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By David G. C. Robertson

A new approach is described for the calculation of the kinetics of metal/slag, metal/slag/gas, and metal/matte/slag/gas reactions. The algorithm assumes that equilibrium is achieved at the interface between phases, and uses an equilibrium solver (such as SOLGASMIX) to compute the equilibrium state at the interface at each time step during the reaction. For multiple phase systems a number of unit operations, representing the different phases and interfaces, must be connected together in a reasonalbly complex manner, and the METSIM software package has been utilized for this purpose. The new approach is superior to the SMAK software developed by the author and his co-workers over the past decade, for the reasons discussed in this paper.

Jan 1, 1995

By Tatsuo Itou

Both sales volume of Aluminum Can and its recycling rate are remarkably increasing here in Japan. In 1993, recycled can volume was 11.78 billion cans ( 116,258 metric tons ) and its recycling rate 57.8 percent. We, MITSUBISHI MATERIALS CORPORATION. the leading manufacturer of aluminum can in Japan and our affiliated companies are very deeply involved in recycling used beverage cans ( U.B.C ) and recycling them back to can stock. In this paper. I would like to present the following; 1. Recent trend of beverage can consumption in Japan. 2. Trend of aluminum can and its recycling rate in Japan. 3. Future of aluminum can business in Japan.

Jan 1, 1995

By Luis W. Pommier

Large quantities of sea sludge containing halogenated organic compounds, such as PCB, oils and metals like arsenic and lead have accumulated throughout the years at the bottom of sea channels and harbors and are obstructing navigation and creating environmental problems which need to be resolved. A sludge from a California port would be dredged by suction pumps, it would be processed in a plant which would be built either on firm soil or on floating platforms. The sludge shows contents of up to 1 ppm of PCB, 15 % oil and 10 ppm of arsenic, which generates a very fetid odor. Bench scale work indicates that most of the contamination concentrates on the solid phase, in fact, only minor amounts of oil report to the sea water and can be readily removed by physical means. After separation of the sea water from the solids of the sludge by decantation, it is possible to solubilize the PCB, the oil and the metals into an organic solvent leaving a non-hazardous soil for disposal near the harbor. The PCB is dehalogenated during the solubilization process leaving a liquor solution containing the oil and metals. The oil is extracted leaving an aqueous solution containing the arsenic. Further process extracts the arsenic from this solution rendering the liquid non-hazardous. Transportation and disposal of the sludge is impractical. There are hundreds of thousands of tons of hazardous soils accumulated in each harbor, which would fill the hazardous waste disposal sites available and it would be, prohibitively expensive to do so. It is not possible to compare the costs of decontamination with a competitive method. If it were, the proposed process would be less expensive than transportation and disposal and it has the advantage of removing the liabilities from the Responsible party. After a full scale continuous pilot project is run to decontaminate a small, 500 cubic yards accumulation of this type of sludge in a California harbor, a full scale environmental project would be initiated. The decontamination of one million tons of sludge would be completed in five years.

Jan 1, 1995

By Djona M. Gaballah I.

Selective chlorination of unroasted and roasted spent hydrorefming catalysts was studied between 300 and 600°C using the following gas mixtures : C12+CO, C12+N2 and CI2+air. Such materials contain Co, Ni and Mo compounds supported by alumina and/ or silica. They also contain variable amounts of V compounds, C, S, etc., accumulated during the life time of the catalyst. Direct oxychlorination of the C+S rich sample allows higher extraction rates than those obtained by the carbochlorination of the same roasted one. It seems that the roasting step doesn't favor the economic metals' recovery. Results of the chlorination of C+S poor spent catalysts, in the presence of CO, in the chlorinating gas mixture, or of carbon added to the sample, were comparable. Cobalt and nickel chlorides were .extracted from the chlorination residues by their dissolution with acidified water, whereas molybdenum and vanadium chlorinated compounds were recovered by selective condensation from the vapor phase. The recovery rates of valuable metals as well as the selectivity were higher for the chlorination of spent catalysts than results obtained by the hydrometallurgical processing of the same sample. Results of the scale-up of the oxychlorination of the unroasted sample confirmed those of the laboratory scale. The global recovery rates were about 88 pct of cobalt, 93 pct of molybdenum and 76 pct of vanadium. The carbochlorination was applied to the recovery of W and Ti from Denox catalyst that is a carbon and sulfur free one. Recovery rates higher than 99 pct at temperatures lower than 500 °C could be obtained. This may indicate that the chlorination process can be applied to the treatment of various industrial wastes or by-product containing transition and/or refractory metal compounds A flow - sheet for the pretreatment of these materials is proposed.

Jan 1, 1995

By Federico Chavez

The process for recovering lead from battery residues used in several Mexican Plants include lead blast furnace and rotary furnaces. The formers are basically fed with recycled batteries together with the necessary additives to produce metallic lead. One of the by-products generated in the blast furnace is a dust mainly formed by lead sulfide. The rotary furnace is used to recover lead .from lead batteries, dross from the refining-alloying process and the leady fines produced in the blast furnace. This paper describes thennodynamic analysis made to the rotary furnace process to understand the effect that each component of the system has upon the lead recovery. In order to enhance the process, the influence of iron chips composition and excess coke on slag viscosity is discussed. A computer optimization program . has been developed to design the furnace charge based on material and energy balances, .together with the thennodynamic equilibrium calculation.

Jan 1, 1995

By Andrew Case

The Port Nickel facility in Braithwaite, Louisiana, is known for pioneering hydrometallurgical processes for the 'separation and recovery of nickel, cobalt and copper. Ten years ago, in 1985, a new CRI-MET process for the recovery of molybdenum, vanadium, nickel, cobalt and alumina from spent catalysts was developed and implemented. Spent- catalysts from the petroleum industry consietute the majority of feed. These are not only a valuable-source of metals, but due to EPA regulations are frequently classified as hazardous under RCRA. Molybdenum and vanadium are selectively leached in an oxidative hydrothermal step. Alumina is then extracted in a caustic digestive leach. The unique technology produces four primary commercial products l molybdenum trioxide, vanadium oxide, aluminum trihydrate and nickel-cobalt concentrate. This paper discusses the process, modifications. during ten years of operation, and the relationship of these modifications to the future of the catalyst recycling business.

Jan 1, 1995

By Baozhong Zhao

The direct smelting of copper concentrates to copper metal in a single furnace offers environmental and energy advantages over conventional two-stage copper smelting processes. However, the direct copper making results in unacceptably high level impurities (As, Sb and Bi) in the anode copper. Experimental studies have shown that it is possible to remove these impurities from molten copper by injection of sulfur-hexafluoride. This paper discusses the experimental findings on the influence of various factors on the rate of removal of impurities, such as the impurity inter-effects, initial oxygen content in the metal and injection rate of SF6.

Jan 1, 1995

The generation of acid mine water is? due to the oxidation and weathering of sulfide bearing tailings and overburdens. Ferrite precipitation prooess has been applied to treat acid mine water. The conventional ferrite preC1pitatlon requires air oxidation at high temperature, or long aging time or addition of magnetite powder ,as promoter. In this investigation, a modified ferrite, precipitation process is developed by which magnetic ferrite can be produced at an ambient temperature. Acid mine waters from Berkeley Pit (Montana, U. S. A.) and from Noranda Tailings (Quebec, Canada) were used. The co precipitation of heavy metals from these two acid mine waters is studied as a function of FeIM molar ratio, oxidation time and settling rate under applied magnetic field. The investigation indicates that the modified ferrite co precipitation can remove substantially all of the, dissolved metal ions from acid mine water. The ferrite product obtained after precipitation' is characterized by XRD, SEM, BET and saturation magnetization. The results show that spinel ferrite, precipitation can be achieved at room temperature and the saturation magnetization of ferrite product from,acid mine water is comparable to that of pure ferrites.

Jan 1, 1995

By William D. Riley

The U. S. Bureau of Mines has developed technology to recover by-product materials from aluminum scrap using engineered scavenger compounds (ESC). ESCs are structural oxides with a channel or tunnel structure that allows them to hold ions of a specitksizes and charges. The scavenging reaction is easily reversible allowing the ESC to be recharged for continued use and the ion is recovered as an electro deposit. Key features of this novel technology are; a) ESC ,systems are designed to have a high degree of selectivity for a desired ionic species. b) The recovered mater.ial requires little or no additional reprocessing prior to reuse. Two current uses for the ESC technology that are described in this paper are the removal and recycle oflithium (Li) from lithium aluminum (Li-AL) alloys; and, using ESCs as a replacement for the conventional demaging (magnesium removal) technology used by the secondary casting industry. Research indicates that the ESC technology proposed for both these applications has either 'distinct economic and/or environmental advantages over previously employed methods of recovering. metal values from aluminum scrap.

Jan 1, 1995

By N. Piret, B. Shoukry, S. Buntenbach

Traditional or artisanal goldmining, also known as small scale goldmining, has a strong and probably a negative environmental impact. The processing methods applied are very frequently a source of severe pollution due to the emissions of mercury by the extraction of gold by means of amalgamation as well as the emissions of cyanide through cyanide leaching of gold bearing ores. The emissions find their way into the environment and contaminate soils, sediments, water and atmosphere. Abnormal concentrations of mercury and cyanides in waterways are known to occur year after year destroying irreplaceable regions of the world. Mercury and cyanide compounds are highly toxic and may directly create permanent damage to the whole ecosystem. Existing methods for recycling of mercury and for decontamination of mercury and cyanide contaminated tailings are not customary applied in small scale mining and are ineffective as well. Based on investigations of traditional and small size goldmining, this paper presents: -processing methods of gold and discarded tailings under consideration of environmental protection; -figures on actual situation; -recommendations for equipment; -some decontamination methods for mercury and residual cyanide. Mineral Processing methods in traditional gold mining Gold is usually existing in its ores as the metal alloyed with metallic silver and perhaps copper. The element may occur in the form of: -native gold -inclusions also of microns or submicroscopic size metal sulfides (auriferous) such as pyrite, pyrrhotite, stibnite, arsenopyrite and galena -combined as telluride or sulphotelluride. The separation process selected depends on whether the gold can be freed from its unfavorable associations (e.g. gangue) at a sufficiently coarse grain-size, or whether it is carried in a heavy sulfide which can be freed similarly. The usual practice is to concentrate the goldbearing mineral at a relatively coarse grain-size and to regrind the ore if necessary. The gold content is concentrated by secondary or tertiary gravital methods or is extracted by chemical methods (amalgamation, cyanidation etc.) Gold, even when of fine grain-size, settle readily due to its high specific gravity from pulps in which the main gangue mineral is quartz or silicates. Amalgamation is the process of separating gold and silver from their associated minerals by binding (entrapping) them into a mixture with mercury. The cyanide process is applied to separate gold or gold-bearing compounds by dissolution from the finely ground ore (CIP, CIL, RIP), or as heap leaching. The dissolved gold is separated from the solids and the metal-rich or pregnant solution is then treated to recover its gold. Gold is also recovered by flotation methods. This process is widely used in treating base metal ores and in separating various sulfide components of ores, as well as in removing the barren gangue. The gold usually associates with a specific product in a sequence of flotation operations and is recovered subsequently in the smelting of the sulfide concentrates and refining of the metallic products, or by cyanidation of the roasted concentrates. Froth-flotation can be applied to separate gold and sulfide minerals from a finely ground pulp. The Amalgamation Process Amalgamation is the main method for the recovery of gold in traditional mining and is applied for the extraction of gold from placers as well as primary ores. The mineral technology used depends on the nature of ore deposits. In winning gold from solid ore, the matrix of minerals and rocks must be crushed and ground to sufficient fineness to liberate the gold. The liberated gold could be treated similar as free gold from placers. Gold is mainly separated from the valueless gangue (barren rock) by utilizing the difference between the density of the impure native metal (density about 16-19) and the gangue (density about 2.5). In simple operations the material is carried by a stream of water down a sluice generally equipped with small transverse barriers (riffles) against which the gold collects. The riffled sluice is the principal device used by artisanal gold miners. Nowadays, spirals as well as centrifuges, such as Knelson separator or Falcon separator, are occasionally applied for gold recovery. Gold may also be recovered from the pulp, by passing it over corduroycovered tables that catch the heavier particles - a method maybe as ancient as gold mining itself. In history, sheep skins were used to catch gold particles in this manner. Furtheron, gravity separation of gold is practiced on jigs, hydraulic traps, shaking tables and

Jan 1, 1995

By W. G. Pariseau

Recent advances in rock mass mechanics and computational technology now allow for stability analysis of excavations in "wet" mines where mining-induced changes in rock mass deformation and fluid flow are coupled and time-dependent. All the usual dry mine parameters including the premining stress state and rock mass properties are taken into account, in addition to water pressure and flow in jointed, possibly porous, rock masses. Finite element analyses of shafts and tunnels as circular, elliptical, rectangular and arched-rectangular hole shapes excavated in an initially stressed and pressurized rock mass indicate that the usual guidelines for optimum shape and orientation of single openings apply. Here, optimum means maximizing the minimum wall safety factor, or equivalently, minimizing the peak stress concentration. The results also show that failure originates in elements at the wall and that the minimum safety factor at the wall in the wet case is always less than the dry case regardless of drainage time allowed.

Jan 1, 1995

Provide longwall operators with an alternative strategy for placement of gob gas ventholes to improve gas production.

Jan 1, 1995

By Best R, Poulos H

This paper discusses the results of an Australian Coal Association Research Program project into the development of a routine analytical design method for roof support in underground mines. Simple design tools have been developed using a combination of elastic solutions, free body diagrams, and pile theory. An approach to the design of roof support in layered strata based on the ability of bolts to resist shear stresses is outlined. It is shown that pre-tensioning and angled installation are effective ways of increasing the effectiveness of bolts in such a situation. In highly stressed strata, macroscopic failure is predicted and a design based on the support of surcharged rock wedges is proposed. The methods are applicable to both coal and metalliferous mines.

Jan 1, 1995

By S. C. Sharma

The aluminium matrix composites with ceramic dispersoids can be separated by density difference concept. In the proposed work composite scrap is recycled using an oil fired furnace. The scrap is melted in the furnace and temperature is maintained below 740 degree centigrade. Because of the density difference the lighter dispersoids will float and heavier dispersoids will settle down. The clean melt is separated be removing the floating and settled disperssoils, and then filtering using ceramic filters.

Jan 1, 1995

By Raja V. Rarnani, Robert L. Frantz

"The more than 75 research projects funded throughout the first 10 years of the Dust Center's operation have resulted in numerous cumulative findings fulfilling the goals of the Center. These project descriptions present the methodologies and project-to-project relationships leading to their various accomplishments and demonstrate the mesh between project objectives and Center goals.To develop equipment for collecting respirable dust samples.To develop experimental methods for particle-by-particle characterization of morphology, size, and chemistry.To develop experimental methods for overall respirable dust sample characterization of size distribution, chemistry, and crystallography.The project directly addresses the Center's goals to enhance the understanding of the scientific and engineering characteristics of fine and respirable mineral particles found in mining and milling atmospheres and to establish the relationship between natural and cultural factors (mine geology, mineralogy, mining and milling methods, equipment, and control measures) in the generation of fine particles. The project also aims to contribute to the development of control mechanisms for reducing ambient respirable dust concentrations and worker exposures.The work on this project is related to similar work on Coal Mine Dust Characterization (Project No. 2701/MN1) and Characterization of Dust Particles (Project No. 4203/PS3).Airborne dust sampling was performed at the following locations: 1) a sand and gravel quarry in Southern New Hampshire, 2) a welding facility, 3) a ceramic powder facility, 4) a metal powder facility, and 5) the air in Cambridge, Massachusetts. A portable sampling box incorporating two Sierra personal cascade impactors was designed and produced. At a 2-LPM flow rate, the effective cut-off diameters of the Sierra impactors were 10.0, 6.0, 3.5, 2.0, 0.9, and 0.5 mm, respectively, for each stage, and the air passed through a PVC filter after the last stage. In addition, the sampling box contained a total respirable dust filter. The substrates were weighed carefully before and after collection, and the weight increases were recorded. All films, foils, and filters were put in the balance chamber for more than 8 hours to stabilize the temperature and humidity before weighing. A Cash 21 microbalance (±0.001 mg) was used to weigh the Mylar films, SS films, and filters."

Jan 1, 1995

By Armstrong M, Kleingeld W. J

Current low prices for many metals mean that deposits have to be mined at high cut-offs (relative to their mean grade), which means that only a small percentage of mining blocks are above cut-off. Worse, at such high cut-offs, the blocks above cut-off are usually not grouped into convenient clumps for mining; they tend to be split into small isolated patches that are difficult to reach and hence expensive to extract. Companies wishing to acquire mineral properties have to be able to work out quickly what percentage of blocks are above cut-off and what can effectively be mined given the mining method envisaged. Moreover they need this information within a relatively short-time. The work presented here relates to typical South African gold mines (ie tabular orebodies) but the long-term objective is to develop tools for quantifying the impact of reserve breakup at high cut-offs for a wide range of underground mines including those that are not tabular. The mining method and the sampling procedure determine whether ore blocks can effectively be located and extracted economically. This project studied the impact of these two factors on the recoverable reserves for Witwatersrand gold mines. In order to be repeatable, the tests were done on numerical models of the deposit obtained by geostatistical simulations. To ensure realism, the orebody model and the mining scenarios were based on a specific mine. The recoverable reserves (ore tonnage above cut-off, the corresponding metal quantity and the average grade) were calculated for a wide range of cut-offs for four mining scenarios, as well as for the base case of free selection: ò Scenario 1: Blocks are taken if their true grade is above cut-off and if they are accessible from a raiseline (no information effect, no marginal blocks). ò Scenario 2: In addition to the accessible pay blocks, adjoining marginal blocks are taken (no information effect, + marginal blocks). ò Scenario 3: Blocks are taken if their estimated grade is above cut-off and if they are accessible from a raiseline. Here the estimator is the average of the face samples (information effect, no marginal blocks): ò Scenario 4: Accessible pay blocks are taken if their estimated grade is above cut-off. Adjoining marginal blocksare also taken (information effect, + marginal blocks). ò Free selection: All blocks whose true grade is above cut-off are taken irrespective of their accessibility. The results can be presented in different ways, for example by plotting ore tonnage above cut-off versus cut-off grade, or metal tonnage above cut-off versus cut-off grade etc. As expected, this shows the hierarchy between the five scenarios from the free selection base case to scenario No 2 (true accumulations, pay +

Jan 1, 1995

By J. Partyka, Trevor R. J. Kelly

This paper presents the results on noise testing of a fan only, as well as the results of a steel silencer and of flexible silencers that were connected directly to a fan. On-site facilities and free-field method set by the British Standards Institution were used to measure and then compare the fan only and different practical silencer configuration setups. In order to determine the fan-silencer combination that would give the maximum noise attenuation, total noise intensity, noise contributed to by the fan motor only, as well as aerodynamical noise created through air interacting with the fan parts were considered to obtain decibel readings for the octave bands. Subsequently, the optimal configuration found was the setup with flexible silencers on the fan inlet and the fan outlet. If only one silencer is used, it should be installed on the fan inlet. The aerodynamic noise affects the low frequencies. The flow noise is then overtaken at 1 kHz by the mechanical noise.

Jan 1, 1995

By Ivo André

Sorption of copper ions from aqueous solutions by dried biomass of the aquatic plant Potamogeton luscens was studied at laboratory scale. The aquatic plant was collected in water resources in Brazil, washed, dried at 60°C and ground in a bladed mixer. Sorption experiments were conducted in agitated flasks and in a packed bed column. Maximum copper removal was obtained between pH 5.0 and 6.6 when copper was present in the ionic form Cu'. Sorption followed the Langmuir isotherm with saturation attained at 35 mg/g. Free energy of sorption was found, to be of the order of -25 kJ/mol. Sorption kinetics data were better described by a second order reaction and rate constants were calculated in 0.030 1/(min.mg) for - 4.0 mm particles and 0.081 1/(min.mg) for - 0.59 mm particles. Removal of metal ions in a packed bed column showed that Potamogeton luscens biomass can be used in several sorption/dessorption cycles. After sorbent saturation, copper ions can be recovered from the loaded biomass by elution-with H2SO4, solution. Main mechanism responsible for heavy metal uptake was found to be ion exchange. Results are discussed in terms of the surface properties of the biomaterial, solution chemistry of copper ions and thermodynamics parameters.

Jan 1, 1995

By W. Evans, T. Steis

"Sulphide ores under certain circumstances will react with explosives to generate an autocatalytic chemical reaction. This reaction is exothermic and results in the production of large volumes of poisonous gases and creates an unsafe, unstable condition with the possibility of a low energy deflagration or even a detonation of the loaded hole. This paper outlines the conditions that need to exist for such a reaction to take place and the precautions necessary to minimize or eliminate the problem in areas of reactive ore. A special case study involving a northern Ontario mine will be detailed.IntroductionOne of North America's leading underground gold producer's processes over 6500 tonnes of ore per day from an orebody containing high concentrations of sulphides. After six years of problem free operation, the mine experienced two serious reactions in two months between the sulphides and AMEX II, the ammonium nitrate and fuel oil explosive it uses."

Jan 1, 1995

By E. Allaine

Carbochlorination kinetics of pure MoO3, Nb2O5, Ta2O5 and V2O5, by Cl2+CO+N2 gas mixtures was investigated between 380 and 1000 °C. Standard free energy of carhochlorination reactions and phase stability diagrams of these refractory metal compounds were calculated. The influence of total gas flow rate, temperature, reactants partial pressures on the reactivity of these oxides were investigated. The apparent activation energies were found to be about 83, 75, 110 and 100 kJ/mole below 650°C for MoO3, Nb2O5, Ta2O5 and V2O5, respectively. Above this temperature, the Arrhenius plots exhibit a rate anomaly attributed to thermal decomposition of COCl2 and/or structural changes of these refractory metal oxides. The apparent reaction order of carbochlorination of these oxides with respect to Cl2+CO was determined. For these refractory metal oxides, the reaction rate was maximum for a Cl2/CO ratio of about 1 in the chlorinating gas mixture. Results of carbochlorination of these oxides are compared and discussed.

Jan 1, 1995