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By S. Yuan

Oxygen ion conducting yttria-stabilized zirconia (YSZ) tube was used to remove oxygen from molten Cu at 1373K. Outer surface of the tube was in contact with the melt and the inner surface containing a thin layer of porous Ni-ZrO2 cermet electrode was in contact with a reducing gas. The migration of oxygen species (O2-) from the Cu melt through the YSZ tube is accompanied by an equal and opposite flux of electrons maintaining electroneutrality. Without applying an external EMF, the fluxes are maximized by short circuiting the melt with the cermet electrode. For efficient oxygen removal, the YSZ tube must be thin, contact resistances should be negligible, and the electrodes must be porous and cover the entire electrolyte surface for charge transfer. This refining process is environmentally sound, can use reducing gases such as H2, CH4 and CO without running the risk of increasing H or C content of the melt.

Jan 1, 1993

By Animesh Jha

Univariant diagrams are constructed for the reduction of nickel and cobalt oxide and sulphide minerals. The results from the carbothermic and hydrogen reduction of sulphide minerals are compared. The importance role of lime and calcium sulphate in controlling the emission of sulphurous- gases during reduction reaction is also explained. The mechanism of carbothermic reduction of nickel sulphide is explained by examining the sulphur exchange and reduction reactions. The phase equilibrium relationships that determine the formation of multicomponent liquid are characterised. Also the governing equilibria for inert atmosphere calcination- roasting of nickel and cobalt sulphide minerals are also described for the metallization of nickel and cobalt.

Jan 1, 1993

By Stavros A. Argyropoulos

Exothermic mass transfer takes place in various areas involving metallic systems, ranging from liquid metal processing operations to the growth of thin films in microelectronics. The formation of intermetallic compounds plays an important role in the exothermic mass transfer of metallic systems. Two types of exothermicity are identified , namely , Microexothermicity and Macroexothermicity. The former is encountered when small amounts of metals are mixed, while the latter is exhibited when a solid metal in a lump form is added into liquid metal. In this paper two types of exothermic mass transfer in metallic systems will be presented and reviewed. Mathematical modelling work for these types of exothermic mass transfer will be analyzed.

Jan 1, 1993

By P. R. Pereira

This paper presents a comparison between the simulations of a semi-empirical model and a theoretical model for the prediction of radial stress in rock. The results of the simulations were compared to the results of a field test. The comparison of the radial stress predictions shows that in the semi-empirical model use of the plane wave approximation as the basis for the prediction of the radial stress provides a much better result than the theoretical model. The theoretical model includes the correct elastic wave geometry and theory but fails twice, firstly by considering the charge as a point (unit) energy source therefore; and secondly by using a Delta function with a very sharp rise and decay time to simulate, with no distinction between non-linear and linear zones, the attenuation of the energy per unit volume at the shock wave front as the wave moves away from the borehole. The results of the semi-empirical model were within the same order of magnitude as the results from the field test whereas only one result from the theoretical model came close to the result of the field test. However, even this closer result for the theoretical should be taken with caution as there was no measurement in the field test made at this distance from the borehole. Finally, because of its potential portability, convenience, and cost-effectiveness the theoretical model can be a most valuable tool for mining and civil construction operators in the early design of blasting rounds and of the mining operation itself.

Jan 1, 1993

By Y. Y. Sheng

Plume flows created by gas injection into liquid metals have been studied extensively, however the dynamics of bubbles within the plume have not received adequate attention, particularly for large, irregular bubbles, characteristic of the processing of liquid metals. The present model uses a combined Eulerian-Lagrangian approach in which an estimated void fraction distribution is used to calculate the liquid flow field with a conventional Eulerian scheme. The trajectories of bubbles are then computed in a Lagrangian manner using the estimated flow field, and experimentally measured information on bubble drag coefficients', lateral migration due to lateral lift forces and interaction with turbulent eddies, and variation in bubble size due to break-up. Turbulence in the two-phase zone is modeled with a modified k-e model with extra source terms to account for the second phase which have been recently determined by the present authors. The computed void fraction and turbulent liquid flow field distributions are in good agreement with experimental measurements.

Jan 1, 1993

By Thomas J. Peters

The Lime Creek study area lies 100 air km east of Boise, and 70 air km northeast of Mountain Home, Idaho. The eastern boundary of the 28,000-hectare, east-west-elongate study area lies 0.2 km west of the 3,077-m-high Smoky Dome. The area is mainly underlain by Cretaceous granitoid rocks of the Idaho batholith. No mineral resources were identified, but two mines and one prospect were found in the study area. At the President and the Last Chance mines, in the southwest corner of the study area, gold mineralization occurs along steeply dipping east-northeast-trending faults and associated quartz veins, and within adjacent Cretaceous granitic rock. The mineralized material is not rich enough to mine underground, and near surface, open-pit-mineable deposit areas could not be identified. The third prospect, the Ventura, is within altered pink granite of probable Tertiary age, but metal concentrations are very low. Geothermal activity was not observed within the study area, but hot springs do occur in the Vicinity. Bedrock observed is only suitable for the most basic high bulk and low end value applications, such as crushed aggregate. Numerous sources for crushed stone occur closer to markets. Alluvial concentrate (placer) samples did not contain free gold, and no substantial alluvial bars were seen; deposits were too small to contain resources.

Jan 1, 1993

By Jerold L. Johnson

Remediation of small-arms firing ranges is being investigated by the Naval Civil Engineering Laboratory and the U.S. Bureau of Mines. Scheduled closures of military installations, as well as the management of active ranges, require the development of methodologies for heavy metals removal to prevent their entering the surrounding environment. The impact berms contain high concentrations of metals, and the soil and vegetation surrounding the berms were found to have slightly elevated levels. The heavy metals characterized are in the form of whole bullets, a wide size distribution of free fragments, smeared lead on the surface of the soil grains, and very finely attached particles. Gravity beneficiation can remove liberated metal contamination effectively. Weak acetic acid leaching shows promise in lowering the final metal contamination to allow the ,soil to pass the Environmental Protection Agency's (EPA) Toxicity Characteristic Leaching Procedure (TCLP) criteria.

Jan 1, 1993

By Willem P. C. Duyvesteyn

A novel hydrometallurgical process for Escondida copper concentrates has been developed by The Minerals Laboratory of BHP. The Escondida Process consists of concentrate leaching, solution purification, electrowinning and residue flotation. Part of the copper will be sold as high grade concentrate and part as high purity SX-EW copper. Contrary to previous efforts for the development of a hydrometallurgical process for copper concentrates, this patented process does not advocate the total dissolution of copper. It only aims for the copper that is readily soluble in a mildly oxidizing environment with an ammoniacal or acidic lixiviant. Both lixiviants were studied, but ammonia was preferred because of fast kinetics at ambient temperatures and pressures. By controlling the oxidation potential, the formation of sulfate ions and, consequently, of an ammonium sulfate byproduct, is precluded. These mild leaching conditions also prevent the dissolution of unwanted impurities and result in the production of ultra-high purity electrowon copper. Solution purification is carried out by solvent extraction with LIX-54. The very high loading capacity of this organic results in a compact SX circuit, consisting of two loading, one scrubbing, and one stripping stage. As the organic is selective for simple copper ions, the copper amine complex is broken down and free ammonia is regenerated and recycled for leaching. High purity copper cathodes are produced in a conventional sulfuric acid based electrowinning system. One scrubbing step is needed to separate the ammoniacal circuit from the acid circuit. Limiting copper dissolution to less than 50% also provides an opportunity to produce high grade concentrates by residue flotation. Copper recoveries in excess of 98% with precious metal values reporting to the final concentrate can readily be obtained. Complete breakdown of the copper mineral- pyrite middlings results in a final concentrate grade that can be even higher than the original feed material. The Escondida Process also provides an opportunity to accept lower grade copper concentrates producing improved copper recoveries in the mill and yet high quality concentrates for marketing. The Paul E. Queoeau International

Jan 1, 1993

Mineral processing plant operators are faced with the necessity to choose between many different possibilities for plant improvement. Only a few such possibilities, however, can be tested on the industrial site. Steady-state simulators make it possible to assess the effects of several different flowsheet modifications in a few days, thus helping the process engineer to make his choice implement the solution that seems the most appropriate and check it. The example described here is the crushing and grinding circuit of the Shila Gold Mine, jointly owned by CEDIMIN SA and BUENAVENTURA SA, in Peru. Several possible modifications for the purpose of increasing capacity have been simulated and the results assessed in terms of technical quality, investment costs and energy consumption. The best solution indicated by the USIM PAC simulator was implemented and gave a 20% increase in capacity with a pay-back time of two months.

Jan 1, 1993

By Matthew N. Plis

This U.S. Bureau of Mines report presents the documentation for COALVAL, a coal property evaluation software package developed on Lotus 1-2-3,4 version 2.2, spreadsheets. The software is compatible with version 3.1 as well, and may provisionally be run on the earlier 2.01 version. COALVAL is a menu-driven program that produces a prefeasibility-level cost analysis of mine-planned coal resources. The package contains cost models for each of five coal mining methods commonly employed in Appalachia: auger, contour strip, mountain top removal, continuous miner, and longwall. Other models, such as a dragline cost model, will be incorporated as the Bureau's Coal Recoverability Program matures. COALVAL allows mine operators, evaluators, consultants, and Government entities to input resource data and the various production, operating, and cost variables that pertain to their property. The program can evaluate up to 25 seams, each to be mined with up to five different mining methods, within a given area. Summary spreadsheets listing the cost per clean ton to mine the resources, f.o.b. the tipple, are produced for each property, seam, and mining method/seam combination.

Jan 1, 1993

By Joanne L. Johnston

Researchers at the U.S. Bureau of Mines have developed a new technique for bonding strain gauges to rock bolts. These instrumented bolts are used to determine load at intervals along the length of the bolt so that reliable, consistent measurements for the design of support systems can be obtained. In this Information Circular, this technique is described in detail and should result in improved miner safety in underground mines.

Jan 1, 1993

Seventy-three of the 90 naturally occurring elements that are found in the earth's crust are metals or metalloids. The quantities of metals used annually in the United States range from about 100 million metric tons (steel) to a few kilograms (osmium). The recovery of metals from discarded products or industrial process wastes, especially those metals that are used in large quantity, are very expensive, or are unusually toxic, is important to the national economy and to the natural environment. From its inception in 1910, the U.S. Bureau of Mines (USBM) has been the Government's prime source of information on metals recycling, as well as a major innovator in recycling technology. Statistical data on scrap generation and processing have been summarized annually for many years in the USBM's Minerals Yearbook. Most of the data for individual metals discussed in this report were extracted from that publication.

Jan 1, 1993

By K. R. Miller

Thunder Basin Coal Company has two mines located in the southern portion of the Powder River Basin. 60-90 km southeast of Gillette, Wyoming. The mines are principally located on federal coal leases acquired in the late-1960's. Development plans for the Black Thunder Mine focused on dragline stripping, but environmental considerations during the mid-1970's made truck-shovel stripping the method of choice when the mine opened in 1976. In 1981, the Coal Creek Mine opened as the first dragline mine in the Gillette area of the Powder River Basin. The regional terrain is flat-lying with occasional clinker-capped hills. The mines are located on the Wasatch and Fort Union Formation contact. The coals are Paleocene in age and the deposits are structurally simple, dipping gently to the west. The seams are thick and are classified as sub-bituminous-C. The Black Thunder Mine, with its 21 m thick seam, is strategically located in the center of the highest heat value mining area of the southern Powder River Basin.

Jan 1, 1993

By V. D. Smar

The flotation process may be considered an interactive system consisting of many chemical, operational, and equipment variables. Changing anyone of these variables causes an overall system response change. This study examines the effects of simultaneously changing the operating variables of: (1) frother concentration and air flow rate, and (2) frother concentration and collector concentration. It is part of a comprehensive study to look at how changes in several of the major variables may be used to produce interactions which will allow the rougher flotation process to be optimized. Ultimate recovery, flotation rate, concentrate grade and froth quality, are used as the major evaluative criteria.

Jan 1, 1993

By E. H. Cho

An acid mine drainage sludge sample containing 3.6% Mn, 0.18% Ni, 0.15% Co and 0.39% Zn was obtained from the central part of West Virginia and leached with sulfuric acid at pH 3 and at room temperature. Air was bubbled through the leach solution to precipitate the iron content from the solution at pH 4.5. The leach solution contained 258ppm Zn, 105ppm Ni, 90ppm Co and 2050ppm Mn. Three distinctive solvent extraction studies were performed to selectively extract these metal ions in a sequential operation with DEHPA, Cyanex 272, and then Lix 84. The AIO ratio was 1 and the extractants were diluted 10 times with kerosene. A study of solvent extraction with DEHPA showed that Zn could be extracted without Ni or Co up to pH 2.75. A pH of 2.75 is considered to be the optimum pH to maximize the selective separation of Zn from Mn. The separation factor of Co over manganese suggests that the two metal ions be extracted together by Cyanex 272. The separation factor of Co over Ni indicates that these two metal ions can be separated most effectively around pH 5.3. Also, Ni can be effectively extracted by Lix 84 above pH 5.5.

Jan 1, 1993

By F. Shen

Qualitative and quantitative results obtained during the physical modeling of the molten aluminum flow in a tundish using an aqueous system are presented. Surface tuft, free-surface powder and laser sheet visualization techniques were utilized for qualitative studies, whereas laser Doppler velocimetry was used to elucidate the 3-D flow regimes quantitatively. The results of the study are used for validation of the CFD codes, and to explore the effect of the alterations below the nozzle in order to: (1) decrease turbulence levels, and (2) collect the inclusions. Near the nozzle, the interaction of the impinging jet and the inclined walls gives rise to vortex structures. Downstream of the nozzle, two counter-rotating secondary cells diminish in strength. As flow turns through the bend, a separation region is created. The flow heading into the closed duct is seen to be nonsymmetric. A video tape highlighting the major findings is presented.

Jan 1, 1993

By Mariana H. Staia

Thermodynamic calculations based on the free energy minimization method were performed for the system Ti-Fe-Mn-0-C1-C in order to evaluate the chemistry associated with the chlorination of an ilmenitic concentrate using CCl4. In the calculations various weight ratios of FeTi03/ CC14, a , were considered, which varied between 0.32 to 0.98 at temperatures ranging from 673 K to 1273 K , at atmospheric pressure. The results obtained indicated that the operating conditions for a process in a packed bed reactor, which implies the chlorination of both Fe and Ti, are 0.39 < a < .49 at T 1173 K.

Jan 1, 1993

By D. Gatzemeier

The Jewett mine is a surface mine in central Texas, producing about 8,000,000 tons/year of lignite. The mine covers 46,000 acres of land. Approximately 430 people are employed by Northwestern Resources Company and through their efforts, the Jewett Mine is one of the most productive mining operations in the country. The Jewett Mine utilizes a unique structure of staff to convert Operations Research into plans which can be implemented at the "front line" level of the Operations Team. This planning not only makes the mine cost effective and efficient, but promotes creativity in mining, which promotes ongoing research to lower the cost of mining.

Jan 1, 1993

By J. M. Goris

The U.S. Bureau of Mines, in a cooperative project with the University of Utah, Salt Lake City, UT, and Homestake Mining Co., Lead, SD, conducted in situ monitoring and numerical modeling of rock masses supported with cable bolts in two mechanized, cut-and-fill stopes and a shaft pillar at the Homestake Mine. Extensometers were used to measure rock displacement, while cable bolt strain gauges were installed to measure loads on both conventional and birdcage cable bolt supports. These instruments provided an assessment of rock mass behavior during mining as well as essential data for verifying results from computer analyses. The numerical modeling program FLAC was used to analyze cable bolt patterns and supports. Results from the evaluation study indicated that cable bolt strain gauges and extensometers were effective instruments for monitoring the behavior of rock masses supported with cable bolts. Also, numerical modeling of the 4S-48N stope using the FIAC code provided displacement values comparable with measurements from field extensometers.

Jan 1, 1993

By Robert P. Vinson

The U.S. Bureau of Mines evaluated a light-scattering technique for discriminating between spherical and nonspherical particles. This evaluation was a three-step procedure. The first step required collecting light-scattering data for a variety of particles. This was accomplished with a particle analyzer called the DAWN-A. The DAWN-A measured the scattered light intensities of individual particles at a forward scattering angle of 40°. These DAWN-A measurements of individual particles are called scattering signatures by the Bureau researchers. The second step in this evaluation was to calculate a sphericity index number using the scattering signatures produced by the DAWN-A. The sphericity index number can range from 0 to 1. A calculated sphericity index of 1 would show that based on the intensity of scattered light, the particle was a perfect sphere. The third and final step of this evaluation was the comparison of the calculated sphericity indices of the various particles. Comparing these indices made it possible to discriminate between the nearly spherical waterdrops and the nonspherical coal and rock dust particles.

Jan 1, 1993