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By J Manuel, A Trudu

Regulations on the emission of particulates from sinter plant stacks are becoming increasingly stringent and reducing these emissions by improving gas cleaning systems is a significant cost to the sinter plants. This paper describes an investigation into the emission of particulate matter from an iron ore sinter bed during the sintering of a Japanese Steel Mill (JSM) style ore blend in a 300 mm diameter pot grate test facility. Several techniques were trialled to determine a reliable method to sample the quantity of dust emitted and determine the mechanism of dust emission from the sinter bed. The nature of the dust was also examined using chemical and size analysis as well as optical and scanning electron microscopy. The paper discusses the techniques used to carry out the program as well as results on dust loading measured during sintering and the nature of the dust captured.

Jan 1, 2002

By Jochen Petersen

Design and operation of heap leach processes are still largely based on,operator experience and rule of thumb. Although considered a low-cost, low-tech route for mineral extraction, the underlying physical, chemical and biological processes are actually rather complex. Numerous heap leach models have been devised over time, but the majority of these tend to simplify the true process and are of limited use in practise. The modelling approach presented here combines the more conventional reaction-diffusion model with models accounting for equilibrium reactions in solution, bacterial growth kinetics, complex reactions schemes, gas flow, heat conservation, etc. One particular model application is discussed in the context of developing a novel high temperature heap leach processes using thermophile micro-organisms. The complexity of processes such as this can only be appreciated with the aid of a systematic model. For the designing engineer an accessible, personal computer based model should be an indispensable tool for the design and optimisation of efficient heap leach operations.

Jan 1, 2002

By S Christensen

In August 2001 the Minister for Conservation declined an application by GRD Macraes for an access arrangement to enable work at the Globe Progress Mine near Reefton. In her decision, Ms Lee said:æI have considered whether potential compensation and the proposed safeguards against some of the adverse effects are sufficient to outweigh my concerns as to the loss of conservation values, consistency with the objectives of the Conservation Act, the purposes for which the land is held by the Crown and, to a lesser extent, the North Westland Regional Management Plan. I do not think they are sufficient. To my mind, my concerns as to the consistency with the objectives of the Conservation Act, the purposes for which the land is held and the loss of some conservation values in particular, outweigh any potential compensation and possible mitigation of adverse effects.Æ Commenting on the MinisterÆs decision Guy Salmon of the Ecological Foundation stated that the Minister should have invited the applicant to provide a 10 000 hectare pest-free wildlife sanctuary as part of the æpriceÆ for obtaining that access. However,æfor many people of green persuasion, it has become fashionable to say no every timeàthose who really have the well-being of the environment at heart, will want to look carefully at the bigger picture of environmental restoration needsàThe deciding criterion: the mining company should show that its involvement on conservation land would produce a net conservation gain. That is a criterion that creates the right incentives for win-win-win solutions on conservation land.ÆThis paper considers whether the concept of off site mitigation is one which fits within the current legal regime. Two questions arise:Can such mitigation/compensation be legally considered in access arrangements or required as a condition of resource consents? Is this a realistic option for industry to be pursuing?

Jan 1, 2002

By B D. Sowerby, N G. Cutmore

Improved process control can be achieved through the accurate and reliable on-line measurement of critical process parameters in real time. Over the past few decades on-line analysis techniques have been developed and applied in the mineral and energy industries for the measurement of process stream composition, mineralogy, particle size and flow rates. This has led to increased throughput and product quality while reducing processing costs and minimising emissions. The support of a sustainable mineral processing industry will require the further development of on-line analysis and control technologies. The application of developments in instrumentation combined with improved control strategies will lead to improvements in process efficiency resulting in large economic benefits to the industry, reduced energy usage and lower process emissions. There is a clear convergence of interests in being able to better measure and control minerals processing in terms of the triple bottom line of economic, social and environmental impacts. Technology is increasingly becoming available enabling measurement across the entire spectrum of minerals processing from mining to hydrometallurgy and pyrometallurgy. CSIRO is developing a range of these new technologies. A number of these developments are discussed in the present paper, namely: on-line particle size analysis and acoustic emission methods to enhance the control and optimisation of grinding circuits; on-line mineralogy of dry powders and slurries; on-line bulk elemental analysers for application on conveyor belts and in smelters; and the development of new sensing technologies for sorting base metal ores.

Jan 1, 2002

By A. V. Tarasov

The proposed process is based on creating a controlled frothed layer of molten slag, in which fine particles of carbonaceous reductant and raw material to be processed are mixed with emulsified iron. Frothing of the slag layer without external blowing occurs as a result of intensive evolution of gaseous reduction products. The froth reaction process is maintained due to the heat of an electric arc in the slag layer. When the metal bath is heated by the arc to 1400- 1 500°C, the low temperature of the slag surface of about 1200-1 300°C is maintained due to low thermal conductivity of slag froth preventing heat loss. In order to maintain the required slag froth level and control the process temperature, air tuyeres are installed above the slag bath; blowing air serves also for oxidation of zinc in fumes and for its transportation. High adsorption and thermal insulating properties of slag froth ensure virtually complete elimination of dust and mist entrainment along with low heat losses. The main macrokinetic regularities of the carbon thermal reduction of zinc-containing slag melts have been studied under frothing conditions. The mechanism of formation of gas-slag emulsion has been identified under the conditions of reaction [C]+[O]=CO occurring locally at the slag-metal interface. It has been demonstrated that under the froth reduction conditions the zinc removal rate from the melt increases on the average by 3 to 5 times. Based on the physical and chemical data obtained, basic principles of the dezincing technology have been developed for different intermediate oxide iron-containing products produced in the process of ferrous and non-ferrous metals production.

Jan 1, 2002

By Stefan Mutz

In Germany the automobile recycling is regulated by law. Current legislation requires that by the year 2015, eighty five w.-t. % of the components from used cars ill be materially recycled. Whilst for 10 w.-t. % of the materials a thermal utilization is certified, there are still some concrete questions that remain unanswered regarding the usability of single fractions. The recent innovative approaches to the concepts of used cars dismantling do not alter the fact that the majority of the materials of used cars still have to pass over the shredder and the connected processing aggregates. The status of the so called SLF (Shredder light fraction) which is about 25 w.-t. % w.-t. in used cars, has not been satisfactorily clarified. Furthermore questions still remain regarding the separation of the NMSF (nonmagnetic metal shredder fraction) which has to be separated in the single metallic fractions like stainless tell, copper, brass, zinc, etc. Attempts of optimization can be found. This paper analyses some of the difficulties being encountered by the automobile recycling industry in Germany, before reviewing some of the innovative approaches that the industry has introduced. Finally the paper goes on to describe the potential of automatic picking. Examples of a series of tests, utilizing this technology, in which a variety of products from a range of shredders were isolated are described in detail. This new technology provides a range of applications to the automobile recycling industry.

Jan 1, 2002

By David B. Dreisinger

Mass and heat balance modeling is a powerful tool for the design and analysis of hydrometallurgical process flowsheets. In this first of two papers, we examine the basic fundamentals of mass and heat balance modeling, and apply these concepts to several flowsheets using a simple spreadsheet model. In this way, we aim to demonstrate how such models are not only easy to construct, but can also be indispensable for comparing various flowsheet alternatives, for making rational economic decisions, and for developing a basic understanding of existing process behaviour.

Jan 1, 2002

By Hassan El-Shall, M. N. Ahmad, Ponisseril Somasundaran, C. R. Holland, G. M. Walker, N. Iles, R. D. Chandler, Regis Stana, B. Duddy, Patrick Zhang

Phosphoric acid is a major raw material for the production of ammonium phosphate (AP) that is used as an intermediate in fertilizer production. Impurities within commercial grade wet process phosphoric acid are important in producing a fertilizer granule with good handling properties. The impurities identified as being important are; iron (III), aluminium and fluorine-containing compounds. Results show that the viscosity of the AP slurry produced increases by increasing the amount of impurity in the acid. Bench scale tests have been successfully replicated on a plant scale leading to a better understanding of the composition of impurity levels within phosphoric acid required to produce a high quality, free flowing, hard, spherical and non-caking granular fertilizer.

Jan 1, 2002

By M Fisher, P Bradley, D Rogers

New England Antimony Mines has operated the Hillgrove Gold Plant at Hillgrove in New South Wales since 1969, producing stibnite and arsenopyrite products by selective flotation. Gold is present in the ore as fine free gold, gold associated with stibnite and gold associated with arsenopyrite, with some ten to 20 per cent of the gold reporting to the antimony stream and 35 - 50 per cent reporting to the arsenopyrite stream. Opportunity to process the arsenopyrite concentrate for onsite recovery of the gold values to improve upon the ten per cent recovery achieved by conventional cyanidation was recognised and subject to comparison with biological oxidation, roasting, nitric acid oxidation, low temperature oxidation (Activox«) and conventional pressure oxidation. Following further testwork and a feasibility study, a 7500 tonnes per annum concentrate feed pressure oxidation autoclave circuit was constructed at Hillgrove and commissioned in October 1999. The plant has operated at the close to design capacity since commissioning whilst optimising various operational and metallurgical aspects. The last three years has seen the process achieve an overall gold recovery of greater than 90 per cent for oxidised concentrates.

Jan 1, 2002

By A Cornelius, P Connor, S Fraser

Iron ore mining is a major source of export income for Australia. However with the decreasing reserves of high-grade, low-phosphorus hematite ore, there is mounting pressure to provide consistent mineralogical ore grade. Enhanced 3D characterisation and modelling are crucial to respond to these exigent requirements. To tackle this problem a revolutionary mine-based, imaging system (based on Visible Near Infrared û Short Wave Infrared reflectance spectroscopy û VNIR-SWIR) has been developed. This innovative, CSIRO-built prototype produces mineralogical maps that will have a major impact on ore grade characterisation. Australian iron ore companies will benefit immensely by pioneering this emerging and unique mining technology. The significance of VNIR-SWIR reflectance spectroscopy is well demonstrated with field portable spectrometers and airborne hyperspectral systems. At the mine-scale level, this newly developed imaging system will allow accurate and objective mineralogical mapping of mine faces and benches with very closely spaced sampling. These spectral mineral maps will improve deposit delineation and bring accurate and objective ore grade characterisation that will minimise drilling and enhance ore recovery. This will in turn lead to cost saving and better long-term block model planning. This system will also improve safety for mine geologists in providing mineralogical information at a distance, avoiding the need for any close contact with the mine face. The mine imaging concept is a logical response to the industry need for automatic and objective tools for sustainable and future mining practices.

Jan 1, 2002

By J. A. Finch

"A method of sampling and presenting bubbles for imaging for use in full-size flotation cells is described. The device (bubble viewer) comprises a tube attached to a sealed glass viewing chamber. The assembly is first filled with frother-containing water (to prevent coalescence) and the tube immersed at the desired location below the froth. For a few minutes bubbles are collected in the viewer free from slurry and are readily imaged. To reduce bubble overlap and the problem of defining the plane of view, the viewing chamber has a sloped side. Bubbles rise, encounter this slope, spread into a single plane and slide up. This simple expedient virtually eliminates overlap and provides an unambiguous focus plane - the underside of the sloped glass. The bubble image is captured and processed to give size data. The bubble viewer has been employed at several concentrators on different types of flotation cells. Examples of the images are given. The impact of position in the cell and the effect of changing gas rate on bubble size are illustrated. This technique provides a sensitive measure of the effects of process variables on bubble size.INTRODUCTIONDespite the extensive use of flotation in the mineral processing industry, the methodology employed for cell design is largely based on empirical rules rather than on first principles. One of the main reasons for this state of affairs is that the local flow structures encountered in industrial-scale machines are very complex. These flow structures are difficult to simulate under the controlled conditions of the laboratory and the difficulty to solve the mathematical models that treat the randomness of such flows also mean theoretical treatment is limited. Understanding flotation cell hydrodynamics requires reliable data, which involves the implementation of measurement techniques capable of performing both at the laboratory- and the industrial-scale, In addition, it is desirable that such techniques are amenable to automation to reduce extensive manual intervention in the data collection process."

Jan 1, 2002

By M. E. Kuchta

Research is currently being conducted at the Colorado School of Mines in the use of high-pressure water for scaling down loose rocks in underground mine openings. In addition to improved miner safety, the adhesion strength of shotcrete applied to rock surfaces treated with high-pressure water is also increased significantly resulting in improved overall support capabilities of the shotcrete layer. Test results show an increase in adhesion strength by a factor of four on a concrete test wall cleaned with water at 21 Mpa (3000 psi) as compared to a surface cleaned at 0.7 Mpa (100 psi).

Jan 1, 2002

Newcrest Mining Limited (NML) owns and manages the Ridgeway Gold Mine (RGM) located outside Orange in the state of New South Wales. RGM is a new underground sublevel caving (SLC) operation that is ramping up production to 4 Mtpa. The success of the SLC method at RGM is strongly influenced by production drill and blast practices. Distinguishing features of the Ridgeway SLC operation include choke blasting against broken rock, drawpoint brow preservation, loading of blastholes with different in-hole bulk emulsion densities, precharging of production rings and routine drawpoint fragmentation assessment. These areas are described in the context of RGMÆs required blasting objectives, production drilling and charging activities and innovative practices.

Jan 1, 2002

By S. J. Ramokgopa

The development of the modern State and the growth of capitalism involves a complex process of interaction between cross-cutting structural dimension: first between politics and economics and, second, between market and hierarchy. Central to such developments are political economies of scale. Mineral specialization in the Third World developed within the framework of an international extension on oligopolistic structure of the advanced capitalist economies of Western Europe and North America. Up to the late 1960s, the world mineral and metallurgical industry was closely controlled by a handful of Western mining and industrial groups. To the extent that, foreign control of the mining sector was seen in the Third World producing countries both as the essence of foreign domination and as its major symbol. In some newly industrializing countries, the State took a more direct role in tying the economy and society together. Central to this process was the growth of large-scale finance capital. From early 1959to the mid-1970s, metal consumption in industrial countries expanded well beyond their domestic mineral endowments. And a free access to Third World minerals was a major element of the economic dynamism of these countries throughout that period. With the change in the characteristics of international investment, Africa has become less important as an outlet for capital exports of European countries. Actually, the African continent now receives only a very minor share of direct foreign investments of Western enterprises. International political economy is concerned first of all with the relationship between the economic and political domains across territorial boundaries. Second, attention should be drawn to the role of the State as the focus of decision-making in a system of competitive States, that is in turn, interdependent with a trans-national market economy in which mining and metallurgy are essential activities that affect the politics of the State, and how this in turn, rebounds on the politics of the international system. Understanding the role of the State must go beyond the glib pronouncements on the ?national interest?. How, and whose interest, the ?national interest? is determined, is precisely the problem. This implies a third theoretical problem that must be addressed: the linkage between the domestic and international domains (or levels of analysis), given that political-economic processes clearly cut across the lines of political decision-making constituted by the institutional structures of the State. Situating the State and economic interests within this vast ?state-society? complex that we call the global order will be a crucial problem for any theoretical approach that involves mining and metallurgy.

Jan 1, 2002

By S. Surapunt, C. M. Nyamai, K. Itagaki

"The use of liquid copper as a medium for zinc extraction has been used in the Warner Process as a method of processing zinc-lead sulphide ore. The recovery of zinc metal is based on the reaction:ZnS(s) + 2Cu(l) = Zn(g) + Cu2S(l)In this method, thermodynamic and phase equilibria investigations of the Cu2S-FeS-ZnS and Cu2S-PbS-ZnS systems are of importance and form the basis for the liquid sulphide phase which appears as a product and is used as a solvent in the Warner Process. Phase relations in the Cu2S-FeS-ZnS and Cu2S-PbS-ZnS ternary systems were determined experimentally at 1473°K to provide a fundamental basis for the new zinc smelting process. The results show that the solid solubility of ZnS in the two systems is very small (2 wt% to 3 wt% ZnS in FeS, 4 wt% ZnS in Cu2S for the Cu2S-FeS-ZnS system; less than 0.5 wt% ZnS in both PbS and Cu2S for the Cu2S-PbS-ZnS system). The Raoultian Activity Coefficient of ZnS in the liquid mixtures and the vapour pressure of zinc over the matte in both systems is relatively large (?° = 7.7 – 15.8, Pzn(atm) = 0.088 – 1.026 for the Cu2S-FeS-ZnS system; ?° = 8.9 – 12.9, PZn(atm) = 0.075 – 0.214 for the Cu2S-PbS-ZnS system). On the FeS-ZnS join, the only phases detected are FeS and iron-rich sphalerite (Zn, Fe)S. The binary join mixture occurs at about 92 wt% FeS-8 wt% ZnS at 1473°K. Electron microprobe examination of the quenched samples indicate about 47 wt% to 48 wt% FeS in sphalerite and about 2 wt% to 3 wt% ZnS in the iron sulphide phase. On the Cu2S-ZnS join, microprobe analysis reveals that the maximum solubility is 4 wt% Zn in liquid Cu2S and 3.6 wt% Cu in solid ZnS. In the Cu2S-PbS-ZnS ternary system, microprobe analysis of the quenched samples indicate on average, 5 wt% ZnS in the liquid phase region. The only phases detected on the PbS- ZnS join are ZnS and PbS. The eutectic phase contains, on average, 13 wt% ZnS. The phase relationships, very low solid solubilities of zinc sulphide in the liquid mixtures of both Cu2S-FeS-ZnS and Cu2S-PbS-ZnS systems, coupled with the high Raoultian Activity Coefficient of ZnS as well as the high vapour pressure of zinc over matte all favour the partitioning of zinc metal into the vapour phase. This new process is cost effective and bypassesthe expensive and tedious conventionaltechnique of zinc production involving oxidationof the sulphide ore by roasting followed bya reduction process to extract the zinc. Theresults indicate that a new zinc smelting technologyusing the Warner Process would bemore efficient and preferable over the traditionalmethods of zinc extraction."

Jan 1, 2002

By Todd M. Ruff

Researchers at the National Institute for Occupational Safety and Health are investigating technologies that could be used to detect objects, small vehicles, and pedestrian workers that may be in the blind areas of haulage equipment used in mining and construction. A detection system that warns the equipment operator that there is an obstacle nearby could prevent collisions and save many lives each year. One popular technology for collision warning systems is radar. Several different types of radar have been tested in the laboratory and on mining equipment. Early in the study, questions arose concerning the best way to test radar systems. Many factors affect the performance of radar, including the size, shape, and composition of the object that is to be detected; the height of the radar antenna(s); and the relative motion of the radar system and/or object. This report discusses several different test procedures and test targets and recommends methods to determine how effective a radar system will be in detecting a person near heavy equipment.

Jan 1, 2002

By D. Mishra

Electric arc furnace dust (EAFD) generated during the recycling of steel- scrap is classified as a hazardous waste for landfilling. This is because it contains leachable heavy metals such as zinc, lead,... Recovery of these metals could result in both resources conservation and resolving waste disposal problems. A study of the thermal reduction of a sample of EAFD was carried out in an inert gas atmosphere using coke as a reducing agent. Preferential volatilization of zinc and lead was achieved during the reduction process at about 800 "C. More than 96 % of both zinc and lead were removed from the dust and were recovered in the condensates. The treatment residue was essentially composed of iron oxides and almost free from heavy metals.

Jan 1, 2002

Over years of exploration the massive and tabular orebodies in the area to the South West of Western Areas Gold Mine had been assessed as containing about 50 million ounces of gold û a world class orebody. Planning initially was for a surface and subvertical shaft system to exploit this area but because of cost, a single lift shaft to an area which could be accessed ex Western Areas was planned to intersect the reef at 2760 metres. It was also planned to mine out the shaft pillar area long before the deep shafts would reach that position. This is not the normal practice in South African Gold Mines. The stoped out shaft pillar was backfilled to minimise movement in the shaft sites. The result of a competitive tender/adjudication process was that Cementation Mining û Skanska won and was awarded the R192 million contract to sink the Main and Ventilation Shafts on 15 June 1995. On 1 April 1999 Western Areas and Placer Dome SA formed a Joint Venture, which now owns and operates the mine on which the South Deep Shafts are situated. This situation prevails today.

Jan 1, 2002

By Henk Dijkman

Existing metallurgical operations can be optimized by implementing engineered bioreactor systems in the process configuration. For instance, metals can be recovered safely and economically from process and waste streams using biogenic sulfide. This paper focuses upon possible applications of high rate biotechnology in metallurgy and mining. Metal recovery from liquid streams (process bleed streams, leach water, waste streams), integrated removal of (fugitive) SO2, treatment of acid blowdown and other options will be described. Practical examples are given. A large-scale application of biotechnology at Pasminco's Budel Zink refinery is described. Here, acid plant blowdown is treated together with electrolyte magnesium bleed. Concentrated zinc sulfide (10 tpd) is produced biologically, eliminating the production of gypsum and closing the refinery sulfur cycle. Recovery of metals from solution at Kovehute Pribram in the Czech Republic is the second practical example. In this case, H2S is produced on-site for metal removal from an alkaline slag dump leachate. At the Caribou mine in New Brunswick, Canada, acid mine drainage is treated with biogenic sulfide. This plant is situated upstream of a lime neutralization plant. As a result, reusable ZnS is produced, the volume of the sludge (gypsum and hydroxides) from the lime plant is reduced by 50%, the sludge is free of heavy metals and the final effluent concentration of heavy metals is in the ppb range. In the second phase of this project, metals will be recovered from stored tailings, resulting in significant revenues.

Jan 1, 2002

By C. R. Edwards

"The Cigar Lake project will develop the world’s second largest high grade uranium deposit. The Cigar Lake Phase 1 orebody contains approximately 226 million pounds U3O8 at an average grade of 20.7% U3O8. The mine, to be operated by Cameco Corporation, will use a unique water jet boring mining method to cut previously frozen ore. A distinctive ore handling design is required to handle the high grade ore slurry exiting the mining machines. The ore will be crushed and ground underground, with the ore slurry then pumped to surface. Loaded into purpose-designed containers on tractor-trailer units, the ore slurry will be trucked to Cogema Resources Incorporated’s McClean Lake mill. McClean Lake will leach all of the ore. Forty-three percent of the resulting uranium solution will remain at McClean Lake for processing into yellowcake. The other 57% of the uranium solution will be shipped to Cameco’s Rabbit Lake mill for processing into yellowcake there. Detailed design for the Cigar Lake project is now underway. Barring regulatory or market delays, production could start up as soon as early 2005.INTRODUCTIONThe Athabasca Basin in northern Saskatchewan hosts a number of large uranium mining and milling operations, including Cluff Lake, Key Lake, McArthur River, McClean Lake and Rabbit Lake. (Edwards 1988, Edwards 1992, Fielder 1998, Edwards and Oliver 2000, Edwards 2001) The latest project in the Athabasca Basin is the Cigar Lake project."

Jan 1, 2002