Search Documents

By A. M. Salomon de Friedberg

"With respect to impurities, HBM&S' copper smelter, located in Flin Ron, Manitoba, is in an unusual position. In addition to the usual concerns, the fact that copper and zinc production at Flin Ron is closely integrated results in the unique situation where feed to the copper smelter typically contains 7% to 8% zinc. This paper discusses the ramifications to copper smelter operations resulting from the marriage of HBM&S' metallurgical plants. Distributions of impurities (specifically Zn, Pb, Ni, As, Bi, Sb, and Cd) are presented and operating practices designed to reduce the impact of impurities on anode copper quality are detailed.IntroductionHudson Bay Mining & Smelting Co. Ltd. (HBM&s), has been operating its metallurgical complex located in Flin Flon, Manitoba, since 1930. The smelter and zinc plant were originally separate entities with respect to production. The smelting operation consisted of traditional multiple-hearth roasters, a reverberatory furnace and Peirce-Smith converters. The zinc plant also utilized multiple hearth roasters and then followed with sulphuric acid leaching, purification and electrowinning. The zinc plant also recovered cadmium from a separate purification/electrowinning circuit.The two plants operated essentially independently of each other until rising zinc levels in the copper concentrate and large stockpiles of zinc-rich leach residues prompted the construction of the fuming plant in 1949. The smelter used pulverized coal to reduce zinc oxide present in the reverb slag and then captured the resulting zinc bearing fume in the fuming plant baghouse. The fume was sent to a separate ""oxide roaster"" in the zinc plant where it was first roasted to remove halogens and then leached to recover the contained zinc. This oxide fume became a major source of feed to the zinc plant accounting for roughly one quarter of the total zinc production. Furthermore, through the smelter's treatment of sulphide leach residue, both copper and zinc recoveries were improved for the over-all complex."

Jan 1, 1993

By Orlando Martino

This regional report covers the mineral industries of Canada and 40 countries and areas in Latin America and the Caribbean Basin. Also included is a brief description of the mineral potential of Antarctica. The Latin American region encompasses an area twice that of the United States. Latin America and Canada have a rich and diversified endowment of mineral fuels, metals, and industrial minerals. Tables 1 and 2 provide a summary view of Latin America and Canada's output of its major mineral commodities in world mineral supply in 1990 and 1991. Table 3 shows the relative importance of a selected group of minerals produced in Latin America in the world mineral economy.

Jan 1, 1993

By A J. Jonaitis

The DENVER Tube Press is a simple, high pressure (1500 PSI (100 bar» filtration unit, developed for processing difficult-to-dewater materials and to produce a handleable filter cake and clear filtrate product. Lab and pilot testwork conducted in Australia on coal fines (55-70\ -35 micron (400 mesh)) have shown that total moisture contents of less than 20\ are consistently achieved in the final cake products from the Tube Press. Currently, these coal super fines are sent to waste due to uneconomical mechanical dewatering methods, which were only able to reduce total moisture levels in excess of 30%. Calculated, throughput rates for the 500 Series Tube Press exceeded 1700 kg/hr (3750 lbs/hr). Feed solids concentration requirements are between 45 and 50\ to achieve these results.

Jan 1, 1993

The U.S. Bureau of Mines Information and Analysis Directorate collects worldwide data on virtually every commercially important nonfuel mineral commodity. These data form the base for tracking and assessing the health of the minerals sector of the U.S. economy. The Bureau's data collection activity was instituted by the 47th Congress in an appropriations act of August 7, 1882 (22 Stat. 329), which placed the collection of mineral statistics on an annual basis. The most recent authority for the U.S. Bureau of Mines survey activity is the National Materials and Minerals Policy, Research and Development Act of 1980 (Public Law 96-479, 96th Congress). This act strengthens protection for proprietary data provided to the U.S. Department of the Interior by persons or firms engaged in any phase of mineral or mineral-material production or consumption.

Jan 1, 1993

By Gordon T. Austin

The combined value of production of natural abrasives, which include tripoli, special silica stone, garnet, staurolite, and emery, increased in 1993. The increase in the value of tripoli production was the result of an increase in total production. Special silica stone experienced an increase in unit value but decrease in the quantity produced. Garnet showed a 19 % decrease in quantity and an 8 % decrease in value. Staurolite increased about 51 % in the quantity produced and 136 % in value compared with those of 1992. Staurolite's significant increase in value of production resulted from a 56 % increase in the unit value. The fused aluminum oxide industry showed an 8 % decrease in the quantity produced and a 13 % decrease in the value of production. The silicon carbide industry saw an 11 % decrease in the quantity produced and an 8 % decrease in the value of production. Combined, the industries decreased 9 % in quantity and 11 % in value compared with those of 1992.

Jan 1, 1993

By Pina P, Pereira MJ

The increasing exhaustion of raw materials entails the exploitation of poorer orebodies where the target mineral occurs frequently in a very fine dissemination. Consequently it is necessary to grind more and more fine to achieve an adequate mineral liberation. In other words, it is of fundamental importance to know what size one should grind in order to avoid the following detrimental situations: 1. Excessive grinding - giving rise to the generation of ultra-fine slime particles which may be lost in the ulterior concentration process and simultaneously leading to higher energy consumption. 2. Incomplete grinding - giving rise to insufficient liberation and consequently leading to considerable losses of the valuable components in the tailings. Although this issue constitutes one of the most important steps in mineral processing, little research has been done compared to other processes, mainly due to the fastidious experimental work required. This paper describes a complete and integrated system of image analysis, where some algorithms to determine automatically the degree of li beration, for different levels of grinding, are proposed. These algorithms, mainly based on mathematical morphology theory were tested with images obtained from polished sections of different grain size fractions. Cases studies on a complex sulphide ore from an important copper and tin deposit located in the South of Portugal are discussed. Samples of the unbroken ore are also studied by image analysis to predict the degree of liberation obtained according to the fineness of grinding.

Jan 1, 1993

By Stanojevic R, McGlinn PJ, Day RA, Levins DM

This paper reports the results of a number of studies that Ansto has carried out for mineral sands companies concerned about low-levels of naturally-occurring radioactivity in their products. Where measured levels of radioactivity have exceeded allowable levels, Ansto has used specialised techniques to identify the source and distribution of the radioactivity and investigated processing strategies to remove the Contamination.

Jan 1, 1993

By CorrOa de Araujo A, Salum MJG

The treatment of mining and metallurgical liquid effluents is becoming, everyday, a necessity felt by these industries. Physical-chemical and chemical methods for treating such effluents are generally necessary whenever heavy-metals and other toxic compounds such as cyanide are present. The present paper discusses the use of precipitate flotation as an alternative physical- chemical method that can be applied for the treatment of effluents containing heavy-metals (mainly zinc and cadmium) and cyanide. Examples of laboratorial scale applications on real effluents are given. In both cases precipitate flotation was able to reduce the concentration of toxic components of the effluents at a very high removal rate, generating a solid waste that can either be disposed, re-used or recycled. A cationic collector - dodecylamine hydrochloride - demonstrated to be the best choice of surfactant for the two systems investigated. Sodium sulphide and dithizone were selected for the precipitation of the zinc bearing effluent whereas a copper salt was preferentially used for precipitating cyanide in a form adequate for its recycling envisaging the use of an AVR (acidification - volatilisation - regeneration) technique.

Jan 1, 1993

By Dmitrievskaya TY, Cheremnykh PA, Kuftinova IV, Yaremenko VN

The comprehensive processing of raw materials and the tendency to waste-free production require the combination of various methods of concentrating mineral resources. Magnetic separation, an ecologically clean method of concentration, is one step in the technological cycle of ore processing, and cleaning and classifying of raw materials. Separators with superconducting magnetic systems cooled by liquid helium are the novel equipment for practical concentration. Recently, high-gradient (HGMS) and open-gradient (OGMS) magnetic separators using the effect of superconductivity have appeared. The separators of the first type are expedient in the head-end of the technological cycle, as they are most efficient for processing of particles 100 ¦m and greater in size. In this case the main task is to obtain pure tailings with a minimum amount of the useful component. This method allows the essential reduction in the cost of the subsequent crushing and grinding, because only the magnetic concentrate is directed to further processing. The separators of the VGMS type are used more efficiently in the final stages of the concentration cycle to condition the end product. The present work is devoted to the theoretical and experimental investigation of the motion of weakly magnetic particles in the working chamber of superconducting separators of the open-gradient magnetic separator (OGMS) and HGMS types. The flat OGMS is equipped by a magnetic system with NbTi racetracks cooled by liquid helium. The chamber is divided into zones by partitions parallel to the plane of the magnetic system. It is shown how, depending on the number of the zones and their depths, the extraction function of the OGMS varies and the transition from the OGMS to the HGMS occurs. The particles 2 mm and less in size are considered. The extraction parameter distribution of the particles was measured for a multicomponent weakly magnetic ore. It was experimentally shown that xD2 is the extraction parameter for the particles in the OGMS on condition that (p-po)D /l8/tl/g

Jan 1, 1993

By Grady B. V O, Cavell K. J, Ault A. R, Newman O. M G, Malcolm J. McPhersqn

Cyclic voltammetry (CV) has been evaluated as a technique for monitoring the quality of an industrial zinc sulphate electrolyte. The basis of the method involves measuring a change in the polarisation of the zinc nucleation reaction at an aluminium surface and relating this to the impurity content and/or the overall quality of the electrolyte. Specifically, the technique aims to be able to indicate and quantify detrimental synergism between impurity elements, something which traditional analytical techniques are incapable of providing. The technique has found some success with regard to monitoring glue additions in a range of metal electrolytes. It has been found that investigations by a number of workers over the past 15 years have produced variable and often misleading results due to the inadvertent use of commercial purity aluminium working electrodes. It has been shown that impurity elements in the working electrode can give rise to a range of responses that are not obtained when pure aluminium is used and that the response is variable due to the lack of surface homogeneity of commercial purity aluminium electrodes. Furthermore, it was demonstrated that previous detection limits reported in the literature were based on the presence of additional peaks in the cathodic scan and not polarisation effects. The results of this study have shown that when a pure aluminium working electrode was used, the method was incapable of detecting any change in polarisation for an electrolyte containing three common impurities (Co, Ni and Ge), at concentrations that would significantly reduce optimum electrolytic performance. A range of methods was tried to sensitise the technique, including raising the temperature and acidity, and adding antimony in order to induce some synergism. In all cases the polarisation response was unchanged. Consequently, apart from the commercialised application for monitoring additions of antimony and levelling agents such as glue, CV has very limited application as an electrolyte screening technique.

Jan 1, 1993

By JSrvinen A, Yll÷ E

At Cominco's Zinc Refinery at Trail, British Columbia impurities are removed from zinc sulphate electrolyte by a two-stage purification process using zinc dust. Copper, cadmium and thallium are removed in the first stage whereas cobalt is removed in the second stage. Cobalt removal kinetics are affected by soluble antimony and copper additions to the electrolyte. This study was focused on the kinetics of cobalt removal by zinc powder cementation. Experimental variables included copper and antimony concentrations, pH and temperature. Common organic additives employed in zinc plants were studied to determine potential interactions with the cobalt removal process. Cementation products obtained from laboratory experiments and plant practice were studied using SEM. A number of significant results were obtained: 1. Copper and antimony ions were sustantially removed from solution during the early stages of the cementation reaction (within the first 15 minutes). Cobalt cementation kinetics are slow and follow a first order kinetic regime. 2. A drop in the cobalt removal rates can be correlated with a rise in the Eh of the slurry. 3. Ligninsulphonate, Percol 351 and animal glue at levels of 2 mg/L significantly impede cobalt cementation.

Jan 1, 1993

By K Schonert, K Eichas

Electrostatic separation of non-conductive materials can be accomplished by triboelectric charging. The efficiency of convential separators becomes worse in the size range below about 100 ¦m. These problems are solved by developing a new double-drum-separator. The investigations have shown the possibility of separating very fine mineral mixtures (eg quartz/calcite) in a strong electric field after tribo-charging in a special dust-feeder. The paper reports about the influence of particle size and field intensity on the separation and deals furthermore with the problem of desagglomeration.

Jan 1, 1993

By Gordon T. Austin

The combined value of production of natural abrasives, which include tripoli, special silica stone, garnet, staurolite, and emery, increased about 4% in 1990. The increase in the value of tripoli production was the result of an increase in the unit value. Emery increased owing to an in? crease in the volume of the material produced and an increase in the unit value. Special silica stone experienced a decrease in unit value and an increase in the quantity produced. Garnet showed a 10% in? crease in quantity and a 73% increase in unit value. Staurolite decreased about 8% in the quantity produced, and the value of production decreased about 10%. The fused aluminum oxide industry showed a 5% decline in the quantity produced and in the value of production. The silicon carbide industry saw a 10% decrease in the quantity produced and a 9% decrease in the value of production. Production for both industries decreased 7% in quantity and value compared with those of 1989.

Jan 1, 1993

By Tack K

During its 28-year life the MHD ISP smelter has gone through two phases, each of about a dozen years. The first phase was a learning one; in the second phase the lessons were applied and throughput and production rose strongly. Early experience revealed the robustness and the flexibility of the Imperial Smelting Process. The experience was demonstrated by strong increases in the throughput of mixed lead-zinc concentrates and of secondary (oxide) zinc materials. Purchased material quantities rose from 175 000 tonnes/year to 200 000. The required capacity increase of the IS furnace to smelt the higher throughput was achieved by relatively minor modifications; for instance a change to the internal furnace profile gained an extra two square metres in cross sectional area. The furnace hearth area has remained practically unchanged over its entire history. The paper concludes that there is still more potential to be drawn from the process and MHD intends to sustain raw material input at a new level of 240 000 tonnes/year. However, this rate will have to be achieved under the imposition of more stringent environmental and product quality standards than ever before.

Jan 1, 1993

ILZRO sights are locked securely on the targets of the expanded applications and ever-improving quality in the major market for zinc-coated steel. A wide range of ILZRO-sponsored research projects examine issues of formability, paintability, and corrosion resistance for traditional hot-dip galvanising, electrogalvanising, and ILZRO's own proprietary zinc coating, Galfan. Recent research has focussed on the on the interaction between Galfan and different substrate steels to determine optimum combinations for different applications. ILZRO enjoys an evolving role in providing the connection between research laboratories and marketing divisions through supporting research and services for the Galfan Technical Resource Centreò(GTRC) and the recently formed North American Galfan Development Authority (NAGDA). GTRC has just produced a new problem-solving manual that provides a comprehensive source of hands-on solutions for the many Galfan licensees throughout the world, and should contribute substantially to the reputation of Galfan as a consistently top-quality steel-coating product. Meanwhile, NAGDA is advancing the market with new advertising for Galfan based on superior corrosion-resistant qualities proven through ILZRO-sponsored research. Practical manufacturing issues remain at the forefront of ILZRO priorities, with research emphasis on cutting and welding zinc-coated steel to provide direct assistance towards improved product quality and a more secure market. Moving to the arena of die casting, when the specifier looks to zinc to fill a design need, ILZRO-sponsored research projects provide comprehensive documentation on metallurgical characteristics for every zinc alloy under almost any imaginable application. On-going ILZRO-sponsored research is integrating this wealth of data with sophisticated computer programs that model die-casting designs with ever-increasing accuracy, as other ILZRO projects lay the market groundwork for zinc in applications ranging from vibration damping to electromagnetic shielding.

Jan 1, 1993

By Richard B. Stein

Bechtel's BEMSIM computer program is a useful tool for solvent extraction-electrowinning plant design optimization. Its power (up to 90 stream components, 240 process streams, 180 process steps) has been applied to investigate floweheet configurations in order to perform basic engineering, sizing of plant equipment and to optimize performance of commercial-size copper plants. Flowsheet variations presented include series, parallel and series-parallel extraction stages, while heat balances simulate operations in summer and extreme winter conditions. The BEMSIM program has also been applied to nickel-cobalt, gold and manganese extraction.

Jan 1, 1993

In the new flowsheet for Inco Limited's S02, Abatement Project at the Copper Cliff, Ontario operations, a copper/nickel sulphide flotation concentrate will be flash smelted, then converted to Bessemer matte. As in current practice, this will be slow-cooled and separated into components by magnetic separation and flotation. The copper content will emerge as a chalcocite concentrate (impure Cu2S), containing some nickel. This copper sulphide will be converted to copper metal.

Jan 1, 1993

By Ronald L. Gibbs

IN THE BEGINNING Contrary to popular myth, the personal computer can trace its roots back to a time before 1981 and the IBM PC. The seeds of the personal computer revolution were probably founded in 1975 with the release of the Altair (kit) personal computer, first advertised in Popular Electronics. June of 1975 marked the beginning of the Homebrew Computer Club in San Francisco. The founding membership list of the Homebrew Club now reads like a "Who's Who" of those involved in the early development of the personal computer industry. The Apple I computer was created by Steve Wozniak in early 1976 from the newly manufactured MOS Technology 6502 chip. It had 4,000 bytes (4K) of Random Access Memory (RAM] memory, a revolutionary amount of memory in 1976. Another early pioneer, the Commodore Pet computer, was another 6502 machine, but with 8K of memory. Tandy Corporation made its name in the hobby industry with leather kits. They embarked on a new path with the production of the TRS-80 line of personal computers. Most were based on the Z-80 chip, but again, were memory limited. A number of other Z-80 based systems followed later, including the Osbourne and the KayPro Computers. These systems were based on the Digital Research CP/M operating system and had a maximum of 64,000 bytes of memory (64K). The Apple I1 Computer appeared in 1977. Newer models of the original Commodore Pet and an Atari computer followed. These machines were also limited to 64K of memory addressing, and the early models typically shipped with only 16K, 32K, or 48K of memory. The Z-80 and the 6502 were the first truly commercialized CPU chips touting boxes with key- boards, monitors (sometimes a TV), and the ability to expand (peripheral slots for serial communications, centronics parallel communications, etc.1. They all shared one technology, audio tape as a storage media. The use of a portable tape recorder provided inexpensive, if not always reliable, magnetic storage. The tape recorders were typically finicky and required patience to use. Adjustments to the volume control were often needed to find "just-the-right" setting for loading or saving information. This kept the personal computer from being accepted in many markets, and gave it a reputation as a hobbyist or experimenters' toy. In early 1979, Steve Wozniak finished the design of a floppy disk drive and controller. This was a revolutionary design which reduced the "then" standard number of controller chips from fifty-plus, to just eight. With the advent of an affordable floppy disk drive mechanism, the personal computer was about to gain respectability. From a business standpoint, it was now possible to save and reliably retrieve business information. It also provided a superior means of distribution for commercially created software. Commercial software became a commodity rather than an oddity.

Jan 1, 1993

By Harry M. Castrantas, James L. Manganaro, Craig W. Rautiola, James Carmichael

Caro's acid (peroxymonosulfuric acid) was successfully field tested as a cyanide detoxification agent at a North American gold mine. An on-site FMC generator injected Caro's acid into a mill tailings slurry sump. The WAD cN-(weakly acid dissociable plus free cN-) was reduced from 40-108 ppm to below the target level of 20 ppm using a 1/1 mole ratio of CA (Caro's acid) /CN-. At an inlet CA/CN-mole ratio of 1.8/1, WAD CN­concentrations as low as 4 ppm cN-were achieved. Raw material costs for the cyanide detoxification were cut by 60% compared to using hydrogen peroxide (H202) alone. Detoxification time with Caro's acid was much faster compared to H202. This resulted in completion of detoxification before the treated slurry reached the tailings pond thereby substantially reducing the probability of wildlife fatalities.

Jan 1, 1993

By A. L. Putz, G. Ladouceur, A. R. Laplante

A laboratory centrifugal concentrator was used to evaluate two gravity circuit configurations treating a flash flotation concentrate at a Canadian gold mill. The Initial circuit consisted of a 76 cm (30 Inch) plant Knelson Concentrator (PKC) for coarse gold removal. Later, a hydroseparator and spiral were Installed, with the hydroseparator underflow feeding the spiral and the spiral tailings plus hydroseparator overfiow reporting to a 51 cm (20 Inch) PKC. Gold recovery In the 76 cm PKC averaged 45%. Gold was recovered consistently In all size fractions greater than 38 µm, where recovery dropped to 22% for the -38 µm material. Changing the circuit to Include the hydroseparator and spiral decreased the Knelson unit recovery to less than 17%. The decrease was attributed to the spiral which recovered much of the free gold ahead of the Knelson and to changes In the mill feed (free gold portions were finer and less abundant). The spiral demonstrated erratic behaviour although It still recovered significant coarse gold (+75 µm) yielding unit recoveries of 18-44%. Although mechanical difficulties were experienced with the 76 cm PKC, Its performance was superior to that of the hydroseparator, spiral and 51 cm PKC configuration. Much of the gold In the ball mill recirculating load was found to be too coarse for significant recovery In the flash flotation cell and should be recovered by gravity from the cyclone underflow or ball mill discharge. The LKC proved to be a successful device to evaluate gravity recoverable gold content. Dilution of test samples with silica further enhanced this methodology.

Jan 1, 1993