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By Cutmore NG

The moisture content of iron ore is important in handling, stockpiling, transport and further processing operations. Typically these ores contain both `free' and `bound' moisture, the latter being moisture that is not removed in a conventional laboratory determination of moisture by air drying at 105¦C, and it is the free moisture that is important in dust control and ore handling. The CSIRO Division of Mineral and Process Engineering has previously developed and commercialised gauges, based on capacitance and microwave techniques, for the on-belt determination of moisture in coal and minerals. However, these gauges determine total moisture, and have a different sensitivity to free and bound moisture in the material analysed. Consequently, the accuracy of determining total or free moisture alone may be significantly affected by variations in the bound moisture content. An investigation has been carried out on the simultaneous determination of free and bound moisture in iron ore fines (

Jan 1, 1993

By M. G. Irish, E. E. Vidal, M. J. Jahraus, P. R. Taylor

An experimental system has been designed to monitor on-line variations of leaching parameters in a closed circuit of cyanide leaching solutions and gold bearing ores. Experiments performed to deter-mine variations in some important leaching parameters of the solution: pH, dissolved oxygen, free cyanide, oxidation/reduction potential, gold content, temperature, pressure and solution chemistry. By comparing results obtained when the leaching solution is allowed to become acid or kept basic, it was possible to infer the chemical reactions that occurred between the solution and the ores.

Jan 1, 2004

By M. Huang

A conductivity-based sensor for on-line measurement of free acid was recently built. This sensor is suitable for high ionic strength solutions and its corrosion-free operation is based on induction currents. It has been tested against literature data and measurements made using a previous developed contact-type conductivity cell, with an average difference within 1%. The electrical conductivities of H2SO4?H2O, H2SO4?MgSO4?H2O and NaCl?Laterite-H2Osolutions at temperatures up to 250 °C were discussed. It was found that the solution conductivity depends on various factors, such as the electrolyte concentrations, the type of electrolytes, temperature and the amount of dispersions. A semi-empirical model was developed to account for all the factors discussed. This model was further tested on actual process solutions from the hydrometallurgy of nickel where sulphuric acid solutions containing a variety of metal sulphates and solids. The average difference between the estimated acid concentration from this model and the one from titration was generally less than 5%, which is excellent for industrial applications.

Jan 1, 2006

By M. Huang

Electrodeless conductivity was employed to investigate the feasibility of continuous on-line monitoring of the free acidity of sulphate and/or chloride solutions of Cu and other base metals from various hydrometallurgical processes. These solutions were measured with both commercial and experimental electrodeless conductivity sensors from 15 to 250°C. It was confirmed that hydrogen ion has the greatest impact on conductivity by carrying the bulk of the current because it is the most mobile ion. In combination with a solution speciation analysis the conductivity sensor can be calibrated to account for the contribution of Cu electrolytes as well other dissolved salts allowing fast and accurate on-line measurement of free acid. The sensor was tested at both lab and pilot scale with very good performance. The average difference between the measured and the titrated acid concentration was less than 5%, which is excellent for industrial applications.

Jan 1, 2007

By Derek J. Fray

"A need exists for fast and accurate analysis of species in various phases at elevated temperatures. Although modern analytical techniques are very efficient, the equipment is usually situated some distance from the industrial operation and time is spent taking the sample and sending it to the analytical facility. Several minutes can easily lapse and, during this time, heat must be supplied in order to keep the system molten and, if the composition is changing rapidly due to a refining process or reaction with the environment, the information may only be of retrospective use. Perhaps more important reasons for the use of on-line sensors are that instantaneous analysis gives better control, process optimisation and the minimisation of energy losses and pollution. To date oxygen has been the only element which is measured widely using solid electrolytes. However, the analysis of many more elements is required and possible electrolytes for other species are discussed. For some elements, ~here is no suitable conducting electrolyte and, therefore, a different approach is adopted where the electrolyte, in which one species is mobile, comes to equilibrium with another species. IntroductionThere is an ever increasing demand for the development of sensors for on-line measurements in most areas of technology and, in particular, metal processing. This is especially relevant in situations where greater control can be achieved by monitoring the chemical composition of the melt during processing and where a minor constituent in the melt can have a major effect on the properties of the finished alloy. Although modern analytical techniques are fast and reliable, the equipment due to its complexity, is frequently situated away from the process area and valuable time may be spent in sampling and transportation. During this period, heat may have to be supplied to prevent solidification and the refining reactions may be continuing, and, therefore, the analytical information may not be of direct use."

Jan 1, 1988

In many base metal sulphide concentrators reagents such as collector and cyanide are often added to the grinding mill as well as to the flotation circuit. Whilst good reasons can be cited for splitting the reagent addition in this way, the benefits of such are rarely quantified and the complex reagent-mineral-media interactions occurring during milling are often poorly understood in terms of pulp chemistry. A new laboratory batch grinding mill designed by Magotteaux allows the user to measure, monitor, and control the pulp chemical conditions during grinding when testing different ores and media. Some of these parameters include pulp pH, pulp Eh, temperature, gaseous atmosphere, and dissolved oxygen concentration. In a recent development, the mill has been coupled with a simple on-line reagent monitoring system, designed by CSIRO, which allows the levels of species such as xanthate and cyanide in the grinding pulp to also be measured continuously during milling using a robust UV detection system. In this way the uptake of collector during grinding and the rate and ex-tent of cyanide interaction with the minerals and media can be determined as a function of grinding time. A series of grinding tests using an Australian nickel sulphide ore was conducted with the coupled system in which the cyanide dose, xanthate dose, and media type were systematically varied. The xanthate and cyanide levels were monitored as a function of grinding time and the data collected are discussed in terms of the pulp chemistry of the system and implications for plant reagent dosing strategies.

Jan 1, 2014

By Daniel Bennett

There are few methods currently applied towards on-line bulk mineralogical analysis. Yet on-line knowledge of process mineralogy could potentially provide large benefits, such as increased extraction efficiency or resource optimization. The work described in this paper involves the development of radio frequency methods for bulk mineralogical analysis. Some resonances that occur in the radio frequency spectrum are mineral specific, and potentially allow quantitative estimation of mineralogy in an ore stream. Results will be presented on the specific detection of chalcopyrite. Initial quantitative measurements investigating matrix effects have indicated the feasibility of on-line mineralogical estimation using radio frequency techniques.

Jan 1, 2006

By K Heiskanen, R A. Grau

Gas velocity (Jg) measurements conducted close to the froth-pulp interface over the cross-section of a flotation cell reveal how efficiently the incoming air is being dispersed throughout the volume of the cell. Furthermore, measurements of Jg at deepest locations in the cell provide valuable information about air recirculation and dispersion conditions in the bulk volume of the cell. Gas velocity in flotation cells has predominantly been measured by a transient capture of gas in a graduated probe. In this project, a new sensor for measuring gas velocity in an on-line manner was developed. A probe is partially immersed in the flotation machine, below the froth-liquid interface. The probe is used to collect the rising air bubbles from the liquid phase. The liquid-froth interface is shifted into the probe under vacuum. A controlled vacuum is kept inside the probe. As air bubbles burst inside the probe, the excess of air is continuously removed from the probe via suction. The removed air is measured using a mass flow meter. The fully automated sensor allows us to continuously measure Jg at different location in a flotation machine. An experimental programme was carried out in a 10 cm diameter laboratory flotation column to determine the accuracy and repeatability of the automated sensor. The new sensor was used for evaluating gas dispersion conditions in a 215 litre transparent laboratory scale flotation cell. Gas velocity distributions along the radial and axial directions of the cell were measured over a wide range of operating conditions. The operating conditions in the cell were modified by altering impeller speed and air flow rate. Two different rotor-stator mechanisms were utilised to disperse the air in the cell, the MultiMix and the FreeFlow mechanism. In this paper, a description of the gas velocity sensor is given, and the results of the experimental work are discussed in detail.

Jan 1, 2005

By Fuzail Siddiqui

"The SIDMIN program aims at filling the mineral processor’s need to know the deportment of ‘minerals of interest’ not just ‘elements of interest’ that pass through the processing plants. Generally, chemistry is used as a tool of routine monitoring on site. Mineralogy, which is relatively much slower, is used more as a tool of research and post mortem investigations and these services are usually provided by a distant facility. The SIDMIN program enables site management to receive chemical and quantitative mineralogical reports on their critical samples daily, simultaneously and affordably.The author developed the SIDMIN program at ZCCM Nchanga Division where it continues to be a powerful tool for monitoring the efficiency of operations. Outlines are given of procedures for quick sample preparation and quantification of significant minerals in process samples. A specimen report is presented, which shows the format of reporting the contributions of individual minerals to metal losses at critical stages of the circuit. It is shown that SIDMIN provides timely information to management, about trends and abrupt changes in the quality of ore, and its processing, in a way never achievable by chemical analyses alone. This greatly helps in resolving the age-old problem of ‘bad ore’ or ‘bad operations’ on a day-by-day basis. For example increase in copper mica in the feed indicates excessive ore dilution during mining. Increased loss of free sulphides was traced to insufficient reagent conditioning time at the Concentrator. Persistent losses of leachable oxides at the Tailings Leach Plant were traced to inadequate leach residence time.SIDMIN is affordable because it can be implemented using basic optical microscopes, minimal quantities of micro-chemical reagents and custom trained site staff who demonstrate good colour perception and an ability to follow laid down procedures consistently."

Jan 1, 2000

By R. Hendrickson

In the 1940's a top blown water-cooled oxygen lance was developed to inject oxygen into liquid iron. This process, the LD or BOF process technique, today is used in 65% of the world's steel production, and represents the largest oxygen market for temperature enhancement in steel and non-ferrous smelting applications. There are three major approaches to the use of oxygen in metallurgical processes: (1) general enrichment of the air supplied to burners or tuyeres, (2) under-flame enrichment or injection, and (3) the use of an auxiliary oxy-fuel burner as a heat source. With each of these techniques there are technical and economic trade-offs.

Jan 1, 1990

By J. J. Whittaker

Zaldivar is an open pit copper mine operation located in the Atacama Desert, in northern Chile. The plant produces Cu cathodes using 4 solvent extraction trains. The plant was started up May 1995. Since 1996 the plant has been using on-stream analyzers based on X-ray fluorescence and titration for process monitoring and control. Elemental analyzer alone is not able to provide the critical information for plant operation, it has to be complemented by on-stream titrators integrated to one sampling system. The analyzers are located in a prefabricated shelter. The analyzer system project, operation and performance issues are the main topic of this paper.

Jan 1, 1999

By Fathi Habashi

The year 1987 marked the centennial of the beginning of modern hydrometallurgy. On October 19, 1887 British Patent No. 14174 entitled Process of Obtaining Gold and Silver from Ores was issued*. The discovery was made by John Steward MacArthur (Fig. 1), a chemist-metallurgist, supported and assisted by Robert and William Forrest, two brothers practicing medicine in Glasgow. The discovery was made in the basement of their clinic. The process, which became known as the cyanidation process in reference to the alkali cyanide reagent used, immediately received industrial success in New Zealand in 1889 and in South Africa in 1890t. It displaced the chlorination method which had been in use. In 1903 MacArthur was awarded the first Medal of the Institution of Mining and Metallurgy in London1131 - The cyanidation process was responsible for the doubling of gold production in the world in the two decades which followed its first application (Fig. 2). To the modern metallurgist, it may be surprising to think of MacArthur coming across an obscure reagent such as an alkali cyanide as a leaching agent for gold ores. It is the purpose of this paper to discuss the background and the factors that led to this invention, the development of the understanding of the process, and the application of modern technology.

Jan 1, 1999

By P. Latostenmaa, O. Forsén, M. Lundström, J. Aromaa

The history of electrolytic copper production in Finland is closely connected with the industrialization of Finland and events of the Second World War. Production of cathode copper by electrowinning from the processing of Outokumpu ore started in 1913 based on the Hybinette nickel process, however due to the poor performance of this process, the plant was closed in 1929. Outokumpu commenced copper smelting at Imatra in eastern Finland in 1936 producing blister copper for refining outside the country. Due to the threating military situation, a new electrolytic copper refinery was built in 1941 at Pori in western Finland to refine the anodes. This was the first electrolytic copper refinery in Finland. It was built with 108 cells having a capacity of 12,000 tonnes/y. In addition, the smelter was relocated to nearby Harjavalta in 1944–1945. To fulfill the war reparations included in the peace treaty with the Soviet Union, a doubling of the smelter capacity was realised, with the Pori refinery capacity increasing to 20,000 tonnes/y in 1946 by adding additional cells. The cornerstone of Finnish metallurgical technology — Outokumpu flash smelting — was invented with the new technology commissioned at Harjavalta in 1949 replacing the electric furnace and providing a further increase in copper output with subsequent enlargement of the refinery. By 1963, the plant consisted of 380 cells with a capacity of 48,000 tonnes/y of cathode copper. The Pori electrolytic copper refinery has operated continuously since 1941. Commencing in 2004 the Pori refinery has been part of the Boliden group of Sweden. The most recent plant upgrade was in 2007 with the installation of permanent cathode technology. In 2017, the production of the Pori refinery was 133,000 tonnes of copper cathode, 2,300 tonnes of nickel sulphate, along with 66 tonnes of silver and 4.6 tonnes of gold. This paper describes these outstanding achievements. INTRODUCTION In 1809 the Kingdom of Sweden was defeated by the Russian Empire in the Finnish War, and Finland was annexed by the Russian Empire as the autonomous Grand Duchy of Finland. Finland’s commercial and industrial interests were developed to serve the Empire’s needs. Finland had raw materials, but at the start of the 20th century Finnish industry was based on the use of wood as raw material and agricultural products. The mining industry was only a few percent of the country’s industrial production.

Jan 1, 2019

Production sharing and cost apportionment in joint ventures is commonplace in Australasia today and elsewhere. It is a recognised convention that, with the exception of a free carry situation, joint venture participants usually share the proceeds of the joint venture in direct proportion to their respective participating interest, after having first paid its respective cash calls, in advance, to cover the projectÆs ongoing operating and capital cost requirements.In surface mines, the parties simply pay their way and take their proceeds in this manner. In underground mines, the situation is no different, though treatment of capital, depreciation and tax may differ between the parties. A common feature in many cases is the creation of a joint venture entity to conduct the business. This entity then collects cash from the parties, banks it, employs the staff, runs the operation, provides reports and pays out the proceeds. This convention appears to be relatively simple in application. In practice, it has been known to be complicated in the situation where the participants take their product at the mine gate and undertake their own marketing and selling arrangements. A more complex situation presents itself where the joint venture tenement boundary with an unrelated third party straddles an economic deposit. In this scenario, both the joint venture parties and the third party may wish to mine the deposit, sharing some infrastructure and costs, yet taking their own product as it is produced. A case study outlining such a situation is presented in the paper, outlining firstly how the major cost categories were identified and treated for cost apportionment purposes. Secondly, a mechanism for the equitable apportionment of product is suggested. Finally, issues such as timing and cost reporting are dealt with, together with a checklist of points which should be considered when a similar situation might arise in the future.

Jan 1, 2002

By RALPH HAYES SWEETSER

ONE per cent. of ash in a ton of coal has been so little considered that in many circles it has been positively ignored. Even P. T. Barnum had never heard of it, or he would have had one on exhibition alongside the Cardiff Giant and the White Elephant. One per cent. of ash is closely related by both those freaks of Barnum in that it is "stone" and, in its aggregate, it is the greatest "White Elephant" that the American public now supports. Some of you may have paid Mr. Barnum for a look at the "petrified man" (named the Cardiff Giant by the gullible wise men of the early seventies); but it is certain that everyone of you is now paying for the support of the great White Elephant that is being constantly carried by our railroads all over the country-at the public's expense. " One per cent. of ash in a ton of coal" requires 120,000 open-top railroad cars each year to transport this use- less stone giant from its native bed in the coal seams of the bituminous regions to the coal bins of the consuming public.

Jan 1, 1924

By S. J. CRAIGHEAD

IN 1912 the United States Smelting Refining and Mining Company made a large investment in a number of coal properties in Utah and in 1915 a subsidiary, the United States Fuel Co., was organized to take over these properties. Operations started in 1916 and the Company soon became, and remains, one of the major coal producers of the State. It now produces approximately one million tons of coal annually, which is about 22 per cent of Utah's output. The U. S. Fuel Co. owns large reserves of good coal and is in a position to expand operations with the industrial growth now taking place in the West. Traveling through the Western States, one is struck by numerous advertising signs portraying the picture of jovial Old King Cole of nursery rhyme fame. His rotund figure and beaming countenance are the symbols of Utah King Coal, the product of the King mine of U. S. Fuel Co. King Coal is a by-word of quality coal throughout all the Western States.

Jan 1, 1948

By Funsho K. Ojebuoboh

With several “green” applications on the horizon, bismuth has become an even more important minor metal in the smelting and refining of lead. Smelters with a complex sulphide feed invariably deal with bismuth. Its behavior during the smelting of lead in conventional sinter-blast furnace operation is discussed. Because it readily deports to the lead phase during the refining of lead, its separation from refined lead remained unsatisfactory in early lead production. When commercial requirements of bismuth in lead became more stringent early this century, the procedure where by calcium and magnesium is used todebismuthise lead was developed. The present conduct of this 1936 process, the Kroll-Betterton process, is discussed with emphasis on operational improvements.

Jan 1, 1996

By V. Vallyathan, Xianglin Shi, N. S. Dalai

While Cr(VI) is a known carcinogen, the underlying biochemical mechanism is still not fully understood (1). In a pioneering study Jennette (2) utilized electron spin resonance (ESR) spectroscopy to demonstrate that a long-lived Cr(V) species is generated during the reduction of Cr(VI) by microsomes in the presence of NADPH. Later Wetterhahn and co-workers (3, 4) showed that incubation of chromate with isolated rat liver mitochondria causes the reduction of Cr(VI), as well as the formation of a Cr(V) species. Analogous Cr(V) species have also been detected in the reduction of Cr(VI) by other cellular systems such as Hanserulla polymorphared (5) and blood cells (6, 7). All these as well as other studies (8-12) have suggested that this Cr(V) species plays a significant role in the mechanism of Cr(VI) toxicity. Thus far, however, the chemical structure of this dominant Cr(V) species formed in cellular systems has not been identified, and this observation provided an impetus for the present investigation. Another reason for undertaking this study was that some recent reports (10-16) suggest that hydroxyl ('OH) radicals may also play an important role in the mechanism of Cr(VI) toxicity. In particular, it has been shown that OH radicals are formed in reactions between Cr(V) species and H2O2 (13-16), and that the radical yield depends on the chemical structure of the Cr(V) species (15). For example, while Cr(V)-diol complexes efficiently generate OH radicals, another Cr(V) species, the tetraperoxochromate (CrO3/8) ion, does not (15). Thus in the present study, we focused our attention on the following: (a) structural identification of the Cr(V) species generated in the reduction of Cr(VI) by subcellular as well as cellular systems, using microsomes, mitochondria, and Escherichia coli; (b) possible detection of OH radical in the same systems since there is no earlier report of chromium-mediated generation of 'OH radicals in a cellular system; (c) possible involvement of molecular oxygen in chromium-related OH radical generation since a recent report (17) indicated that Cr(VI) mutagenesis is strongly oxygen dependent; and (d) elucidation of the mechanism of OH radical formation in these systems.

Mar 1, 1992

By N. S. Dalal, X. Shi

"Electron spin resonance (ESR) measurements provide evidence for the formation of Cr(V) intermediates in the enzymatic reduction of Cr(VI) by glutathione reductase (GSSG-R) in the presence of NADPH, indicating an initial single-electron transfer step in the reduction mechanism. Depending on the pH, at least two different Cr(V) species are generated which are relatively long-lived. In addition, we have detected the hydroxyl (·OH) radical formation during the GSSG-R catalyzed reduction of Cr(VI) by spin trapping, employing 5,5-dimethyl-1-pyrroline-N-oxide (DMPO) and a-(4-pyridyl-1-oxide)-N-tert-butylnitrone (4-POBN) as spin traps. Superoxide dismutase (SOD) causes only a minor effect on the ·OH radical and Cr(V) formation, indicating that the ~ - is not significantly involved in the reaction mechanism. Catalase enhances the Cr(V) formation and substantially inhibits the ·OH radical formation, indicating the involvement of hydrogen peroxide (H20 2) in the reaction mechanism. Addition of H20i suppresses Cr(V) and enhances the ·OH radical fonnation. Measurements involving N-ethylmaleimide show that the Cr(V) species, produced enzymatically by the reduction of Cr(VI) by GSSG-R, react with H2O2 to generate ·OH radicals, which might participate in the initiation of Cr(VI) carcinogenicity.INTRODUCTIONC(VI) compounds have been found to exert serious toxic and carcinogenic effects on humans and animals [1-4) and to cause mutations in bacteria and transformation of mammalian cells [5-8). In contrast, most Cr(lll) compounds are relatively nontoxic, noncarcinogenic, and nonmutagenic [9, 10]. Cr(VI) and Cr(lll) oxidation states are different in their metabolic pathways: Cr(VI) ions are rapidly transported across cellular membranes [2, 11-13), while Cr(lll) moieties do not easily penetrate cells and are not oxidized by cellular constituents [3]. Since it is known that the reduction of Cr(Vl) is required for its reaction with DNA [2], the molecular mechanisms for the intracellular Cr(VI) reduction have been the focus of studies during the past decade but the details are still not understood."

Jan 1, 1990

By N. S. Dalal, X. Shi

It has been known for more than a decade that vanadium (V) stimulates the oxidation of NADH by plasma membranes (1) but the underlying mechanism is still not fully understood. This effect has been attributed to a membrane-associated NADH-dependent vanadium (V) oxidoreductase (1). Subsequent studies suggest that vanadium ( V) can accept an electron from fiavoprotein dehydrogenase that oxidizes NADH (2). The phenomenon ofNAD(P)H oxidation coupled to vanadium(V) reduction has also been demonstrated in other biological systems (3-6). A recent electron spin resonance (ESR) study from our laboratory reported on the accumulation of vanadium (IV) duringthe reduction ofvanadate (vanadium(V)) by the ftavoenzymes glutathione reductase (GSSG-R),4 lipoyl dehydrogenase, and ferredoxin-NADP+ oxidoreductase in the presence of NAD(P)H (7). It was concluded therein (7) that these ftavoenzymes function as NAD(P)H-dependent vanadium(V) reductases. More recently, however, Liochev and Fridovich (8) have argued that the ESR data (7) do not demonstrate that the investigated fiavoenzymes act as vanadate reductases. They suggest an alternative mechanism in which the fiavoenzyme simply serves as a generator ofsuperoxide (02) radical, which acts as a propagator of the radical chain reaction leading to NAD(P)H oxidation (9, 10), as summarized below:

Nov 1, 1995