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By A. D. Trujillo, R. D. Wunder

The Chino Mines Co., a Kennecott- Mitsubishi partnership, located in Hurley, NM, recently completed a $405 million modernization of its mine, concentrator, and smelter facilities. The mine/concentrator modernization commenced in 1980, and the smelter modernization began during 1982. Modernization of the mine and concentrator facilities involved increasing the mining rate from 98 kt/d (108,000 stpd) to 152.2 kt/d (167,800 stpd). Ore mining was designed to increase production from 20.2 kt/d (22,300 stpd) to 34 kt/d (37,500 stpd). A new concentrator was con- structed near the mine using semiautogenous grinding. The new smelter uses the INCO flash smelting process, increasing capacity by 40.8 kt/a (45,000 stpy) to 99.8 kt/a (110,000 stpy) of saleable copper.

Jan 1, 1988

By R. D. Wunder

The Chino Mines Company, a Kennecott-Mitsubishi partnership, located in Hurley, New Mexico, recently completed a $405 million modernization of its mine, concentrator, and smelter facilities. The mine/ concentrator modernization commenced in 1980 and the smelter modernization began during 1982. Modernization of the mine and concentrator facilities involved increasing the mining rate from 98 kt/d (108,000 stpd) to 152.2 kt/d (167,800 stpd). Ore mining was designed to increase production from 20.2 kt/d (22,300 stpd) to 34.0 kt/d (37,500 stpd). A new concentrator was constructed near the mine using semi-autogenous grinding. The new smelter uses the INCO flash smelting process, increasing capacity by 40.8 kt/a (45,000 stpy) to 99.8 kt/a (110,000 stpy) of salable copper.

Jan 1, 1985

By J. P. H. Steele, M. U. Ozbay

As mining operations progress toward tele-mining and autonomous procedures, the need for machine performance monitoring increases. Presently, through a combination of vision, sound, and other subjective observations, an operator attempts to optimize the mechanical excavator’s operation. As the operator is moved away from the face in the case of tele-mining or completely removed for autonomous operation, the qualitative sensory input is lost. This lost information must be replaced with quantifiable sensory input. Chip formation detection may be a suitable replacement sensory input. Chip formation can be predicted with high confidence (>80%) through the analysis of the load waveform associated with the bit/rock interface.

Jan 1, 2002

By John D. Godfrey

Geological mapping on the Canadian Shield in northeastern Alberta outlined severalgranitoid rock massespotentially suitable as building stone. A particularly attractive prospect, the Chipewyan Red Granite, was subjected to an aerial survey and ground check. The petrologic and fracture characteristics critical for quarrying and use as a building stone were assessed in the course of detailed mapping at two of the most favourable sites. The extension of good rock was tested to shallow depths at one site by shallow diamond-drill coring. , The Chipewyan Red Granite displays a warm red colour, medium grain size and fairly massive texture, and takes a good polish. Deleterious geologic features studied in outcrop and subjected to structural analysis included regular joint systems, quartz veins, pegmatite dykes, basic shear zones and fault zones. Many of these key geologic features are systematic and hence predictable for stone quarrying purposes; other features, such as irregular fracelM tures, are non-systematic and arefar less predictable. The megascopic structural features studied show similar preferred orientations which appear to be collectively related to the tectonic history.

Jan 1, 1979

By S Ellis

In January 2008 Chirano Gold Mines Limited committed to expansion of the Chirano Gold Project from its existing design capacity of 2 Mtpa ROM ore to a new design value of 3.5 Mtpa. In addition to increased throughput, the design had to contend with increasing ore hardness and competency, while at the same time make cost effective use of existing equipment with minimum disruption to existing production. The solution adopted involved some novel approaches including tertiary crushing and operation of the SABC circuit in overflow ball mill mode and parallel elution with a common acid wash column. This paper describes the approach taken to the design of these elements to achieve a cost effective and safe capacity expansion.

Aug 8, 2011

By Vinay Jain, Dharmendr Kumar, Beena Rai, Venugopal Tammishetti

"Selective dispersion-flocculation is considered to be an effective process for the beneficiation of ultrafine particles. This process is based on the preferential adsorption of a flocculant on the mineral particles to be flocculated, leaving rest of the mineral suspended. It has been successfully implemented at plant scales for the beneficiation of ultrafine particles of iron ores, for which conventional methods such as gravity separation, magnetic separation and flotation do not work efficiently. However, the key element responsible for the success of any selective flocculation process is the appropriate choice of the flocculant used for achieving the desired selectivity. At our lab, we are working on design and development of such selective reagents for mineral processing applications, including the beneficiation of iron ore slimes, using a combined molecular modeling and experimental approach. In this study we have employed density functional theory (DFT) to calculate the interaction energies and explain the interaction mechanisms of chitosan with the main minerals present in iron ore slimes, namely, hematite [a-Fe2O3], goethite [a-FeO(OH)], gibbsite [a-Al(OH)3] and kaolinite [Al2Si2O5(OH)4]. The magnitudes of the computed interaction energies follow the trend: Hematite > Goethite > Gibbsite ~ Kaolinite Al-OH terminated > Kaolinite Si-O terminated Analysis of the optimized geometries and electronic structures reveals that the O & N atoms of chitosan molecule form coordinate bonds with surface Fe-atoms of hematite while only weak hydrogen bonds are formed in the case of goethite, gibbsite and kaolinite surfaces thus explaining reasons behind the stronger interactions with the hematite surface. The theoretical findings were validated by performing selective flocculation experiments using chitosan as a flocculant. The selective flocculation experimental results show that a final concentrate of ~60% Fe can be obtained from a feed containing 53.13% Fe with Fe recovery of 74%. The mineral estimation in the obtained concentrate indicated that hematite and goethite are recovered in concentrate while gibbsite and kaolinite are rejected in the tails. These observations were consistent with our theoretical findings. Our work highlights the promising role molecular modeling techniques such as DFT can play in the design and development of selective reagents for beneficiation of alumina-rich iron ore slimes."

Jan 1, 2018

By D. S. Flett

"The current state-of-the-art of chloride hydrometallurgy for treatment of complex sulphide bulk concentrates is reviewed. General considerations regarding the various flowsheet steps are examined and options discussed. Then, individual flowsheets are presented and discussed. Finally, the forward prospects for chloride hydrometallurgy for treatment of complex sulphide bulk concentrates is considered and conclusions drawn concerning the likely application of this technology in the future. IntroductionHydrometallurgical processes for treating sulphide concentrates, in general, have received considerable attention over the last three decades or more. Many flowsheets have been developed, many pilot-plant studies have been undertaken and several processes are now successfully operating. For example, direct ammoniacal pressure leaching has been used by Sherritt Gordon Mines since the 1950s to extract nickel from pentlandite concentrates, the roast-leach-electrowin route is widely used to recover zinc from sphalerite concentrates and direct sulphuric acid pressure leaching of sphalerite concentrates has been successfully commercialized. Also, Duval Corporation operated a direct cupric/ferric chloride leaching process (Schweitzer and Livingston, 1982) with electrowinning to recover copper from chalcopyrite concentrates, this process (now closed) being the only chloride process which has been commercialized for a sulphide flotation concentrate. Despite these developments, it has long been considered, particularly for copper sulphide concentrates, that direct hydrometallurgical processes are in the main unlikely to be able to compete successfully with smelting for large-scale operations of simple high-grade single metal concentrates. As long as such concentrates can be produced commercially, smelting is likely to remain the principal processing route (Flett, 1981). This view is being challenged nowadays through pressure leaching developments made by Dynatec and CESL in Canada and the recent start-up of the Western Metals Gunpowder plant at Mt. Gordon in Queensland (Flett, 2000). Complex sulphide ores offer even greater opportunities because of the ability to produce a bulk sulphide concentrate from the complex sulphide ore with considerably higher metal recovery than is often possible from the production of individual metal sulphide concentrates from differential flotation. Interest continues to focus on hydrometallurgical solutions to these processing problems, particularly with regard to chloride hydrometallurgy. This paper, therefore, reviews current state-of-theart with respect to chloride hydrometallurgy"

Jan 1, 2002

By H. I. Kim

The leaching of a complex matte in chlorine and chloride media was studied. The matte was prepared from manganese nodules by the reduction smelting-sulfidation route. From XRD analysis, the major phases of the matte were identified as CuFeS2, CuS2, (FeNi)9S8, (FeNi)S2, Ni9S8, Ni3S2, (CoFeNi)9S8 and Co metal. Investigated were the chlorine, hydrochloric acid, hydrochloric acid-oxygen, ferric chloride, ferric chloride-oxygen, cupric chloride and cupric chloride-oxygen systems. The results are discussed in terms of reagent concentration, retention time, leach temperature and gas sparging rate. The chlorination process resulted >99% metal extraction efficiency within a short retention time and at atmospheric temperature. However, there were no preferential extractions of Cu, Ni and Co with respect to Fe. The cupric chloride-oxygen system produced leach liquors with the lowest Fe content and with a high base-metal extraction. Sulfide sulfur was converted to mixtures of elemental sulfur and sulfate in all the studied systems.

Jan 1, 2009

By O. Hyvärinen

Outokumpu has developed a new chloride leaching process called HydroCopper®. In this process copper sulfide concentrates are leached at atmospheric pressure in concentrated sodium chloride solution using cupric ions as the oxidant. Copper is recovered from the purified leach solution by precipitating cuprous oxide, which is then reduced to pure copper and further melted and cast directly into copper products. The key reactants: sodium hydroxide, hydrogen and chlorine are generated from the spent sodium chloride using chlor-alkali technology. An important feature in the HydroCopperTM process is that the gold contained in copper concentrates is leached as chloride complexes and recovered from solution by activated carbon. Conditions for the leaching of gold-bearing pyrite can also be achieved in the chloride system by optimizing the redox conditions. This paper deals with the basic factors affecting gold leaching from copper sulfide concentrates. Opportunities for the recovery of refractory gold associated with arsenopyrite and pyrite will also be discussed.

Jan 1, 2005

By C. R. Everly

"The purpose of this paper is to review the most effective methods of reducing chloride transfer and chloride removal in the solution extraction and electrowinning (SX/EW) process. Elevated chlorides in electrolyte have various negative effects including a reduction in current efficiency, increased handling costs at rod plants and smelters, increased anode corrosion, cobalt losses due to increased electrolyte bleed, degradation of HDPE piping, and increased corrosion in the SX/EW plants. Historical controls that Sierrita has used to control chloride transfer, in order of effectiveness, have been chloride gasification at the EW that is directly correlated to amperage and chloride concentration in electrolyte, wash stage bleed and efficiency, width and velocity of aqueous bands, and electrolyte bleeds. Maintaining high bleed rates and high amperage settings has been a challenge with decreasing pregnant leach solution (PLS) grades, so keeping chlorides out of the electrolyte has become imperative. The effectiveness of reducing aqueous entrainment, optimizing wash stage efficiencies, and improving organic quality to reduce the transfer of chlorides to the electrolyte are illustrated in this study. INTRODUCTION The transfer of impurities from PLS feed streams to electrolyte in the Copper Solution Extraction process is a very common problem and is the reason that the wash stage exists in most SX operations. The main impurities affecting the SX process are iron, chloride, nitrate, and manganese. Elevated chlorides in the electrolyte have various negative effects including reduced current efficiency, increased handling costs at rod plants and smelters, increased anode corrosion, increased cobalt losses due to increased electrolyte bleed, degradation of HDPE piping, and increased corrosion in the SX/EW plants. Freeport-McMoRan Sierrita Hydromet is unique in that a high-chloride byproduct stream from the molybdenum process is pumped into the SX raffinate solution pond. This byproduct steam accounts for the majority of chloride introduced to the circuit, and over the years has built up to a point where 4000ppm chloride is consistently in the PLS feed to the SX. Concentrations of chloride over 70 ppm in electrolyte will result in downgraded cathode, so it is important to limit chloride carryover from SX as much as possible. Historically, Sierrita has been able to manage chloride levels with reactive techniques including increasing electrolyte bleeds and rectifier amps. Decreasing copper in PLS has made high amps harder to maintain, and increasing bleed rates have a direct impact on production goals."

Jan 1, 2015

By Edgar Peek

"The two dominant metallurgical problems in treating most base metal sulphide concentrates in both the chloride and sulphate system are iron removal and sulphur elimination, respectively [1-3]. In this paper the opportunities, limitations and fundamentals of the chloride metallurgy system are described against this background. Only the treatment of oxide and sulphide ores is considered. Both hydrometallurgical and pyrometallurgical unit process operations are highlighted, since most successful base metal processes are based on a combination of the two. Hence, an overview of the technical and also some economical aspects of chloride metallurgy are presented.This overview summarizes the successful applications of chloride metallurgy, but it will not give exhaustive process and plant descriptions. It predominantly focuses on the essential technical features of the metallurgical unit process operations, while providing numerous references separately."

Jan 1, 2011

By William D. Riley

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

Jan 1, 1995

By R. J. Nankee

Coal is our most abundant, low cost energy resource. Expansion of its use is being challenged due to "SO2 emission" regulation with even more restrictive legislation pending. High quality coal reserves are becoming more limited due to greater use in recent years. Aids to allow more use of coal in today's environment include beneficiation of coal before combustion and scrubbing the emissions from coal during combustion. Dow's efforts to help meet these challenges by beneficiating coal include true heavy media gravity separations with chlorinated solvents and liquid/liquid partitioning processes and "Dow Solvent Recovery Technology" to recover the solvent from product (or floats) and rejects (sinks), The objectives of the efforts to clean coal are to reduce sulfur and ash. In this paper, the solvents will be described; a general flow diagram presented; some of the results on upgrading various coals will be described, and projected costs of full-scale plants using chlorinated solvents will be compared to conventional cleaning plants.

Jan 1, 1985

By I. Iwasaki, R. Titi-Manyaka

Chlorination and chloridization behaviors of pyrite, pyrrhotite, marcasite, chalcocite, covellite, galena, sphalerite, heazlewoodite, and elemental sulfur were investigated by thermogravimetric analysis. The possible reaction mechanisms are discussed on the basis of the theoretical weight changes and thermodynamic considerations. Chlorine is a more effective chloridizing agent than hydrogen chloride. In the light of the experimental results, a scheme for producing nonferrous metal chlorides, molten sulfur, and ferric oxide from complex sulfide flotation concentrates is discussed.

Jan 1, 1974

By M. A. Gimenes

The utilization of chlorination in extractive metallurgy and advanced ceramics areas has been widely investigated as a preparative route in order to obtain intermetallic compounds, which are used as precursors in the development of new materials and process. The major processes of decomposition of rare-earth ores use sulfuric acid and sodium hydroxide at high temperatures, however there is not much work concerning chlorination. In this work, a systematic study of the reaction between xenotime (REPO4), chlorine and carbon has been performed. Particular emphasis was on kinetic studies to establish optimized conditions for the reaction. The kinetics of chlorination of xenotime raw material by rare-earth elements/compounds has been studied over a temperature range from 600°C to 950°C. The influence on the rate of conversion of xenotime to RECl3 on temperature, partial pressure of chlorine, carbon content, and particle size were investigated. A global rate equation that includes these parameters has been developed. The results show that the process follows the unreacted core-shrinking model with a formation of a porous product layer. The powder X ray-diffraction technique corroborated this model showing clearly the patterns related to the formation of yttrium oxychloride (YOCl), indicating that the reaction mechanism involves the presence ofan intermediate step before the formation of lanthanide chloride.

Jan 1, 2000

By A. L. Sweetser

EXPERIENCE has shown how difficult it is to obtain information regarding laboratory-tests in connection with the chlorination-process for the extraction of gold from its ores, and I therefore present the following method, somewhat in detail, for the benefit of those who may desire to pursue research work in this field. The ore chosen was a partly-decomposed porphyry, extremely siliceous and comparatively soft, and of an average value per ton of from $25 to $26 in gold and $0.68 in silver. The chemical analysis gave : Fe2O3, 3.35; FeS, 1.5; MnO2, 0.75; ZnCO3, 4; Al2O3, 3.20; H2O, 0.7; SiO2 and insol., 83.50 per cent. The ore, first crushed to pass a 5-mesh screen, was coned and quartered until a 45-lb. sample was obtained. Samples for assay and analysis, taken from this lot by means of riffles, were crushed to pass a 100-mesh screen. The original sample was divided into 10-lb. lots, of which one was crushed to pass a 10-mesh screen; another through a 12-; the third through a 20-, .and the last through a 30-mesh screen. Because of the production of an excessive quantity of fine material it was deemed inexpedient to crush finer than 30-mesh size-a decision the wisdom of which is proved by the data in Table I., showing the increasing ratio of slimes, in proportion as the ore is crushed finer. In order to determine the percentage of fines in the sizes of mesh selected, a weighed sample of ore was taken from each mesh, and a sample from the 10-mesh lot was passed successively through 20-, 40- and 100-mesh screens, and the percentage remaining on each screen determined. This process was repeated with the 12-, 20- and 30-mesh lots, with the results given in Table I.

Sep 1, 1907

By Charles H. White

Discussion of the paper of A. L. Sweetser, Tress., xxxviii., 236. CHARLES H. WHITE, Harvard University, Cambridge, Mass. (communication to the Secretary*) :-Those interested in leaching-processes gladly welcome contributions on either laboratory-tests, such as are reported by Mr. Sweetser, or mill-tests made on larger quantities of ore; and especially valuable are such reports, even with negative results, if the methods adopted are the outgrowth of an intimate knowledge of the conditions to be met. It seems very desirable, therefore, that as complete details as possible be given in reporting on such tests, particularly with respect to the character of the ore under examination. The questions of prime importance in the sampling of ore and in the making up of charges for laboratory-tests are those respecting its grade and uniformity. In Mr. Sweetser's paper the first of these questions is answered definitely, but the answer to the second, although apparent on inspection of the results, might be more strongly emphasized with advantage, since it is only on account of the extreme uniformity of the ore that the satisfactory results obtained could have been expected. It seems advisable to call attention to the fact that for average ores, and more particularly for uneven, or 11 spotted ores, the quantities used by Mr. Sweetser are not usually regarded as sufficient to insure satisfactory results. Let us examine the method somewhat in detail. The ore was crushed to pass a 5-mesh screen, and a sample of 45 lb. was taken out for assay and tests. The diameter of the largest grain of this ore, according to Richards,1 was 2.67 mm.-assuming here, as in the following cases, that the wire of the screen was of the largest size used for the purpose, thereby giving any possible advantage in this respect in favor of the method. The table in Richards's book, p. 852, shows that 45 lb. is a sufficient quantity for a fair sample with uniform ores, but not sufficient

Jan 7, 1908

By Samantha Moodley, Rauf Hurman Eric, Cevat Kucukkaragoz, Aditya Kale

"Two titania slags, rutile and synthetic rutile were chlorinated with petroleum coke and CO in a small bubbling fluidized bed reactor. The study aims to identify differences in chlorination mechanism, compare conversion rates, blowover and the chlorination of impurities for the various titania feedstocks at different temperatures.Chlorination rates were highest at 1000ºC; rutile chlorination significantly increases as temperature increases from 800ºC to 1000ºC. At 1000ºC, synthetic rutile had the highest chlorination conversion rate; this was followed by Slag B which in turn was more reactive than Slag A and rutile. The mechanism for slag, synthetic rutile (SR) and rutile chlorination differs. Synthetic rutile feed is porous, providing a larger surface area for the chlorination reaction, hence the highest conversion rates was attained. Titania slag becomes porous with the initial chlorination of FeO and MnO whilst rutile remains solid. As the porosity of slag particles increases so does its tendency to be elutriated. Ti2O3 is oxidized within the early stages of chlorination during the chlorination of FeO and MnO. Ti2O3 not oxidized is then rapidly chlorinated.IntroductionTitanium dioxide (TiO2) is the most common compound of titanium, about 95 - 98% of extracted titanium minerals is processed into TiO2 white pigment [1]. Two processing routes exist for the production of TiO2 pigments, i.e., sulphate and chloride based processes. In the chloride process, titania feedstock is fed to a fluidized bed reactor together with reductant and chlorine gas. A temperature of 1000 - 1300ºC is maintained in the reaction zone and apart from silica, zirconia, uranium and thorium, virtually all the metal oxides in the feed are converted to their respective chlorides [2]. Chlorine is recovered and recycled back to the reactor."

Jan 1, 2012

Zirconium chloride is of great commercial importance as starting materials for production of ZrO2, Zirconium metal and other Zirconium compounds from its main resources (Zircon Sands). The present study concerns with preparation of pure ZrO2 from Zircon by direct chlorination technique. Different parameters affecting the chlorination process are studied viz. carbon, chlorine flow rate temperature and time. The chlorination extent is determined from the loss in weight and chemical analysis of reaction products. The maximum chlorination extent -92% are achieved at 1100°C for 30 min. Zirconium oxide is produced from the collected zirconium tetrachloride either by calcination at 900°C or by hydrolysis in water in presence of RCI with a purity = 99%. Evaluations of the products of the process are investigated microscopically and by X-ray diffraction. The apparent activation energy of the chlorination of Zircon is determined to equal 36 kJ/mole.

Jan 1, 1997

By Larry G. Twidwell, Jannette L. Chorney, Bryce D. Ruffier, Katelyn M. Lyons, Daniel W. Gaede, Ryan J. Foy, Jerome P. Downey

The Army Research Laboratory (ARL) has an interest in the recovery and processing of rare earth elements. At Montana Tech, elevated temperature chlorination of rare earth oxides is presently being investigated as a potential methods leading to the selective separation and recovery of rare earth elements from mineral ores and concentrates. After preliminary evaluation, ytterbium oxide was selected as a representative surrogate material for more extensive chlorination studies. Methods used to determine the conversion and recovery include X-ray diffraction (XRD) and inductively coupled plasma (ICP) analysis. These data have been used to establish and confirm process conditions that consistently yield high conversion efficiencies. Based on the promising results, further experimentation is underway to ascertain the metallurgical response of other rare earth oxides and carbonates to the roasting process. The end goal is to create a robust process for industrial application that has greater efficiency and reduced costs as compared to current practice.

Jan 1, 2015