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By K. R. Robilliard

An outline is given of the problems facing tlile lead and zinc industry from the viewpoint of the range of residues currently produced from electrolytic zinc, blast furnace and other processes. Smelting approaches available using top submerged lancing technology are discussed and analysed. Pilot plant results for a range of lead and zinc-bearing materials are presented.

Jan 1, 1992

By Akio Ohta

The Hyuga smelter has been producing ferronickel by a rotary kiln-electric furnace process in Miyazaki, Japan. Several approaches to improve our operation have decreased the electrical energy consumption. A new process was developed to decrease the cost of energy even further. Oil and technical oxygen are injected through lances to heat up the calcined ores (calcine) instead of the electric power. Main problems during the development of the process were the short life of the water-cooled lances, the check on security of the safety system and the eruption of combustion gases through the calcine bed. These problems have now been overcome successfully, and stable operation can be maintained. The addition of 1 Litre of heavy oil per tonne of ore can save the electrical energy requirement by 8.6 kwh per tonne of ore. The new process has resulted in a reduction of the electrical energy consumption by more than 10 percent

Jan 1, 1992

By J. Trow

Dowsing is really IESG which inductively locates electric gradients (dv/dx) on the flanks of SP anomalies. "Sensors" are in one?s head. The "meter" consists of one?s body, limbs, and two $.69 welding rods. The method was calibrated near Mamainse Point, Ontario, where IESG-negative chalcopyrite-bornite-chalcocite-native copper ores reveal mineral zoning related to the IESG-positive Keweenaw fault, down which oxidizing solutions moved. In Michigan, the IESG-positive Keweenaw fault suggests that oxygen-bearing solutions from the Jacobsville Sandstone moved downward to oxidize hydrothermal sulfur to produce native copper, and to supply sufficient water to satisfy Walter White.

Jan 1, 1992

By T. Gonzales

Magma Metals Company operates an Outokumpu Flash Furnace, four Peirce-Smith Converters and two Anode Casting Wheels supported by six Anode Vessels. Process gasses from the Flash Furnace and Converters are treated in a two train/double contact sulfuric acid plant. Sulfur capture for the smelter is +98%. The new flash furnace was commissioned on July 7, 1988 and has processed over three million tons of sulfide concentrate without a major rebuild. Magma has gained unique experience in the operation of the flash furnace at high oxygen enrichments with low off-gas dust loadings. New procedures have been developed to maintain secondary material generation at equilibrium and for maintaining metallurgical control of operating parameters. This paper describes all the procedures, operation control parameters and operating philosophy that has allowed Magma to achieve superior performance.

Jan 1, 1992

By M. A. Alan

The Bellavista Gold Deposit lies 75 Kms north west of San Jose, the capital of Costa Rica, Central America and 3 Kms north east of Miramar, in the Province of Puntarenas. The total road distance from San Jose to the deposit is 120 Kms all paved road except for a 2.5 Km graded, gravel road on the property (Figure 1). Infrastructure services in the Miramar-Puntarenas area are well developed with electrical power distribution, a modern port facility and community services being available. The deposit lies on the south west flank of the Tilaran Mountain Range between an elevation of 550 and 800 meters above sea level. The local topography is steep, originally covered with pre-montaine, tropical wet forest vegetation which has been largely destroyed due to clearing for cattle grazing. The annual rainfall is approximately 2,950 mms, 90% of which occurs between May and October.

Jan 1, 1992

By M. E. Myers

An experimental program is being carried out to determine the thermodynamic characteristics of zinc solubilization in high-temperature iron and iron-carbon alloys. Two versions of an isopiestic technique are being used, with zinc at a lower temperature being equilibrated with pure iron foils or molten iron-carbon alloys at a higher one. The lower temperature sets the partial pressure of zinc vapor, and thus the activity relative to a given reference state. Initial results show Henrian behavior for dilute zinc solutions in austenite and a molten 4.6% C alloy, with unit-pressure solubilities in pure Fe that closely match the predictions of Wriedt.

Jan 1, 1992

By John L. Sundstrom

Complete systems were designed -and are in operation to recycle the effluent streams and to remove impurities from tankhouse. electrolyte, Heavy em¬phasis was placed on making usable products from as many streams as poss¬ible at minimum capital and operating costs. Almost complete recycling: and reuse of water and sulfuric acid were paramount. Techniques used in-clude solvent extraction - electrowinning, evaporation - crystallization and filtration.

Jan 1, 1992

By R. Hogg

Sedimentation in highly flocculated suspensions of fine particles such as clays occurs through individual settling units (flocs) which have very open structures and correspondingly low density -typically less than 5% solids by volume. It follows that such settling processes rapidly lead to the build-up of a bed of flocs which are essentially close-packed, with inter-floc porosity of perhaps 50%, but with an overall solids content of no more than about 2-3 percent by volume. An important consequence is that the thickening process is dominated by the consolidation of this bed rather than by simple settling of the individual flocs. Experimental measurements of sediment consolidation in flocculated clay suspensions indicate that for a given system, consolidation rates are essentially determined by solids concentration and can be evaluated using the classical Kynch treatment. However, these rates are strongly dependent on the physical as well as chemical conditions of the flocculation process. Furthermore the extent to which gravity consolidation proceeds depends on the total weight of sediment (i.e. on both height and solids concentration). The implications with respect to thickener operation and the requirements for laboratory testing for thickener design are discussed.

Jan 1, 1992

By Roger N. Kust

Removal of heavy metals from industrial process streams is becoming increasingly important for _the recovery and reuse of values in process tails. Technology has been available for several years which removes heavy metals, from dilute (0.1-3.0 g/L) streams, as hydroxide or hydrated oxide sludges, allowing discharge of washed cakes with up to 60% solids. This paper reports on improvements to this technology which now allows treatment of streams with metal concentrations in excess of 60 g/L while eliminating the need for thickeners. Streams containing copper, iron, aluminum, chromium, nickel, zinc, cobalt and lead have been successfully treated.

Jan 1, 1992

"A 3-dimensional finite element model for stress/stability analysis of rock excavations in underground mines is presented. Developed for use on personal computer under OS/2 operating system, the model employs the 8-node isoparametric brick element and accounts for such loading conditions as in situ stresses and gravity loading of the rock mass. In addition, modelling of backfill in mine stopes as in situ stress-free material is incorporated. Material failure is assessed by Mohr-Coulomb or Hoek-Brown failure criterion. A mine design example is presented to illustrate the potential use of the model as a tool for stope design.IntroductionNumerical modelling of mine structures has become a vital tool for mine design in recent years. The need to maximize ore extraction ratio and to reach deeper mineral deposits underground has led the mining industry to employ numerical methods of analysis to undertake complex ground control studies in order to better understand the ground response to mining excavations and to evaluate the ground support requirements. Thanks to the rapid developments in computer technology, it is now possible to perform very comprehensive analyses including, but not limited to, 3-dimensional, elasto-plastic, or large deformation or time dependent nonlinear analyses on personal computer.During the past ten years or so, many researchers undertook 3-D finite element analyses of rock mechanics problems in mining engineering. The following is only a sample review. For example, Chan'!' used three-dimensional finite elements to study the mechanical response of jointed granite during shaft sinking at the Canadian Underground Research Laboratory. Wang et al.(2) performed 2-D and 3-D finite element analyses of room-and-pillar mining system with flat and rolling coal seams. Thatejatu used three-dimensional finite element method to examine the problem of branching tunnels. Dolezalovaw used three-dimensional finite elements for the analysis of tunnel-face advance with partial excavation as well as full-face excavation in combination with rein for cement of the face by long anchors. Peili (5) used three-dimensional finite elements for the simulation of rock-liner interaction near the tunnel face."

Jan 1, 1992

By Lorenzen L, Van Der P F

It is the aim of this paper to review recent research in understanding the role of cyanide in the elution of gold. Under conditions of severe pre-treatment (high temperatures and levels of cyanide), the dynamics of elution are determined mainly by the adsorption equilibrium and the flow conditions in the column. When conditions are less favourable for desorption, transport phenomena are rate controlling. The most important sub-processes of elution are the changes in cyanide, potassium and gold concentrations, as well as the change in passivation of the carbon surface. Mathematical models to simulate the various sub-processes are described briefly.The presence of an irreversibly adsorbed species such as AuCN on the carbon is determined mainly by the pH, temperature and the type of carbon. Cyanide in the pre-treatment step will convert the AuCN to reversibly adsorbed Au(CN)2. Competition between cyanide and Au(CN)z for adsorption sites will enhance the elution of gold, but plays a minor role at elevated temperatures. The most important effect of cyanide is its reaction with the functional groups on the carbon to passivate the surface for the adsorption of anionic metal cyanides and thereby promote the elution of gold. This passivation, caused by the degradation of cyanide, is strongly temperature dependent. Free cyanide in the elution step of an AARL elution is of lesser importance than the cyanide in the pre-treatment step. Elution without cyanide is possible only after cold acid washing, and has been proven on plant scale.

Jan 1, 1992

By Robert H. Peters

This report presents a literature review conducted by the U.S. Bureau of Mines. The review summarizes what has been learned from the large volume of empirical studies on the effectiveness of eight types of interventions intended to increase organizational effectiveness via in the management of human resources. The interventions concern the following: recruitment, selection, training, objective feedback, goal setting, reward systems, participative management practices and organization development. Although many of these interventions appear to have the potential for improving the safety and efficiency of mining operations, it does not appear that they are being widely used. Examples are given of the successful use of a few of these interventions at mining operations. An analysis of the relationship between coal mine productivity and safety is also presented. This analysis generally supports the view that good safety performance and high productivity are NOT incompatible goals. In fact, safe mines also tend to be more productive and vice versa.

Jan 1, 1992

By Jerome P. Downey

In the thermal treatment of electric arc furnace (EAF) dusts, zinc is reduced, volatilized, and ultimately recovered either as liquid metal in a splash condenser or as solid zinc oxide in bag filters. During the process, the duet's chlorine and fluorine content also enters the gas phase and condenses as dross in the splash condenser or as salts which contaminate the zinc oxide product. Pretreatment of EAF dust by pyrohydrolysis appeared to offer a means of minimizing the duet's halogen content. The primary research objectives were to experimentally verify the technical viability of pyrohydrolysis and delineate the process parameters requisite for efficient halogen removal. To this end, representative EAF duet samples were secured and characterized by x-ray diffraction, scanning electron microscopy, and Mössbauer analyses. Specific- experimentation focused on the response of halogen extraction to variations in temperature, retention time, water vapor partial pressure, and various additives. The experimental results proved that 97 to 99 percent chlorine extraction and 80 to 85 percent fluorine extraction are consistently achieved when EAF dusts are blended with silica and roasted at temperatures of 850°C or greater in a furnace atmosphere of 75% steam (diluted by air). A statistical analysis further established that more than- a single optimal point exists, thus affording flexibility in parameter selection (e.g., by increasing temperature, the necessary retention time and additive concentrations are decreased). The findings substantiate the feasibility of pyrohydrolysis roasting in reducing the chlorine and fluorine in the EAF dust to a level that will obviate industrial concerns about halogen contamination. The end-product of the pyrohydrolysis procedure is a de-halogenated, self-fluxing calcine which can be directly charged to a plasma or flame reactor. The paper includes design parameters and flow diagrams illustrating the pyrohydrolysis process integrated with the plasma and flame reactor technologies.

Jan 1, 1992

Treat contaminated coal mine drainage to meet EPA and State water quality requirements. Approach A model (fig. 1) is presented for selecting, designing, and sizing one or several passive mine drainage treatment systems that can be used in remediation of abandoned mine lands (AML). The three principal types of passive mine drainage technologies for the treatment of coal mine drainage are an aerobic system, a compost wetland, and an anoxic limestone drain. The multistep approach presented here provides a simplified method to characterize the type and magnitude of the water quality problem and then to select either a single treatment system or a combination of treatment systems to address the specific site situation. How It Works Step 1. Discharge Characterization. Characterization of the discharge consists of measuring the discharge flow rate and collecting water samples at the point of discharge for chemical analysis. Both the flow rate and chemistry of a discharge can vary seasonally and in response to storm events. It is important to account for this variability by determining flow rates and water chemistry under various conditions.

Jan 1, 1992

By S. McAlister

"Falcon Concentrators Inc. has developed a high capacity centrifuge for the recovery of fine, free gold as well as other metals and minerals which were previously thought to be unrecoverable by gravity means. Development started in the early 1980's and the first commercial operation was commissioned in 1986. Gold applications include scavenging conventional gravity and cyanidation circuit tailings, cleaning gravity concentrates, cleaning flotation concentrates to melting grade, scavenging flotation tailings, and placer mining. Recent development work by Falcon has expanded the applications scope of the centrifugal concentrator to include many minerals amenable to gravity concentration including iron, tin, industrial minerals, and hazardous wastes. This paper discusses this technology including its history, present applications, and future potential. OVERVIEW OF CENTRIFIJGAL CONCENTRATIONUsing centrifugal force to enhance the separation of materials by differential specific gravity has been researched for over a century. Many attempts have been made to concentrate minerals in high gravity fields. Patents were granted on this subject as early as 1891 (see Figure 1). Patenting activity continued into the 1920's and has been relatively quiet since. It is significant that no centrifugal system of gravity concentration has been broadly accepted by the mineral processing community until recently. Much of the world's reserve of mineral deposits which are amenable to conventional gravity concentration technology (coarse-grained) have been mined and therefore there is an increasing demand for technology which can economically recover the fine-grained gravity recoverable minerals in the remaining deposits. In addition, centrifugal concentration can play an increasing role in solving environmental problems by offering an inexpensive method of concentrating hazardous materials such as uranium, plutonium, mercury, lead, and other heavy metals. The overall cost of disposing of these substances safely can be drastically reduced if they are recovered into a concentrated form prior to disposal."

Jan 1, 1992

The mining licence for the Macraes gold mine places emphasis on the progressive rehabilitation of the land to a state compatible with the landscape and environment that existed prior to mining activities taking place. The shallow soils and hostility of the environment dictate that choices of plant species should focus on persistence rather than high productivity, choices that are made easier by observing the vegetation patterns that have developed naturally within the area, by recontouring landforms to integrate with the surrounding countryside and the use of appropriate plants and establishment techniques.

Jan 1, 1992

By R. Craig Smith

This report presents the software documentation for PREY AL, a prefeasibility mineral property evaluation program developed by the U.S. Bureau of Mines on a Lotus 1-2-3 spreadsheet. It is presented in a step-by-step "user?s manual" format. Appendixes contain the technical assumptions, program default values, and a summary printout detailing capital and operating costs and cash-flow analysis.

Jan 1, 1992

By Animesh Jha

The carbothermic reduction of chalcopyrite has been studied in the temperature range 1073 to 1273K in presence of lime. The role of lime during the reduction process is explained and the phase equilibria leading to the metallisation of copper and iron are discussed. The effect of coal and carbon monoxide on the reduction process have been studied and the rate governing steps are identified. This investigation also cites examples of possible mechanisms of physical separation of metallic Cu from iron during the reduction process.

Jan 1, 1992

By P. B. Altringer

The Bureau of Mines, U.S. Department of the Interior, is investigating biodegradation of cyanide as a means of decommissioning heap leach operations. Biological oxidation decreased weak acid dissociable (WAD) cyanide in process solutions1from 50 to 170 ppm down to 0.1 ppm. The tests were conducted both in trickling column reactors, using quartz as the growth surface, and in upflow columns, using activated carbon as the growth surface. In addition, exploratory tests indicated that bacteria will destroy residual cyanide in leached ore. A flowsheet has been proposed for closure of heap leach operations in which the metals processing portion of the plant, possibly the carbon adsorption columns, or a collection pond is used as a bioreactor. The cyanide in the process solution is destroyed in the bioreactor and the treated water is used to rinse residual cyanide from the spent heaps. The water is recycled until the effluent WAD cyanide concentration meets discharge standards.

Jan 1, 1992

By R. H. Hanewald

The processing of EAF baghouse dusts from both the specialty steel industry and low alloy producers will be reviewed. In addition, the INMETCO process has been modified so as to recover nickel, chromium and iron from many other waste materials such as pickling solutions or filter cakes, spent nickel and chromium plating baths, carbon refractories from pickling tanks, and super alloy wastes including baghouse bags. INMETCO is the only North American company presently capable of recycling nickel-cadmium batteries by high temperature metals recovery. This, along with the details of INMETCO's BDAT Test Program and results performed to pre-agreed standards with the EPA will be discussed.

Jan 1, 1992