreadsheet type table editor gives more control to the user, the new graphics routines have fewer limitations and more formatting properties. The capability and speed of calculation routines have also been improved.

Jan 1, 1998

By M. Wasel

The Gross Rosebel gold deposits are located in the Guiana Shield of north central Suriname. Initial discovery of surficial gold in 1880 by local artisanal miners preceded small-scale mechanized mining from 1885 to 1939. The first systematic exploration program was carried out by Placer Development from 1974 to 1977. In May 1992 Golden Star Resources optioned the property. Initial shallow reconnaissance diamond drilling of the extensive surface geochemical anomalies intersected sporadic gold mineralization with no apparent continuity between drill sections. Successive deep augering, trenching and systematic grid drilling based on information from surface mapping allowed development of a preliminary geological model. Further drilling of specific structural-lithologic targets and more complete synthesis of geological data from the trenching and deep auger sampling added to the geological model and defined the multiple controls of gold mineralization. Carefully planned infill drilling on a tighter grid spacing resulted in progressive definition of reserves within six discrete gold deposits. In a complex geological setting, the key to success at Gross Rosebel was persistent, systematic exploration, detailed mapping, careful core logging and perceptive geological interpretation. Reserves now stand at 48.6 Mt at 1.6 glt Au, or 2.4 million ounces of gold. The purpose of this paper is to describe the progression of exploration activity that led to the definition of substantial gold reserves and to summarize the geology of the deposits.

Jan 1, 1998

By R. J. Sweigard

Stabilization of slopes on abandoned mine land (AML) invariably involves some channelization to control surface drainage. Typically, these channels are lined with riprap or gabions, depending on gradient and expected flow rate. The conventional treatments pose a problem since they require frequent maintenance and replacement at times. Soil bioengineering presents an alternative to the conventional measures. In soil bioengineering, living woody plant material forms the main structural component in systems designed to prevent shallow mass slope failures, surface erosion, and channel bank erosion. An experimental application of soil bioengineering techniques was designed and implemented at an AML site in eastern Kentucky. The design consisted of live fascines and live stakes using willow branches installed with coir geotextile. Channel gradient, length, and cross-section were considered in the design.

Jan 1, 1998

By D. W. Gunkle

Processing of various ores and materials in a reducing atmosphere has been done for many years. However, the typical device currently used is a large, often high maintenance, expensive piece of equipment; the rotary kiln. While it is a very reliable and a proven technology, the rotary kiln also has its limitations. It is limited by its ability to process very fine materials without creating a huge dust loss to the air pollution control equipment. This leads us towards the development of an alternate technology; the Gas Suspension System. Gas suspension preheating of various materials has been in commercial use since the early 1950&apos;s, but recently has been expanded to include Gas Suspension Reduction. Laboratory experience has proven successful on several materials; Nickel Laterite Fines, Iron Ore Fines, Fluorspar, and Clays. The gas suspension reduction system has many advantages over the conventional reduction kiln when processing fines. They are; lower cost, more fuel efficient, able to process fines, less real estate required, etc.

Jan 1, 1998

By B. R. Arvidson

Rare-earth elements have some unique properties that are used in many common applications, such as TV screens and lighters. In the 1970&apos;s, rare-earths began to be used in a new generation of magnetic materials that have very unique characteristics. Not only were these stronger in the sense of attraction force between a magnet and mild steel (high induction, B), the coercivity (He) is extremely high. This property makes the magnetization of the magnet body composed of a rare-earth element alloy very stable, i.e., it cannot easily be demagnetized.

Jan 1, 1998

By Sungdon Kim, Chuljoo Kim, Joonsoo Kim, Hosung Yoon

"This study was performed to establish the optimum leaching condition through the experiments for the oxidized roasting followed by leaching of fluorocarbonate rare earth mineral (bastnasite) using sulfuric acid, and to establish the optimum condition for the recovery of cerium by ion- sieve method from the leached solution of bastnasite. The optimum conditions for the sulfuric acid leaching by the oxidizing roasting of bastnasite concentrates are that the roasting temperature is 550 -600 °C, the roasting time is 2 hrs, the concentration of sulfuric acid is 6N, the leaching temperature is S0°C and the leaching time is 3 hrs. At this time, the leaching yield of total rare earth oxides in the leaching of bastnasite concentrates is about 91%. When cerium is recovered by ion-sieve method from the solution obtained by the sulfuric acid leaching of the roasted bastnasite, the optimum conditions are that the TREO(total rare earth oxide) of leached solution is below 70 g/l, the flow rate of leached solution is 9.6 ml/min and the ratio of height to diameter of resin packed in column is above 9. In these conditions, the recovery of cerium of yield 85% and purity 96% is possible.IntroductionThe rare earths are generally called to Lanthanides, which are totally 17 elements including Scandium of atomic number 21 and Yttrium of atomic number 39 in addition to 1 S elements from Lanthanum of atomic number 57 to Lutetium of atomic number 71. Since the separation to each element is very difficult because of their similar chemical properties, the rare earths were used as the mixed rare earths and the mischmetal without separating to each element. However, the high purity rare earths are recently produced commercially to each element so that they are used as the materials for high tech. industry such as electric and electronic materials, catalysts, optical materials, special alloy and 8Uperconductive materials, and their consumption is rapidly increasing. Therefore, the purpose of this study is firstly to prepare leached solution by using the series of process of the oxidation-roasting and leaching by sulfuric acid. Next, second purpose is the separation and recovery of cerium by ion-sieve method."

Jan 1, 1998

By Thomas P. Mucho

Cable bolts are emerging as the newest ?twist? for roof support in U.S. underground coal mines. For decades cable bolts installed in underground metal mines in the United States and Canada used cement-based grouts for anchoring. The cement anchoring process, because of the time and expense for installation, made cable bolts impractical for use in coal mines. Today, the introduction of resin-anchored cable bolts provides a system more consistent with tradi­tional U.S. coal mine roof bolting practices and requirements. Expecta­tions are that the utilization of cable bolts for a number of U.S. mining applications will expand, particularly in coal mining.

Jan 1, 1998

By Stephen John Brace

Increasingly, electronic blast initiation systems are being made available to the mining and construction community, both in South Africa and internationally. Indeed, in some parts of the world, perhaps half a dozen electronic products are being used, with a choice also of shock tube, electric and fuse and igniter cord systems. As these developments have taken place, improvements have been made in safety, reliability and accuracy, so much so that high performances in all these areas are now expected. However, disadvantages often seen by customers, other than : higher price, are decreased user-friendliness and loss of flexibility.

Jan 1, 1998