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By C. Dorfling, M. Tadie, M. Tucker

Electrowinning is the final step in the hydrometallurgical production of high purity copper, involving the passage of electric current through an electrolyte and consequent plating of solid copper to form cathode sheets. Key electrowinning performance indicators are the current efficiency, specific energy consumption, yield, and quality of the metal. The high energy demand and associated cost mean that determination of performance indicators is critical during operation, but ‘online’ measurement is impractical due to the nature of the measurements and corrosive environment brought about by acid mist. This research considered the development of a predictive electrowinning model as a shift towards a pre-emptive approach to attaining plant performance data. A steady-state model was created from input variables available in the industry, using a first-principles approach combining mass balances, electrochemical and thermodynamic equations, and property correlations. A circuit diagram equivalent of an electrowinning cell, containing multiple pairs of electrodes, was used as the backbone of the model. The kinetics of each electrochemical reaction were modelled including iron as a major impurity. Losses in current efficiency due to ineffective electrode contact, short circuits, and stray currents were also incorporated. The model was used to predict the current efficiencies for tests performed at varying conditions in a bench-scale electrowinning cell; the average absolute error between the measured and predicted current efficiencies was 3.2%. The model requires a unique parameter fitting approach for each industrial operation; if parameters are customised for specific plants, the model will be a useful tool to predict performance and can aid the development of effective process control systems in copper electrowinning tank houses. Keywords: Copper; current efficiency; electrowinning; modelling; plating rate

Jan 1, 2020

By Cláudio Antônio Goulart Valadares

O fluxante para aços baixo carbono, aplicado no lingotamento contínuo de placas, apresenta como características a temperatura de fusão entre 1.030°C e 1.070°C e a tendência a cristalização suprimida. Desta forma, o filme de escória apresenta predominantemente a fase vítrea que facilita a transferência de calor na interface molde de cobre e pele de aço em solidificação. Há uma tendência em retirar ou reduzir o teor de flúor nos fluxantes, com o objetivo de minimizar a erosão da câmara de exaustão do lingotamento contínuo, além de ser um risco potencial para a saúde e segurança e do aumento da taxa de erosão da válvula submersa. Este trabalho apresenta os resultados de análise dos filmes de escória do fluxante referência e a sua versão isenta de flúor via microscópio eletrônico de varredura e microscópio óptico de luz polarizada. Mais resultados como difratometria de raios-X e análises térmicas também complementam esta análise assim como algumas características físico-químicas dos produtos em questão.

Jul 30, 2018

By D Connelly

Silver and gold bearing ore from the Troy Resources NL Casposo Gold-Silver Project, located within the San Juan Province of Argentina contains a complex mix of gold, silver, electrum and silver sulphides in the ore. Casposo is a typical low sulphidation epithermal style gold–silver deposit where mineralisation is hosted within rhyolite – andesite flows and breccias. Veins are typically banded quartz–chalcedony colloform - crustiform banded with quartz - carbonate infill. Mineralisation is associated with an assemblage consisting of quartz, chalcedony, adularia, calcite, illite, sericite and trace sulphides. Gold and silver occur as electrum, native silver, sulfosalts and silver sulphides. This paper presents a case study that describes the process selection, development and engineering of a tailored process plant for the recovery of gold and silver from this ore.The original feasibility study, modelling, metallurgical testwork and engineering studies are outlined. The final flowsheet was based on minimising capital cost, operability, recovery and minimising technical risk.The process flowsheet uses the traditional Merrill Crowe route because of the high silver to gold ratio in the feed and achieves maximum gold and silver recovery while providing a common facility for future ore body treatment.

Aug 8, 2011

By Thomas P. Mucho

Cable bolts are emerging as the newest ?twist? for roof support in U.S. underground coal mines. For decades cable bolts installed in underground metal mines in the United States and Canada used cement-based grouts for anchoring. The cement anchoring process, because of the time and expense for installation, made cable bolts impractical for use in coal mines. Today, the introduction of resin-anchored cable bolts provides a system more consistent with tradi­tional U.S. coal mine roof bolting practices and requirements. Expecta­tions are that the utilization of cable bolts for a number of U.S. mining applications will expand, particularly in coal mining.

Jan 1, 1998

Why A Friction Hoist? B EFORE discussing the equipment, it would be instructive to review the factors that influenced the management of Opemiska Cop-per Mines to purchase a friction hoist rather than a conventional double drum hoist. The mine required that 250 tons per hour be hoisted from a depth of 2,100 feet. They also specified that the top speed should not exceed 1800 feet per minute. Eight ton capacity skips in balance and a maxi-mum hoisting speed of 1725 feet per minute would meet the required <Output on a duty cycle as follows: Loading time Creep away from loading pocket Accelerate (at 2.5 ft/sec2) 10 seconds 5 seconds 11.5 seconds Full speed run Decelerate (at 2.5 ft/sec2) Creep into dump Cycle time Trips per hour Tons per hour 72 seconds 11.5 seconds 5 seconds 115 seconds 31 31x8 = 248

Jan 1, 1962

By E. B. Nelson, B. W. Gandrud, B. M. Bird

"The Lewisburg No. 2 mine of the Sloss-Sheffield Steel & Iron Company is located in Jefferson County, Alabama, about 7 miles due north of Birmingham. At this point the coal from the Mary Lee seam when coked in by-product ovens yields an excellent quality of metallurgical coke suitable for use in the iron blast furnace; it is also an excellent steam coal. In mining, all three benches are worked. Coarse impurities are largely gobbed by the miners underground.In addition to giving the data obtained from screen-sizing and float-and-sink tests of a representative sample of the raw coal, this report presents the results of slotted-screen tests to show the proportions of flaky particles in selected sizes, and the results of tests to show how much coal is liberated from impurities by crushing the coarsest sizes. These data have been obtained in connection with an extensive study of coal-washing now being conducted by the U. S. Bureau of Mines and the University of Alabama, with U. cooperation of the different operators of Alabama. As the work progresses other reports will follow containing furtner data on the washability both of the Mary Lee seam and of other seams in Alabama and giving the results obtained in preparing these coals by various methods.Although a great amount of investigative work on the preparation of the Mary Lee scam was previously carried on by the various coal companies of the district, comparatively little of this information has been published. In governmental publications three references have been found. Forbes5 gives a number of sections with proximate and ultimate analyses of face samples taken in the mines. Gandrud and Britton'' show sections of this seam at Flat Creek and New Castle; they also give the specific gravity and ash contents of the partings of coal and impurities. In their paper Yancey and Fraser7 include washability studies and washing data from the Sayreton mine of the Republic Iron & Steel Co."

Jun 1, 1930

By M. Handley

The Witwatersrand Basin contains by far the most gold ever found, and has hosted mining from its discovery in 1886 to the present. For many years, South Africa was the world’s largest producerof gold, nearly all of which came from the Witwatersrand. Since 2000, South Africa has fallen back several positions because of declining gold output. There are many complex and varied reasons for this; however, declining gold resources in the Witwatersrand Basin are not one of them. As far as the author knows, there are no qualified estimates in the literature of gold remaining in the Witwatersrand Basin. This paper collects mining data from several sources and then, using elementary gold accounting and error analysis, attempts to estimate the amount of gold remaining in the Witwatersrand Basin. It includes gold underground in existing and defunct mines, in evaluated ore resources, and dumps. Compiled data from 1887 to 2019 shows that 50 200 t of gold were produced by Witwatersrand mines, while it is estimated that a further 48 100 t remainunderground, both within and outside of mine leases, a further 1 600 t on the surface in tailings,and an unknown amount in rock dumps. Nearly all of this gold will remain inaccessible with current mining methods, and major technical developments in mining will be necessary before any of the gold can be categorized as a code-compliant resource or reserve. To win this prize, the mining industry will have to rethink its approach to mining, both in old mining leases and in the unexploited ground. It will also have to find effective means of preventing gold theft and informal mining, which are on the rise.

Apr 5, 2023

By Ana E. Bohé, Georgina De Micco, Juan P. Gaviría, FEDERICO J. POMIRO, Gastón G. Fouga

Chlorination and carbochlorination processes have industrial applications in metallurgical activity for extraction and purification of uncommon metals such as rare earth elements (REE). This study reviews the chlorination and carbochlorination reactions of light REE (LREE) oxides with chlorine considering the thermodynamic, stoichiometric, and kinetic aspects of the reactions. Lanthanides between lanthanum to gadolinium were considered as LREE, in agreement with previous literature, and the results were detailed in this review. LREE were analyzed taking into account their oxidation states and were divided into three groups accordingly. The results presented show that, although the LREE are chemically similar, their behaviors during the reactions with Cl2 and Cl2–C, and the different LREE-O–Cl compounds formed, have particularities. It was observed that gadolinium, in both thermodynamic calculations and experimental results, presents some differences, and it can be considered intermediate between light and heavy REE; i.e., reactions between LREE2O3 and Cl2(g) begin at approximately 250 °C, except for Gd2O3 that begins at 327 °C. The present work will contribute to a better understanding of the chemistry of LREE oxides and Cl2 under different conditions and the products obtained in the LREE–O––Cl2(g) and LREE–O–C–Cl2(g) systems.

Oct 15, 2021

By Oliver Bowles

ASBESTOS is a name applied to a group of naturally fibrous minerals. As indicated in a later section devoted to a detailed discussion of the early history of asbestos, the tern may be defined as a. fibrous form of serpentine or amphibole. It does not include fibrous forms of other minerals, such as wollastonite, nemalite (fibrous brucite), or the fibrous forms of calcite or gypsum. A material that has the characteristics of silk or cotton and at the same time will not burn is unique. Because it combines these qualities with other advantageous properties, asbestos has specialized uses for which no substitutes are yet available. Asbestos furnishes a major raw material for a great variety of essential products and their manufacture constitutes a vast industry. The United States leads all countries in the manufacture of asbestos products. The value of such commodities manufactured in 1952 exceeded $332 million. They are not only of vast importance to budding construction and industry but axe absolutely, essential to certain important fields of use, for example, steam packings and friction materials, such as brake-band linings on automobiles.

Jan 1, 1955

By W. R. K. Wu

This bulletin traces the development of high-pressure, coal and tar hydrogenation technology, based on an intensive review of the pertinent literature. The bulletin was written as a part of the Bureau of Mines research program on synthetic liquid fuels. It covers the history and economics of the process; the chemical aspect of hydrogenation of coal, tar, and middle oil; the engineering aspect of converting coal and tar to liquid fuels, principally gasoline; and the equipment for the process. The literature covered includes documents of the United States and British Governments, journals, and other publications. Bureau results in the hydrogenation field are also incorporated.

Jan 1, 1968

A study was made to determine the effect of increasing concentrations of dissolved oxygen on the floatability of galena pyrite and chalcopyrite. Adsorption, flotation and contact-angle tests were done in deoxygenated, in air-saturated and in oxygen-saturated solutions. The results showed that the adsorption of collector increased as the concentration of oxygen increased. Adsorption followed the exponential law r = kC'/"• Discontinuities in the curves were observed after the adsorption of several monolayers of collector. Although adsorption increased with increasing oxygen concentration, the floatability of the pyrite minerals did not increase, because oxidation had adverse effects on the floatability of these minerals. The floatability of galena was maximum in oxygen-saturated solutions, pyrite was depressed and chalcopyrite was also slightly depressed. Contact-angle tests proved that a bubble could not be attached to large flat surfaces in deoxygenated solutions, because sufficient surface free energy was not available for adhesion after the deformation of the bubble. In the presene of air, all the minerals yielded the same maximum angle of 72 degrees, characteristic of isopropyl xanthate.

Jan 1, 1970

By Yang Xiao, Zhang Yimin, Bao Shenxu, Liu Chun

Stone coal is a unique vanadium-bearing resource in China. Many techniques, such as salt roasting-water leaching, blank roasting-acid leaching, direct acid leaching etc. have been developed for vanadium extraction from stone coal. The vanadium leaching rate can reach 74.9% for stone coal from Jiangxi, but only about 27% of vanadium is leached for Hubei ore by applying salt roasting-water leaching technique. This paper investigats the vanadium occurrence in stone coal by microscope observation and electron probe, and compares the minerals components of stone coal from Jiangxi and Hubei. Although most vanadium exist as an isomorphism by replacing Al(III) from dioctahedral structure in mica group minerals in stone coal from two regions, the free vanadium is remarkably abundant in Jiangxi stone coal than in Hubei stone coal, which results the fact that vandium is relatively readily extracted from former. Moreover, the content of calcite in Hubei stone coal is much higher than that in Jiangxi stone coal. Calcium can react with V2O5 to form water insoluble calcium vanadates during roasting and this may be the reasone why the water leaching rate of vanadium is low for Hubei ore. Acid leaching is more beneficial to the vanadium leaching but other extra methods, such as adding aid-leaching agent and/or increasing acid concentration is need for the ore where vanadium is embeded firmly. This study can effectively guide the selection of vanadium extraction techniques for stone coal from different regions.

Jan 1, 2014

By Henry Kreisinger, John Blizard, B. J. CROSS, C. E. Augustine

This report gives the results of 26 tests of a four-pass Edgemoor boiler fired with powdered coal at the Lakeside station of the Milwaukee Electric Railway & Light Co. The tests were made by the fuel section of the Bureau of Mines in cooperation with the research department of the Combustion Engineering Corporation and the operating department of the Milwaukee Electric Railway & Light Co. The object of the tests was to determine the thermal efficiencies and capacities obtainable by burning powdered coal under large central-station boilers, and the possibility of operating such boilers continuously at high efficiency and capacity without destructive effect on the furnaces and without difficulties in refuse removal. In any system for burning pulverized coal the furnace is the most important part because, to justify the cost of pulverizing, the powdered coal must be burned with higher efficiency than coal fired with mechanical stokers. In other words, it is the furnace that by giving higher thermal efficiency must pay for the installation, maintenance, and operation of the pulverizing equipment. No matter how simple the apparatus for the preparation of pulverized coal may be, or how simple the pulverizing process, unless the furnace is so designed that it can be operated continuously with high thermal efficiency, the whole system is a failure. For high thermal efficiency the coal must be burned almost completely with low excess air. But low excess air and complete combustion give high furnace temperature, which in turn causes erosion of the furnace lining and fusion of the ash; and removal of the fused ash is difficult. The necessity of complete combustion with low excess air thus brings with it these two important problems in the design of a furnace for burning powdered coal: 1, Prevention of erosion of the furnace lining; 2, easy removal of refuse from the furnace. For the purpose of solving these problems, the boiler tested was equipped with a furnace having hollow walls, through which about 60 per cent of the air needed for combustion passed before it entered the furnace. By passing through the hollow walls, the air cooled the furnace lining and prevented excessive erosion. A water screen was placed in the furnace about 3 feet above the bottom to keep the refuse deposited at the bottom from fusing and to make its removal easy. The design of the furnace, water screen, and burners was based on the experience gained in the previous cooperative tests1 with a smaller furnace, experimental water screen, and burners at the Oneida Street station of the Milwaukee Electric Railway & Light Co. The boiler tested had 13,057 square feet of heating surface. It was one of eight boilers fired with powdered coal, and was designated as boiler No. 8. The Lakeside station is the largest central station in the world that burns powdered coal exclusively. The coal used in the first five tests came from Illinois. The fuel in the other tests -:vas a mixture of Illinois and Pittsburgh coals.

Jan 1, 1925

By Paul C. Schmall, John F. Donohoe, Arthur B. Corwin, Derek Maishman

Ground freezing was utilized to provide complete stability of the excavation face and complete groundwater cut-off for the jacking of the three tunnel boxes for the Interstate 90 / Interstate 93 approach to the Fort Point Channel crossing. Through a wide range of geological conditions and large buried obstructions, the freezing provided complete stability of the face so that a 11.5 m (38 ft) high free standing vertical face could be mined without the need for any additional face support. Obstructions were incorporated into the massive frozen ground matrix, and held in place so that they could be excavated with a minimum of disturbance. The freezing provided an absolute groundwater cut-off, and permitted the work to be done without disturbance to the active rail system immediately above. With the use of instrumentation such as borehole thermocouples, the effectiveness of the freezing was guaranteed and the jacking proceeded with complete confidence and assurance of the ground conditions ahead.

Jan 1, 2001

By Arthur L. Murray

"Oil-shale camps are peculiarly favored, in that before they are established it can be ascertained with a,of certainty, that the life of the project is not limited. Unlike camps at metal mines, where the metal content of a given area is frequently an unknown quantity until after years of development, oil-shale camps should, from the outset, be planned and built as permanent types of camps. Where this procedure is followed camps will be established which better serve the needs of the industry and the cost of their general care and upkeep will be less.Selection of camp or townsite.The site of the camp or town, whether on company property or not, should be selected with care. It should be separate if possible from the location of the plants of the company so as to be free from noise and fumes and so as to provide a change of environment for employees in going from their work to their homes.The principal features governing the site to be selected are as follows:Drainage. The general contour of the surrounding country should be such that drainage is away from the site. The camp or town should, if practical, be situated on higher ground than that in its immediate vicinity.Soil. The nature of the soil on which the camp or town is located may bear a decided relation to health. A porous, well under drained top soil of at least four feet in depth insures dryness and facilities the placing of foundations and the laying of water mains and sewer pipes. Such a soil also is an advantage in growing trees, shrubs and grass plots, which are a decided adjunct to making the community attractive."

Jun 1, 1921

By Paul J. Axtell

The results of in-situ geophysical cross-hole tests on improved soil by soil mixing (SM) and jet grouting (JG) are described. This testing was conducted on soil improved by SM and JG columns constructed in the downstream free-field of Tuttle Creek Dam near Manhattan, Kansas as part of the seismic retrofit. Results of similar geophysical testing performed on untreated soil in the vicinity of the Downstream Test Program (DTP) area, as well as beneath the embankment at several locations, are also described and used for comparison purposes. In-situ shear moduli are also compared with those determined in laboratory resonant column tests. The increase in stress wave velocities and associated shear moduli by SM and JG treatment are presented for use in liquefaction potential and seismic deformation analyses of SM or JG treated soil. This data is required to determine the decrease in liquefaction potential and earthquake-induced permanent deformations due to SM or JG with respect to that of untreated soil.

Jan 1, 2008

By Charles D. Litton

This Bureau of Mines report presents a discussion of the essential components of pneumatic monitoring systems and their associated functions. Design criteria are presented which can be used for the design and fabrication of pneumatic monitoring systems having total system response times on the order of 15 to 30 min. To illustrate the utility of these design criteria, two detailed design examples are presented,

Jan 1, 1983

By T. V. Simpkinson

Abstract A brief history of the electric arc furnace process of steel-making is given. The greater relative importance of this method of steel manufacture to the Canadian steel industry, as compared with its importance in the steel industry of the United States, is shown. The scope of the process is outlined and brief mention is made of the difficulty of obtaining melting stock low in alloy content. The physical chemistry of steel-making is discussed at length in simple terms, with emphasis on oxidation, de-oxidation, and the role of hydrogen. Carbide-type and silicon-type slags are described and the particular usefulness of each is outlined. The importance of various factors in the melting practice is evaluated on the basis of practical experience. Introduction Although electric furnace steels constitute only a small portion of the total weight of steel used in industrial operations, their importance is relatively much greater than is indicated by comparative tonnage figures. Tool steels, which are vital to all industry, are made almost exclusively by the basic electric arc furnace process, as are stainless steels, valve steels, and the higher alloy types of the class usually referred to as "alloy steels&apos;. For many applications where steel other than electric furnace quality is often used, and when first cost is secondary to performance in service, the extra steel cost of electric furnace quality material is usually returned with interest by consistently longer service life. The electric furnace is pre-eminent in the quality alloy steel field because of the control that may be exercised over conditions of oxidation, de-oxidation, and temperature, the fundamental operations in steel making.

Jan 1, 1948

By Sharif Jahanshahi

Calcium ferrite slags are often associated with Professor Yazawa due to his pioneering work on the thermodynamics of this type of melts. Over the past years CSIRO has invested some effort in studying physico-chemical properties of such melts to fill in some gaps in our knowledge and explore opportunities for application of the understanding developed. These investigations cover thermodynamics, transport properties of calcium ferrite based slags, as well as the kinetics of reactions of such slags with refractories. The present paper provides an overview of some of these studies and highlights some of the interesting behavior of such melts. The oxidation state of copper and arsenic in calcium ferrite based slags are predominantly Cu+ and As3+, respectively, at oxygen potentials below 10.1 atm. The concentration ofCu2+ in such slags becomes significant at oxygen potentials of greater than 10&apos;1 atm at 1300 ?C. The activities of CuOo.s and AsOl.S in calcium ferrite slags show strong deviations from the Raoultian Law, while that of CoO is very close to ideal behaviour with respect to pure solid CoO. Addition of Si02 to calcium ferrite slags can have significant effects on the activities of FeO and Fe2O3 and hence the stability of magnetite phase. Transfer of oxygen in calcium ferrite slags is fast with diffusivity of 2xlO?3 cm2/s at 1350 °C and activation energy of 16 kcal/mol Presence of solid phases, such as magnetite, has pronounced effect on the viscosity of calcium ferrite slags. The observed dependence on solid loading and shear rate indicates deviation from Newtonian behaviour. The interfacial tension between copper mattes and calcium ferrite slags is strongly dependent on the matte grade, with the determined values being much lower than the corresponding ones for interfacial tension between similar mattes and iron silicate slags. MgO, Cr2O3 and MgCr2O4 have low solubility in calcium ferrite slags and their solubility increases with increasing copper oxide content of the slag at 1300 °c. The oxidation state of the slag has strong effects on phase transformation, dissolution rate and disintegration of refractories in calcium ferrite slags. Other key factors with major impact on slag-refractory interactions include viscosity and surface tension of slags as well as the contact angle between slag and refractory material.

Jan 1, 2003

By W. H. Jang

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

Jan 1, 1995