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By Guozhu Ye

Hydrometallurgical zinc recovery from EAF dust has several advantages compared to pyrometallurgical alternatives in terms of low temperature operation, lower energy consumption and higher flexibility. Many hydrometallurgical processes have been suggested and tested over the years without success. The main reasons are: -Low leaching yield of zinc due to the fact that a high fraction of ZnO in the EAF dust exists in the zinc ferrite structure which makes selective leaching of ZnO not possible -Many of the proposals could not handle the halide in the EAF dust To eliminate these two disadvantages, two zinc ferrite elimination concepts have been tested and developed in the REZIN project of the EU 5th Framework Programme. The two concepts for zinc ferrite elimination could be shortly described by the following chemical reactions: A. ZnOFe2O3 + 2CaO = Ca2Fe2O5 + ZnOfree B. ZnOFe2O3 + C = Femet + CO/CO2 + ZnOfree These two concepts were investigated in details in combination with a subsequent leaching step using the novel EZINC process for recovery of zinc from EAF dust. Leaching of pretreated samples has shown great increases of a zinc recovery yield. A zinc recovery of over 90 % could be reached, as compared to about 50 % for no-pretreated samples. This paper will describe the two concepts in details.

Jan 1, 2006

By Andreas Hucke

For the roadway design in the German hard coal mining industry, an advanced combined planning system has been applied during the past 20 years. The German mining industry is working with single entry roadways system. After first longwall passage the roadways will be stabilised with side wall building material packages. Later this roadway will be used again for the second retreating longwall. The intention of the implementation of several different design methods for the planning of the roadways is to enhance the reliability of the results. On one hand the planning system uses numerical simulation and physical modelling in addition to analytical and empirical methods. On the other hand in-situ monitoring and analysis during the roadway development will be used to verify and calibrate the numerical and physical models. Especially before the implementation of new support elements in underground, this system is suitable and reasonable because the new support elements will be tested in the physical and numerical simulation prior to cost intensive underground tests. The interaction between the numerical and physical modelling in comparison with underground monitoring and analysis during development and the later use of roadways will be shown with some examples. The first example shows a rock bolted rectangular roadway which will be mined at both sides of the roadway. Different support and roadway building material package systems are investigated under various stress conditions. The results are utilised to optimise the roadway support and the roadway side package systems. The influence of different points in time of the installation of several support elements in a combined arch and bolted roadway is shown as another example. Two different types of support systems are compared within the physical models. These models are used as a base for ongoing numerical analysis and simulation to find out the ideal point of time to assemble the different support elements. The last example handles the influence of slickensides in the roof of arch shaped roadway on their stability. Different slickenside positions and densities are investigated and classified.

Jan 1, 2006

By M. Loan

The Zinifex's Hobart Smelter uses the paragoethite process to remove dissolved Fe(III) from concentrated zinc leach liquors. This produces a residue consisting primarily of 6-line ferrihydrite (a hydrated Fe(III) oxyhydroxide), several insoluble components derived from the calcined zinc concentrate neutralization agent and other precipitated phases, such as jarosite and silica. The precipitation of 6-line ferrihydrite in the paragoethite process was studied using a laboratory-scale continuous crystallizer, and the conditions were selected to limit high levels of dissolved silica and jarosite. This approach allowed the reactor pH and the rate of precipitation to be correlated with residue solid-liquid separation, particle size, morphology, residual zinc and sulfate concentrations, and phase formation (e.g., goethite, jarosite, schwertmannite, and 2- and 6-line ferrihydrite). These studies delineated the mechanism of 6-line ferrihydrite precipitation in the kinetically controlled paragoethite process, and its inter-relationship with goethite and jarosite precipitation under conditions where 6-line ferrihydrite is favoured. Unexpectedly, the generation of a more crystalline goethite precipitate with larger "primary" particle size did not produce a residue of improved properties, as bulk aggregates dictate the physical properties of the residue and not the crystallinity. Furthermore, it is difficult to precipitate 2-line ferrihydrite or schwertmannite under existing paragoethite process conditions.

Jan 1, 2006

By V. L. Mitsopoulos

This paper provides a summary of tailings disposal techniques and the improvements that have been made through the introduction of thickened tailings disposal. The general properties and characteristics of thickened tailings are described, as is a design process for selecting appropriate technologies for thickening, pumping, transporting and storing tailings. The factors affecting the selection of an appropriate disposal site and operational considerations for the effective utilisation of tailings storage areas are also documented.

Jan 1, 2006

By R. C. Bratton, R. Q. Honaker

Hindered-bed separators are recognized as low-cost, high-capacity devices for both classification and density separation; however, since their inception, there have been few significant advances in the fundamental technology. Recently, Eriez has shown through modeling and pilot-scale testing that the innovative approach to feed presentation offered in the CrossFlow teeter-bed separator provides improved metallurgy when compared to traditional hindered-bed classifiers or single-stage coal spirals. This design feature prevents excess water from entering the separation chamber and disrupting the overall fluidization flow rate within the teeter zone. Most recently, a side-by-side industrial scale evaluation has verified that this technology improves overall efficiency and simultaneously reduces the separation cut-point. With regards to coal processing, data from full-scale units indicate that the CrossFlow offers good separation efficiency, high unit capacity, and metallurgical results consistent with laboratory- and pilot-scale separators.

Jan 1, 2006

By E Hondros

Innovation and Business Skills Australia (IBSA) commissioned The Boston Consulting Group (BCG) to undertake a study into how the role of AustraliaÆs senior managers is likely to change between now and 2020 and to identify the skills and attributes that will be needed to respond to those changes. This report builds on a previous study prepared by BCG in the early 1990s for the Industry Taskforce on Leadership and Management Skills (Karpin Committee), which provided a snapshot of the Senior Manager in 2010. The following powerpoint slides summarise the 2020 Vision û The Manager of the 21st Century û outlining how the role of AustraliaÆs senior managers is likely to change between now and 2020 and to identify the skills and attributes that will be needed to respond to those changes. The presentation is summed up in the following quote from Jon Nicholson û Senior Vice President of BCG: We believe that to succeed in the years up to 2020, executives will need to master a range of hard and soft skills. Amongst other things, they will require to manage multi-generaional teams, the creativity to measure staff performance on outputs rather than inputs, and a high degree of technical and functional expertise in addition to their general management credentials. This paper is available as a PowerPoint presentation only.

Jan 1, 2006

By M. Jacobs

Keywords: Smelting, converting, sulphide, sulphide smelting, platinum, platinum group metals, PGM, base metals, nickel, copper, matte, slag, furnace, electric furnace, Söderberg, electrode, granulation, converter, flash drier, sulphuric acid, acid plant, Ausmelt, Sirosmelt, pyrometallurgy, metallurgy, Anglo Platinum, South Africa Waterval Smelter complex is situated in Rustenburg, in South Africa?s North West Province. The smelter objective is to process wet concentrate to produce crushed, slow-cooled, sulphur-deficient nickel-copper matte rich in platinum group metals (PGMs), gold, and base metals for despatch to the Magnetic Concentration Plant at the Base Metals Refinery. Throughout its history, the smelter complex has been continuously upgraded in line with increasing production demand, changing feeds, environmental initiatives, and advances in available technology. The smelter receives filter cake and slurry from Anglo Platinum concentrators and joint ventures. Wet concentrate is fed through a flash drying process utilising coal-fired, fluidised bed hot-gas generators, to produce dry feed material for the electric furnaces and slag-cleaning furnace. For primary smelting, two electric furnaces are used, each with a rated capacity of 34MW. Furnace matte, containing the bulk of the base metal sulphides and PGMs, is tapped periodically into refractory-lined ladles and granulated using high-pressure water jets, then dried through electrically powered pneumo-driers to become the main feed to the Anglo platinum Converting Process (ACP). Slag is tapped semi-continuously, granulated, and treated through the slag mill. The ACP treats the combined matte output of Waterval, Polokwane, and Mortimer smelters. It is a top-blown furnace, with furnace matte, air, and oxygen being injected into the converter via a lance submerged in the slag. Converter matte is tapped and bottom cast into moulds, slow-cooled, crushed, and despatched to the refineries. Slag is granulated and dried for recycling to the slag-cleaning furnace. ACP slag is fed to the slag-cleaning furnace along with a reductant and a sulphur source. Slag-cleaning-furnace matte is granulated for processing by the ACP, while slag is granulated and processed in the slag mill. The slag mill and flotation circuit treats granulated slag from the electric furnaces and slag-cleaning furnace to recover entrained matte containing valuable PGMs and base metal sulphides.

Jan 1, 2006

The mine manager is one of the oldest jobs in the world. Over many centuries the fundamentals of how this job was approached did not change much. However since the later part of the 1980s there has been a dramatic shift in the expectations and role of the mine manager as the pressures of globalisation and consolidation have increased the size of companies and the production levels of mining operations. The changes have been dramatic, with demanding requirements on mine managers to continually improve the skill levels of people, to apply and develop rapidly changing technologies and to consider far broader business issues that need to be managed in a truly globally connected world. This paper will attempt to outline some of the issues, the complexity surrounding them and some of the approaches that have been made to manage them. There is not a single correct answer or approach, but there are many key success factors that have led to some amazing levels of performance being achieved as we go deeper, broader and literally move mountains to meet the customerÆs needs for today and tomorrow. This contrasts with many mining operations in developing countries that still have a traditional approach to how they mine. Society is the river of life that continually flows and changes the environment that surrounds it. The pressures from the customers and world growth, shape and force alterations to be made in an industry that has to live with the far greater primal and uncompromising forces of the earth we mine. This has led to some paradigm shifts in how we accept what we manage. TodayÆs mine manager must manage a far broader range of issues, than just how do we get tonnage out of the mine and product out of the ore. These include but are not limited to technical, commercial, product quality and end use understanding, employee and community issues, environmental and the ever increasing complexities of sustainable development. Organisations will have to look at how they structure their management of the business to manage functions to meet the complexity of different stakeholders needs û the business, the employees, the customer and the broader community within an environment that is becoming more attuned to the harm impacts to the world in which we operate. The attraction and retention of skilled people that contribute to the value and worth of the corporation, will become critical to sustain a companyÆs growth. One of the fundamental elements of successfully doing this will always be the skills of the mine manager and his/her extended team with the continued development and support that they will need to meet these demands.

Jan 1, 2006

By J. Preussner, U. Glatzel, R. Völkl, S. Prins, M. Wenderoth

Platinum base alloys are very corrosion resistant and have got a high melting point. Similar to Ni-base superalloys, which are used for jet turbines, the hardening effect of the intermetallic L12Pt3Al phase is used to receive a material that is creep resistant at high temperatures. Chromium is added to the alloy system to stabilize the L12phase down to room temperature. With the right amount of nickel the misfit and shape of the precipitates can be controlled. Various alloy compositions have been melted and analysed. With scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) a microstructure can be observed, which is very similar to the one in Ni-base superalloys. To support alloy development with simulations, a thermodynamic database of the Pt-Al-Cr-Ni system is about to be established. The SEM and EDS measurements provide useful input to the thermodynamic optimization. Also many data from the literature have been used to receive the best approximation. The Cr-Pt binary phase diagram has been reassessed and the latest results of thermodynamic modelling are presented.

Jan 1, 2006

By T. Haubold, K. Ortner, T. Jung, D. Roth-Fagaraseanu, C. Mattern

Application of integrally bladed disks (blisks) is of increasing interest in compressors of aero engines. Blisks are preferred due to their potential for size and weight reduction, for increased performance and for reduced manufacturing costs compared to conventionally bladed disks. Erosion of the blisk aerofoils in service reduces engine performance, and can result in short shop visit cycles. This significantly increases the life cycle cost of these components, particular when considering that eroded aerofoils can't be exchanged easily for blisks during refurbishment. Shop visit cycle times can be extended and maintenance costs can be reduced through the application of an effective protective coating. The ongoing development of an erosion resistant coating and deposition process suitable for coating complex blisk geometries is described here. The coating is a multilayered W /TiB2 system exhibiting superior erosion resistance compared to known single- and other multilayer concepts. A modified sputter process is used to enable coating even of blisk geometries with shadowed surface to competitive recurring cost.

Jan 1, 2006

By Oleg I. Platonov

The process for desulfurizing coke oven gas in a regenerative system ?scrubber-stripper?, with sour gas being fed to Sulfur Recovery Unit (SRU) and tail gas being recycled to raw coke gas scrubber, has been developed. A key problem of this process is the presence of elemental sulfur in the SRU off-gas, which may deposit on gas-blowing equipment, thus disrupting its operation. A new treatment technology for SRU off-gas that has been worked out for a Claus unit operated by «Russian Metallurgical Company» (RMC) in Magnitogorsk (Russia) is presented. It incorporates a catalytic hydrolysis/hydrogenation stage, where all sulfur-bearing species such as sulfur dioxide, carbonyl sulfide and elemental sulfur are converted to hydrogen sulfide. The SRU in Magnitogorsk comprises three main units: gas re-heater; catalytic hydrolysis reactor and waste gas cooler. Re-heater is required to increase temperature of the process gas up to a level of catalytic conversion (beyond 330-3500C). Oxygen utilized as an oxidizing agent reduces the volume of waste gas to a minimal possible value. The operational data garnered since 16.07.2004 clearly shows that the new technology allows high-level purification of Claus tail gas from elemental sulfur. Unlike SCOT ? process, this technology does not require separate stages for H2S removal and enrichment that tangibly simplifies its implementation at lower capital and operation expenditures.

Jan 1, 2006

An Atomic Force Microscope (AFM) was used to measure the surface forces between glass sphere and silica plate in CnTAC1 (n=12, 14, 16, 18) solutions. The results showed the presence of long-range attractive forces that can be fitted to single exponential functions. With a given surfactant, the attractive force increased with increasing concentration, and reached a maximum at the point of charge neutralization (p.c.n.). The decrease in the attractive force above the p.c.n. is probably due to the inverse orientation of the surfactant molecules. A plot of the log (p.c.n.) vs. the number of carbons in the hydrocarbon chains of the Cn TACI homologues showed a linear relationship with a slope of -0.37, indicating that the surfactant adsorption entails a decrease in free energy by -0.85 kT per mole of CH2 (or CH3) group. These results suggest that the adsorption of long-chain surfactants is controlled by hydrocarbon chain association during the process of forming surface hemi-micelles (or domains). Possible origins of the long-range attractions are discussed on the basis of the results presented in this communication.

Jan 1, 2006

As part of a comprehensive risk analysis which was carried out into the effectiveness of the water barrier between South Deep and Randfontein Estate mines, the potential threat posed by large seismic events was assessed. The study covered several aspects. Firstly, an estimate of the maximum credible earthquake was obtained from a probabilistic analysis of the regional seismicity of the previous 25 years. Allowance was made for ?reservoir-induced? effects by increasing the estimate of the size of the maximum credible earthquake from ML= 5.1 to ML= 5.5. Based on available knowledge of the geological structure, the possibility of such an event occurring in the vicinity of the barrier pillar was estimated. The possibility of substantial damage to the barrier rock mass, resulting as a consequence of a large event, was assessed. The likely damage to the concrete control plugs installed in five tunnels that penetrated the barrier, which might result from a ?near-miss? by the largest possible seismic event or from a ?direct hit? by a smaller event, was also considered. It was concluded that there was a negligibly small possibility that the maximum credible earthquake could occur close enough to the barrier, and in such a manner, as to cause any damage to it or to the plugs in the tunnels passing through it. The possibility of serious plug damage occurring as a result of a ?direct hit? by as maller event was slightly greater, but still sufficiently remote as to be of no practical concern at all.

Jan 1, 2006

By Pinakin C. Chaubal

Today?s steel industry is in a vibrant and resurgent mode. This transformation has been in the making for some time now. Over the last few decades, the industry was steadily transforming itself into becoming a high tech industry. New technology was adopted, efficiencies were enhanced, lean manufacturing concepts were brought in and a strong customer focus was developed. Today?s mills employ sophisticated instrumentation, computerized monitoring, on-line smart systems etc. driving processes that are producing at rates of many tons/minute. All this is not possible without judiciously using the latest available technologies in various fields and developing a more sophisticated work force. Prof. Sohn has been a pioneer in driving the concept of process engineering in process metallurgy. In this paper the focus is on some aspects of process engineering ? primarily process modeling - as applied to iron and steelmaking processes. Examples are shown to demonstrate how problems have been addressed. Some thoughts on future directions are presented.

Jan 1, 2006

By B Manda, K L. Sandvik, K Musiwa

Mining and processing of pyrite ore at Iron Duke Mine, north east of Zimbabwe, generates large quantities of acidic mine water as a result of the oxidation of iron sulfides on exposure to air and water used in the drilling and blasting operations. The acid mine drainage (AMD) contains elevated levels of dissolved Fe, Al, Mn and sulfate and has characteristic pH values ranging from about 0.50 to 3.00. Handling and disposal of such a drainage places significant impacts on the economics of the mining operation due to the corrosive nature of the drainage on infrastructure, the limitations placed on water reuse and discharge to the environment under a new law governing effluent discharge. Treated sludge at Iron Duke is chemically unstable, changing pH from ~7 to ~3 within four days after deposition in the evaporation ponds. The effluent does not meet the permitted level of neutral pH, 500 mg/l sulfate and less than 2000 mg/l total dissolved solids. Excessive acid seepage from the evaporation ponds has resulted in contamination of the ground water below the ponds area, which shows high mean annual levels of iron (368.67 mg/l), sulfate (1702.89 mg/l) and low pH (2.86) in addition to other pollutants. This poor quality seepage infiltrates into the nearby Yellow Jacket River, contaminating the public water source. Furthermore, a deterioration of the land area and vegetation adjacent to the tailings dump is also observed. Understanding the controls on the neutralisation of acidic drainage and long-term sludge stability after placement in evaporation ponds is essential to minimise costs of closure requirements and for the protection of environment and human health. This study examined the effects of the master variables pH, redox potential, acidity and alkalinity on acid neutralisation. The results indicate that ferrous hydroxides are not as stable as ferric hydroxides and that proper oxidation of iron also leads to better sludge stability, higher treatment efficiency and a manageable sludge viscosity. Metal hydrolysis and secondary mineral formation at the evaporation ponds under a wide range of pH and redox conditions is responsible for equilibrium shifts in metal reactions, resulting in high potential for metal leaching and mobility. Mechanisms of metal attenuation are also discussed.

Jan 1, 2006

By L. A. Jagger

The world?s second largest producer of platinum, Impala Platinum Ltd, approved two new twin shaft projects at the end of September 2004, Nos. 16 and 20 Shafts. Both shaft projects are stand-alone entities and are being sunk from surface. Previously Impala had embarked on a strategy of extending the life of its third generation shafts by means declines. No. 16 Shaft is the first of a new fourth generation shaft complex, while No. 20 Shaft is the last of the third generation type shafts in the so-called shallow to intermediate mining zone. This paper details the basic designs of each project and covers the initial implementation. Although both projects are twin shaft systems, the access methods from the shafts to the reef horizon differ. Initiatives implemented to speed up the projects are also briefly covered.

Jan 1, 2006

By Wenshan Zhang

This paper described the present status of China electrolytic manganese industrial production. Electrochemical reactions on cathode and anode, the major technological process, technical requirements on the production and technical index and quality control of the products and the ways of increasing current efficiency during Manganese electrolytic process have been expatiated.

Jan 1, 2006

By K. Purazrang, P. Sh. Naseri, P. Abachi

In present work, the comparative measurement of aluminum alloys' resistance to the unstable fracture was provided. Besides, the rupture mechanisms of high strength 7075 and 7050 aluminum alloys were investigated. The specimens were used as solution treated, quenched and aged condition. The elastic-plastic behavior of specimens was determined by carrying out tensile test on cylindrical specimens. The small sized specimen with 6.35 mm thickness and V-notched radius less than 60 µm was used for evaluation of damage properties, in accordance with ASTM B871-96 standard test method. All tear specimens were machined in L-T orientation. The mechanical tests were conducted at RT on an universal Instron machine under cross head speed of 0.1 mm/min. The results of mechanical tests made the evaluation of tear strength to 0.2 % tensile yield strength ratio, as a measure of notch toughness, available. The comparison of specimens' resistance to crack propagation and unstable fracture due to the presence of crack-like strain concentrator was provided using tear test data. The microstructure of specimens was studied under optical microscopy. The rupture micro-mechanisms were analyzed by examination of specimens fracture surfaces using SEM. The microstructure examination indicated almost equiaxed grains on the transverse directions and elongated grains on rolling direction. Moreover, intermetallic particles were evident at microstructure. Considering the SEM fractographs, it seems that the intermetallic particles act as void nucleation and damage initiation sites. However, the damage mechanism of tensile specimens and severely notched specimens, especially near the notched root differs due to stress and strain states.

Jan 1, 2006

By Pinakin C. Chaubal

Today?s steel industry is in a vibrant and resurgent mode. This transformation has been in the making for some time now. Over the last few decades, the industry was steadily transforming itself into becoming a high tech industry. New technology was adopted, efficiencies were enhanced, lean manufacturing concepts were brought in and a strong customer focus was developed. Today?s mills employ sophisticated instrumentation, computerized monitoring, on-line smart systems etc. driving processes that are producing at rates of many tons/minute. All this is not possible without judiciously using the latest available technologies in various fields and developing a more sophisticated work force. Prof. Sohn has been a pioneer in driving the concept of process engineering in process metallurgy. In this paper the focus is on some aspects of process engineering ? primarily process modeling - as applied to iron and steelmaking processes. Examples are shown to demonstrate how problems have been addressed. Some thoughts on future directions are presented.

Jan 1, 2006

By A. J. Van Der Merwe, J. F. Erasmus

One of the valuation approaches applied to Advanced Exploration Areas and Pre-Development Projects is the so-called ?in situ Mineralization Method? or the ?Yardstick Method?. This method is based on the concept of a known undeveloped Mineral Resource being worth a certain fraction (the ?Yardstick?) of the contained commodity value (?metal in ground?), using commodity prices ruling at the date of valuation. The Yardstick value is derived usually from an average market-based figure obtained from an analysis of recent transactions and is expressed as a monetary value per ounce or per tonne. It maybe modified to accommodate the quality (e.g. grade) and category (e.g. confidence level) of the Mineral Resource/Reserve involved and the time, effort and expenditure expected to be involved in bringing the project to fruition. Some eighteen recent and relevant transactions were analysed, allowing the following general conclusions to be reached: ? a Yardstick with which to value undeveloped PGE mineral resources is likely to range between 0.5% and 2.5% of the in-ground contained metal value ? the expected method of mining (especially with regard to mining costs) and the grade of the mineralization both have a strong influence on the Yardstick ? the status (classification) of the Mineral Resource has some influence on the Yardstick and ? the ruling price of platinum and the regional location of the deposit appear to have insignificant influences on the Yardstick.

Jan 1, 2006