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By F. Robert Hubbard

IMCO Recycling Inc. has developed a new, patented technology for the production of fertilizer, K-SOIL?, as a by-product of its aluminum recycling operations. This new technology can substitute for conventional technology which now results in a saltcake residue that is placed in 'landfills. Four years of research and development work by IMCO culminated in a U. S. patent issued April 5, 1994. As part of the technology development effort, IMCO engaged the services of a nationally renowned research organization and a prominent university. These two organizations have conducted in-depth agronomy studies In the laboratory, greenhouse, and the field. Results have shown K-SOIL? to be performance equivalent, on a nutrient content basis, to conventional potash fertilizer. The first field applications on commercial farms were made in the spring of 1994. K-SOIL? is a potassium-bearIng, granular solid which may find use in fertilizer blends, direct application, and other forms of fertilizer products. The overall benefit of this new technology is to create a useful by-product rather than generate a useless residue and, thereby, reduce or eliminate the amount of salt cake now placed in landfills. As such, It is a significant, step toward IMCO's ultimate goal of complete recycle.

Jan 1, 1995

By A. E. Ketler

Optical smoke monitoring fills an important gap in ventilation and fire safety: namely monitoring of smoky, low temperature fires where little CO and heat are generated. Smoke monitoring also avoids the nuisance alarms due to diesel exhaust, battery chargers, blasting and welding. The smoke optical density (OD) fire alarm standard specified by MSHA presents an opportunity for improved safety. Experience of actual mine usage of the SmokeBoss*100 is reviewed, with particular regard to effectivity, maintenance and cost.

Jan 1, 1995

By P. R. Taylor

Diamond films have been successfully formed in an inductively coupled plasma (ICP) chemical vapor deposition (CVD) system from several gas mixtures: CH,-H,, C2112-112, and C2112-112-02' Our previous thermodynamic study indicated that the substrate temperature could be lowered by the presence of oxygen species at moderate system pressures (0.3-0.5 atm) and that higher volumetric growth rates required a high temperature source and a moderate pressure system in CVD processing. The principal experimental results were consistent with the thermodynamic predictions. The deposited films were characterized by laser Raman spectroscopy, scanning electron microscopy, and X-ray diffraction. The films were well faceted and uniform, with the growth rates over 10 pm/hr on molybdenum substrates. The crystal size ranged between 1 and 2 microns for a two hour experiment. It was possible to decrease the substrate temperature to below 800 °C in this system.

Jan 1, 1995

By B. A. Wills

Much research effort has been spent in attempting to reduce the high energy costs in grinding, but relatively little in developing methods to enhance the liberation of the minerals from each other. This paper presents some ideas on the nature and role of grain boundaries in mineral assemblies, and their influence on the propagation of cracks through the rock. It is argued that if the mechanisms of fracture are more clearly understood, crack propagation may be controlled in such a way that intergranular fracture dominates breakage, producing less fines and a higher degree of liberation.

Jan 1, 1995

By A. W. Khair

This paper deals with the evaluation of the interaction between rock and the cutting tool, and with methods for determination of workability, and abrasivity of rock. A description of instrumentation is included along with research on the wearing process of bit tips and pick consumption. Analyses of bit rotation, evaluation of cutting, normal forces and energy consumption is presented. Finally influence of the basic water jet parameters and water jet assistance on the cutting process of hard and abrasive sandstone is discussed.

Jan 1, 1995

By Brian H. Zelenko, Patricia M. Perry

INTRODUCTION The environmental requirements of the next section of Washington, D.C. METRO subway tunnels present unique challenges to the Contractor. The 14th Street Tunnels contract includes twin 975 m (3200 linear ft) soft ground tunnels. A stringent environmental soil and groundwater monitoring and free product recovery program was specified by the owner. A project-wide dewatering program hinges on satisfactory completion of the environmental requirements. Implementation of the Contractor's environmental program is discussed, including the pros and cons of the program, as they relate to progress of the project. Environmental issues on tunneling projects have become an important part of the urban tunnel construction process. Delays associated with environmental issues can have a major cost impact on tunneling projects. This paper will discuss the first of five Washington Metropolitan Area Transit Authority (WMATA) tunnel and station contracts awarded in 1994. These contracts are part of WMATA's Fast Track Plan to complete the original 166 km (103 mile) system by 2001. As such, stringent environmental requirements have been specified as a part of these contracts to limit delays associated with local regulators in order that the tunnels may be constructed on schedule.

Jan 1, 1995

By N. Menad

Thermal treatments of five different types of non-ferrous metallurgical wastes, under controlled atmosphere, were carried out at temperatures lower than 800 °C. The aim of these treatments was to reduce the toxic elements content and to increase that of valuable metals in the residue. <Best results were obtained by their treatments in air or hydrogen or successively both of them. Simple treatments using air or hydrogen of three samples allowed the elimination of more than? 95 % of their toxic elements and&apos; almost doubled their valuable metals&apos; concentration. For the rest two samples, combined treatment was necessary for their efficient decontamination and the concentration of valuable metals, in the treatments residue, to a reasonable value. Most of the solids issued from these treatments can be recycled in .the current non-ferrous metallurgical processes.

Jan 1, 1995

By N. O. Lotter

Evaluation errors and value frequency distribution models of the gold ore bodies in the Witwatersrand and Free State systems are reviewed. It is found that the low-grade sections of the data are prone to the largest evaluation errors, and that an understanding of the shape of the value frequency distribution is essential to the calculation of mean grade. The evaluation of a mineral process for a particular ore requires attention to mil-feed sampling, sample processing, and monitoring. In particular, the calculation of a representative mass of mill-feed sample (Ms) should take account of size-by-size value variance. Alternative Ms models are discussed.

Jan 1, 1995

By M. W. Rutland, E. Manev, R. J. Pugh

Data collected from several different fundamental surface chemical techniques were compared to study the interfacial interactions in the dodecylaminelmica flotation system. In the present study, the method used was the microinterferometric free foam film technique of Scheludko (1967) in which the stability, thickness and interfacial potentials at the air/dodecylamine solution interface were determined. These results were compared to previously published data, obtained from surface force measurements (Rutland et al. 1992), in which the interaction and hydrophobic adhesion (pull-off force) between molecularly smooth mica sheets in the amine solution had been reported. Also equilibrium contact angle measurements were used for comparison. The data was collected over a range of pH values and related to the batch flotation response of mica in dodecylamine solution. It was found that maximum flotation occurred at pH 8, but this did not correlate with the minimum in double layer interaction potential. However, it appeared to correspond with a tightly packed collector monolayer giving maximum hydrophobicity to the mica surface. Finally, from the extended DLVO theory, it was shown that heterocoagulation between the bubble and the mica could only occur, providing there was a very long range hydrophobic interaction force to counterbalance the repulsive van der Waals and electrostatic forces.

Jan 1, 1995

By M. Akser

Ilmenite, rutile, and zircon deposits of commercial importance have not been reported to-date from Turkey. However, information from recent reconnaissance activities indicates the possibility of an economically viable heavy-mineral deposit along the Black Sea coast of Turkey in the vicinity of Ormanli, northwest of Istanbul. Consequently beach and sand dune samples were collected from that area for additional analysis. Laboratory methodologies, designed to simulate standard industrial heavy-mineral plant practices, were used to analyze and evaluate the samples. Based on the analyses, and current market needs, none of the deposits in the Ormanli area qualify as a commercial heavy-mineral deposit.

Jan 1, 1995

By C. A. Young

The remediation of cyanide (CN-) and nitrate (NO)-) anions in mine and agricultural waters by various photolytic methods has been reviewed and investigated. Photolytic methods such as direct photolysis, homogenous photolysis, and heterogeneous photocatalysis are briefly described and compared. Results and discussions show that each method has certain advantages and disadvantages. For each method, Eh-pH diagrams prove useful for determining reaction mechanisms. Preliminary results obtained for cyanide oxidation and nitrate reduction show that homogeneous photolysis can be superior due to faster kinetics than the other methods. The photolytic methods were individually, not simultaneously, tested and compared. Differences in concentrations of products were obtained and attributed to differences in photoconversion efficiencies and other inherent characteristics of .the photolytic methods. Various reaction mechanisms are proposed in accordance with the literature as well as measurements obtained from solution analysis using ion selective electrodes and ion chromatography .

Jan 1, 1995

By Carl C. Nesbitt

A process has been developed to recover and recycle metals from wastes of brass foundries which contain copper, zinc and lead in various quantities. Tests were conducted to evaluate several leachants, including sulfuric acid, ammonia, hydrochloric acid, cyanide and acetic acid, and to determine the optimum leaching conditions, such as air flow rate, initial copper ion concentration, temperature, and agitation strength. Sulfuric acid containing copper sulfate with dissolved oxygen is the most successful leachant. More than 99% of the copper and zinc originally present in the waste was dissolved, while only 0.5% of the lead entered the solution after 14 hours of leaching. The leaching mechanisms of copper, zinc, and lead are proposed. The copper and zinc can be recovered from the solution by electrolytic processing. The unleached residue may be converted to a lead carbonate which can be converted to litharge at 400-450°C and to massicot at temperature above 500°C by calcination.

Jan 1, 1995

By S. E. El-Alfy, John Starkey

"The Iron Ore Company of Canada treats up to 125,000 t/d of iron ore at its Carol Concentrator in Labrador City, NF.A complete water balance study in the concentrator was done to show how to reduce the consumption of fresh water, to improve metallurgy in the magnetic separation (mag) plant, and to help reduce maintenance costs for the reclaim water and tailing pumping systems.The study showed that more than 60% of the water used in the mill was internally recycled dirty water from dewatering cyclone overflows, and that water reduction was closely tied to the effective use of these internal reclaim pumping systems. In addition, new operating parameters were set for the 4 -15,000 USGPM reclaim water pumps which should save over $100,000 per year in maintenance costs.IntroductionThe study described in this paper was set up for the purpose of lowering water usage in the concentrator, and to reduce tailing and process water pumping costs (operating and maintenance). Another benefit was also expected, namely, to improve magnetic separation efficiency through better water and density management of magnetic separator feed streams.The procedures selected to perform this work were: ( 1) to prepare accurate, as built flowsheets of the entire iron recovery process, including fresh and process water systems, (2) to calculate normal material balances in all circuits at full production, (3) to use the computer spreadsheet model so generated, to evaluate specific ways to reduce water consumption and (4) to re-evaluate metallurgical performance and operating parameters in the light of this information.Overall control of the 28 spiral iron recovery lines was found to be excellent because automated start up and shut down of the individual lines had been incorporated in the design from the start. Because production rates can vary due to sales requirements, mine and mill maintenance delays and hardness variance, the mag plant (which treats spiral tailings) must deal with a wide variety of operating conditions. Good water management therefore is a key item in achieving high recovery of the fine free magnetite which is too fine for recovery in the spirals.In order to make the study as accurate as possible, process data for major flows was reviewed by metallurgical staff and then by mill supervisors. The operating picture of the concentrator so generated was judged to be a good estimate of the mill at full production. By changing key inputs, the variance of process water demand and tailing slurry produced for several other operating conditions were studied.The usefulness of this exercise has prompted this present presentation to be made. Older plants by nature have undergone many revisions as operators have worked through ore changes, market changes, labour cost increases and the availability of new equipment, to improve their operation. Sometimes therefore it is necessary to stop and reassess what is happening in a plant in order to continue the never ending work of process optimization. The techniques used here were ideally suited to the gravity/magnetic concentration flowsheets used, but there is no reason why similar studies could not be done in other process plants.The authors of this paper hope that this experience at IOC will be helpful to others who face similar challenges in the pursuit of excellence in their processing plants."

Jan 1, 1995

By Omar A. Muhtadi

Brohm Mining Corporation, in conjunction with Geobiotics, Inc. has nearly completed a pilot heap biooxidation test on sulfidic ore from the Gilt Edge Mine near Rapid City, South Dakota. Some results from the pilot testing have shown the correlation between the extent of biooxidation and the increase in cyanide gold recovery seen in the laboratory. Bench scale testing showed approximately a 1: 1 correspondence between percent biooxidation and percentage increase in gold recovery. The economics of large scale biooxidation were also evaluated in terms of increased gold recovery versus the time and cost of biooxidation. In the pilot test, the rate of biooxidation became limited by the acid water neutralization system. Later in the test, measures were taken to overcome this problem. Results from bench scale column bioleach testing showed that the Gilt Edge sulfide ore is quite amenable to biooxidation with a substantial increase in gold recovery with just partial biooxidation. Direct cyanide gold recovery of 51 % on ore crushed to -3/8" was enhanced to 82-85% after oxidation of37% of the sulfide as measured by iron. Laboratory experiments also showed that the slow rate of biooxidation of this ore could be accelerated by removal of metal sulfate build up from the leach liquor. The combination of these normally non-toxic metals became inhibitory to biooxidation if not removed by the neutralization circuit.

Jan 1, 1995

By G H. Clark

Batu Hijau is a porphyry copper-gold deposit located onSumbawa Island in the western Banda Arc of Indonesia. The deposit has been evaluated from 54 000 m of drilling in 105 diamond drill holes over a surface area of 1.2 km2 and to a depth of 1000 m below surface (412 m below sea level). A provisional plan is being evaluated to mine 642 million tonnes at an average grade of 0.61% Cu and 0.55 g/t Au (variable cut-off) from an open pit in the higher grade portion of the resource. &nbsp; The deposit is associated with a calc-alkaline intrusive complex that was emplaced in a thick sequence of andesitic pyroclastic rocks. The oldest and most widespread intrusion is porphyritic to medium-grained, equigranular, quartz hornblende diorite. At Batu Hijau the western diorite contact zone was intruded by two phases of tonalite. The older tonalite is a stock increasing from 200 m diameter at surface to 500 m at sea level. It consists of quartz, plagioclase and hornblende phenocrysts set in a groundmass of similar composition. A younger tonalite intrudes the tonalite stock, quartz and plagioclase phenocrysts are more abundant and it has a finer groundmass than the older tonalite. Brecciation occurs near the older tonalite contacts but there are no breccia pipes or late-stage features such as pebbledykes or postmineralisation intrusive rocks. &nbsp; Hydrothermal alteration of Old Tonalite and adjacent rocks is centred on the Old Tonalite and is zoned from a core of pervasive potassic alteration grading to an outer propylitic halo. At depth a propylitic assemblage is developed in the low grade core in the Old Tonalite. Phyllic alteration, late stage and mainly fracture controlled, overprints both potassic and inner propylytic zones. Intermediate argillic alteration overprinting is widespread, particularly on the eastern side of the hydrothermal system, where advanced argillic alteration overlies argillic alteration. &nbsp; Ore grade mineralisation is cylindrical in shape, up to 800 m in diameter, and is centred on the Old Tonalite. A high grade shell (&gt;0.75% Cu) forms an upward tapering cone in and around the Old Tonalite and reaches the surface in the centre of the deposit. Lower in the shell &gt;l g/t Au and &gt;2 g/t Ag accompany &gt;1% Cu. Below 75 m above sea level mineralisation in the Old Tonalite rapidly decreases as a weakly mineralised core develops, but the limb continues to contain mineralisation to at least 412 m below sea level. Fracture and vein-controlled chalcopyrite and bornite are the dominant hypogene copper minerals and are the hosts for most of the gold mineralisation. Gold occurs free and in the lattice of the copper sulphides, and has been observed in quartz. &nbsp; Weathering, especially where argillic alteration is developed, has produced a strongly leached cap, up to 147 m thick, below which is an irregular copper enriched supergene zone. Where leaching is not developed, such as over the centre of the deposit, an irregular oxide zone and a weakly developed supergene zone may be present.

Jan 1, 1995

By Ari I. Kogut

Impurity minerals in fluorspar ores and concentrates from a deposit in Southern Africa have been studied by reflected light, transmitted light, and cathodoluminescence microscopy. The principal impurities are quartz, calcite, aegirine, apatite, ankerite, magnetite, goethite, and synchysite [Ca(La,Ce,Nd)(C03l2Fj. Cathodoluminescence microscopy was found to be very useful in studying the character of the fluorite and especially for recognizing the presence of apatite and calcite impurities. Fluorite exhibits blue, calcite shows yellow, and apatite has white, light purple, and pink cathodoluminescence. The cathodoluminescent character of apatite varies with its geological environment and position in the orebody. The results of this microscopic study show that phosphorus present in flUorite concentrates occurs principally in binary locked apatite-fluorite particles. Successive fluorite cleaner concentrates contain progressively smaller amounts of locked apatite-fluorite particles. Free apatite has been effectively partitioned to the final tailings.

Jan 1, 1995

By W. H. Jang

Although surface chemistry fundamentals of semi-soluble minerals have been studied by many researchers, detailed understanding of these systems is still incomplete. In-situ FT-IR/IRS techniques have recently been used to successfully describe the adsorption of carboxylates at semi-soluble mineral surfaces. However, the wetting characteristics of these adsorbed films require further consideration. In this regard, the hydrophobicity and stability of transferred Langmuir-Blodgett (LB) monolayers of fatty acids at fluorite and calcite surfaces has been studied by contact angle measurements with polar and apolar liquids. Generally, it was found that the transferred LB monolayers of fatty acids at a calcite surface are unstable whereas such monolayers transferred at a fluorite surface are stable, as revealed from advancing and receding contact angle measurements. These results are believed to be due to the incomplete reaction of fatty acid monolayer at the calcite surface. In addition it was found that a closely packed well-ordered stearate monolayer with good hydrophobicity, equivalent to that of a transferred LB monolayer, can be formed at fluorite surfaces by spontaneous adsorption and self-assembly from aqueous solutions.

Jan 1, 1995

By J. M. Newell, G. R. Peatfield

"The Red-Chris porphyry Cu-Au deposit is located between Ealue and Kluea lakes, southeast of the village of Iskut on the Stewart Cassiar highway in northwestern British Columbia. It was explored by Texasgulf Inc., in a joint venture with Great Plains Development Company of Canada, Ltd. and Silver Standard Mines Ltd., during the period 1973 to 1980. Exploration resumed in 1994, following acquisition of the interests originally held by Texasgulf and Great Plains Development by American Bullion Minerals Ltd.Prospectors were first drawn to the area by prominent limonitic stain zones exposed in creek gullies in the western part of the property. These zones are developed on the alteration halo at the western periphery of the deposit. The potential ore zones do not crop out and were first exposed in a bulldozer trench excavated in 1971. Subsequent exploration was by percussion and diamond drilling, guided to some extent by induced polarization surveys. In 1976, estimated resources contained within two crudely designed open pits were 41 million tonnes with an average grade of 0.56% Cu and 0.34 g/t Au, with a cutoff grade of0.25% Cu. New resource estimates based on a major drilling program completed by American Bullion in 1994 were released as this paper goes to press. These estimates were calculated using various copper cutoff grades; at the 0.4% Cu cutoff, the ""in-situ geological reserve"" is given as 100 million tonnes grading 0.58% Cu and 0.46 g! t Au (American Bullion Minerals Ltd., 1995).The deposit consists mainly of pyrite, chalcopyrite and increasing bornite at depth, in zones of quartz-vein stockwork hosted by an elongate body of altered monzonite porphyry of latest Triassic or earliest Jurassic age. The stock intruded volcanic and sedimentary rocks of probable Stuhini Group affinity and is in faulted contact with sedimentary rocks of the Jurassic Bowser Lake Group. Gypsum stockworks are developed in the higher levels of the subvolcanic porphyry system. Late-stage quartz-carbonate veins carry small amounts of galena and sphalerite. Complex faulting within the deposit makes drill-hole correlations difficult. Alteration assemblages include an early potassic phase, almost completely destroyed by later phyllic alteration, and surrounded by a propylitic assemblage dominated by ankeritic carbonates in altered sedimentary rocks.The deposit has characteristics of bath the alkalic and calc-alkalic classes of porphyry copper deposits. The development of quartzvein stockwork suggests a calc-alkalic affinity, but the hostrocks contain little or no free quartz, molybdenum is present in trace amounts only and gold values are significant. Copper grades vary between wide extremes with unusually high grades in some sections of the deposit. The weight of evidence available in the 1970s led us to place the Red-Chris deposit firmly in the alkalic family. The quartz-sericite alteration assemblage was attributed to breakdown of potassium feldspar in a near-surface alteration environment in which seawater may have had a significant role. These interpretalions are retained here, but preliminary conclusions from the most recent work suggest that they may require some modification."

Jan 1, 1995

By Kuo En Chang

Many rare earth - transition metal (RE-TM) compounds absorb/desorb hydrogen reversibly at room temperature and atmospheric pressure. For LaNi5 which is used as a battery material, the electrochemical nature of this process is well known. In the case of Nd-Fe-B which has found wide application as a powerful permanent magnet, the absorption of hydrogen has both significant advantages and disadvantages. However, a fundamental understanding of the hydrogenation process at ambient temperatures and its effect on subsequent corrosion behavior is currently lacking. This paper reports the results of the hydrogenation of NdFeB two alloys, (NdDy)15Fe78.3A10.7B6 and (NdDy)15Fe67Co5V4A12B7, which are compared with that of LaNi5. Results show that hydrogenation can be accomplished by either electrochemical methods or immersion in dilute sulfuric acid. For the latter method, the change in lattice parameter indicates that the level of hydrogen absorbed by the NdFeB particles corresponds fairly closely to an overall composition of Nd2Fe14BH2.7. Cyclic electrochemical charge/discharge experiments show that the maximum hydrogen discharge capacities of the NdFeB, NdFeB-Co-V, and LaNi5 are 40, 60, and 210 mA?h?g-1, respectively. Anodic potentiodynamic polarization measurements and calculated values of icon reveal that absorbed hydrogen in NdFeB-Co-V and the NdFeB may lead to significant increases in corrosion rates.

Jan 1, 1995

By C. J. Beyke

In recent years recycling of household batteries has received increasing attention, primarily for environmental reasons. This article reviews the major battery types and some of the technologies available to recycle them. It also discusses issues such as collection and sorting which are related to battery recycling in the United States. Finally, results from research being conducted by the U.S. Bureau of Mines on the reclamation of nickel-metal hydride, alkaline, and zinc-carbon batteries are presented.

Jan 1, 1995