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By Theo Lehner

"During my first contact with industrial metallurgy as a summer vacation worker at the Steelplant at Luleå, Sweden, I came during a visit to MEFOS into contact with works of Prof. Worner caried out during the piloting of the Worcra continuous steelmaking process. These tests are still today remarkable as an innovative step in the art of metalmaking. By that they involved the necessary ingredients for the development of our art: seeing, knowing and doing. Industrial injection as applied during slag fuming will be discussed below.Phenomena of injection metallurgyPhenomenon according to Collins dictionary is"" anything that can be perceived as an occurrence or facts by the senses"". To open the senses for the interesting phenomena in pyrometallurgy must be the main task of any educator. The investigations by Engh et al. around the mixing phenomena of the WORCRA process are an early example of combining senses with knowledge. To see what you model must be a crucial part in any development. This can also involve to see and control that one is subject to the same conditions as in published models. Below the need ""to see"" will be illustrated by some recent investigations around slag fuming. In the literature various models for reactions occuring during the fuming of slags are presented. Two recent models hint ·ata) the occurrence and importance of iron for the fuming processb) the occurrence and importance of lead droplets during respectively."

Jan 1, 1996

By Gus Van Weert

Hydrometallurgical oxidation of sulphides is capital and energy intensive, with autoclave and bio-technology competing for lowest overall cost status. The use of surface aerators instead of stirred tank reactors could provide lower costs for bio-oxidation of concentrates. With this in mind, the Delft Inclined Plate reactor was designed with inclined plates above a settler shaped reactor to continuously return slurry from the lowest point in the settler to the surface of the liquid. The multiplate superstructure overcomes the scale-up restriction of the standard circular surface aeration patterns. DIP aerator energy and volume requirements for oxygen transfer from air will be presented in terms of kg O2/kWh and kg O2/m3/h transferred as a function of wt % sand in the slurry and compared to stirred tank performance. Scale up from the 4 m3 pilot unit will be discussed.

Jan 1, 1996

By Thierry Bernard, Pierre M. Vuillaume, Michel Kiszlo

"In the context of its studies for the trench ministry of the environment and for the French national coal board, INERIS (the French institute for the industrial environment and hazards, formerly CERCHAR) has made a complete critical survey of the methods generally used to reduce the levels of blastingvibrations."

Jan 1, 1996

By D. H. C. Wilton, W. A. Sears

"Abstract-The 682.8 ± 1.6 Ma Tickle Point Group consists mainly of rhyolite flows and tuffs with- in the Avalon Zone of the Appalachian Orogen in Newfoundland. Stratabound massive sulfide mineralization, consisting of pyrite, sphalerite, chalcopyrite and galena, occurs at the Winter Hill prospect, where a lower pyritic, Cu-rich zone and an upper Zn-Pb-rich zone are hosted by a carbonate-calc-silicate lens. At the Frenchman Head prospect, stringers of pyrite, minor sphalerite, chalcopyrite and rare galena are hosted by felsic volcanic rocks of the Tickle Point Group .Base metal ratios, metal zonations and the overall stratigraphic framework suggest that these sulfide occurrences represent volcanogenic massive to semi-massive sulfide mineralization (stringer type at Frenchman Head). As such these prospects represent the only known VMS occurrences within the Avalon Zone of Newfoundland. Pb isotope data indicate that galena from the Winter Hill prospect is less radiogenic and older than galena from Dunnage Zone occurrences, and suggest that the Winter Hill mineralization formed in an environment tectonically distinct (exotic) from the Dunnage Zone."

Jan 1, 1996

By Abbas H. Mirza

Arsenic and selenium are found in low quantities together with other metals in several nonferrous metallurgical process streams such as scrubber blowdown solution, acid plant wastewater, gas cleaning plant water, etc. Normally, the other metals in these streams are present as cations and can be precipitated by conventional lime treatment and sulfide polishing. However, arsenic and selenium are invariably present as anions, AsO33-and AsO43 in the case of arsenic and SeO32 and SeO42 for selenium. Conventional lime treatment removes most of the arsenic, but it does not remove selenium. The present paper reviews the processes and technologies developed to date on the removal of arsenic and selenium from metallurgical process streams.

Jan 1, 1996

The leaching of gold and silver by ammonium thiosulfate solutions in the presence of copper has been actively studied in recent years. Newmont Gold Company has successfully tested the ammonium thiosulfate for gold extraction following biooxidation pretreatment of low grade refractory carbonaceous/sulfidic ores. In this paper, the chemistry of the copper catalyzed leaching process is reviewed. Factors affecting both the leaching reactions and the stability of the lixiviants are reviewed and discussed from a solution chemistry perspective.

Jan 1, 1996

By R. L. Player

"The Copper Isasmelt process has been developed over the past 15 years by Mount Isa Mines Limited (MIM) and the Commonwealth Scientific and Industrial Research Organisation (CSIRO). The first two commercial plants were commissioned in mid 1992.The results of four heat balances on the Mount Isa plant are presented. At a smelting rate of 98 t/hr of chalcopyrite concentrate plus 14 t/hr reverts, the total heat generated was -91MW. Approximately 39% of this energy came from coal, while 50% of the energy reported to the process waste gas. To a first approximation the furnace is near chemical equilibrium.The impurity distribution in the Mount Isa plant was presented. Approximately 91 % As, 85% Cd, 75% Bi, 68% Zn, 60% Sb and Tl, 45% Pb and 30% Te in concentrate was eliminated from the matte.The ""bubble"" frequency of the gas cavity below the foot of the lance was measured at -2. 1Hz. Side bands displaced by -l.lHz modulated the bubble frequency. This was consistent with radial gravity wave motion in the slag bath. The two processes, gas bubbling and wave motion appeared to be coupled together; the bubble frequency was twice the slop wave frequency. IntroductionCopper Isasmelt has been developed over the past 15 years by Mount Isa Mines Limited and the Commonwealth Scientific and Industrial Research Organisation. The process is based on the Sirosmelt lance, invented by researchers at the then Division of Mineral"" and ProcessEngineering ofCSIRO in 1973.The first two commercial scale copper furnaces were commissioned at Mount Isa and the Cyprus Miami Mining Corporation smelter at Miami, Arizona in August and June 1992 respectively.The process concept, the history of the development, and the Mount Isa plant have been described (1, 2, 3).This paper sununarises heat balances obtained on the furnace, the impurity distribution among the output streams and lance injection characteristics."

Jan 1, 1996

By Chamberlain A. C, Fisher N, Avraamides J

The thermal decomposition of sodium ethyl xanthate (SEX) adsorbed onto activated carbon was studied by coupled thermogravimetric analysis-Fourier transform infrared spectroscopy (TG-FTIR). Two discrete mass losses were observed, in the temperature ranges 100 - 230¦C and 200 - 340¦C. The same two gases, carbonyl sulphide (COS) and carbon disulphide (CS2), were the main gases evolved in each of the mass losses. Samples of activated carbon from two industrial plants were obtained and analysed by TG-FTIR. COS and CS2 were not detected in one of the samples. The other sample did show evidence of COS and CS2, which indicated that fouling of the carbon by SEX was still present. Other organic compounds were detected in the evolved gas stream of both samples, indicating the presence of organic reagents other than SEX.

Jan 1, 1996

By James A. Voigt

The efficient separation of metal species from aqueous streams by precipitation techniques requires 'a fundamental understanding of the various processes that occur during precipitation. These processes include particle nucleation, particle growth by solute deposition, agglomerate formation, and agglomerate break-up. The application of the population balance approach has been used to develop a kinetic model that accounts for these competing kinetic processes. The usefulness of the model is illustrated through its application to the precipitation of yttrium hydroxynitrate, YHN. The kinetic parameters calculated from the model equations and system-specific solution chemistry are used to describe several aspects of the effect of pH on the precipitation of the YHN. Implications with respect to the simultaneous precipitation of more than one cation type are also discussed through use of example systems: The effects of solution chemistry, precipitator design, and solvent choice are considered.

Jan 1, 1996

By Laihua Wang, Peter Hayes, Hae-Geon Lee

"This paper introduces a new process for the efficient removal of dissolved gases and inclusions from liquid metals. This process involves the creation and dispersion of fine bubbles in molten metals by introducing inert or reactive gas into a region of turbulent flow. The highly turbulent metal flow splits the gas into fine bubbles and results in good mixing between the gas and molten metal phases. These conditions are ideal for contacting inclusions in the metal with the bubbles and subsequent flotation of the inclusions to the metal-slag interface where the inclusions are then absorbed by the covering slag layer. Dissolved gases, such as [H], [0], [N] in the metals are also transferred to the gas bubbles and removed from solution.The process concept has been previously demonstrated using a full-scale air/water model to simulate the ladle-to-tundish system of continuous casting of steel. The present cold modelling work has further demonstrated the ability of the process to remove gas solutes. The results indicate that the efficiency of new process is several hundred times greater than that of conventional high speed rotating injectors which are currently applied in the treatment of liquid light metals.IntroductionDuring metal smelting, refining and alloying processes, unwanted gas and second phase liquid or solid impurities are incorporated into liquid metals. In the case of steelmaking, the gas-forming impurities include [0], [H] and [N], and the solid impurities as a result of deoxidation include Ah03, Si02 inclusions. Common impurities in liquid aluminium are dissolved hydrogen and solid Ah03. To avoid subsequent problems during processing and to improve the physical properties of the metal products it is necessary to significantly reduce the level of impurities."

Jan 1, 1996

By David E. Siskind

In the period 1989 to 1994, the U.S. Bureau of Mines assisted the Office of Surface Mining, Reclamation and Enforcement (OSM) in studying a high-complaint situation near an active surface coal mine. As part of a review for its project report, the Bureau had to address issues on the adequacy of the safe blasting criteria and analysis procedures in its 1980 report RI 8507, Structure Response and Damage Produced by Ground Vibration From Surface Mine Blasting.

Jan 1, 1996

Alliance Gold Mines was established in the early part of 1994 to acquire the assets of Diamin Resources NL at Maldon, Victoria. These comprised Exploration Licence 3422, some 20 sq km in area and enclosing the main part of the Goldfield, and a CIP plant - with a nominal capacity of 250 000 tpa - which was commissioned in 1988. Between 1988 and 1992 Diamin had mined - by open pit methods - and milled around one million tonnes of low grade gold ore, and recovered 55 000 ounces of gold. By 1992 the known shallow resources had been depleted. Historical gold production from the Maldon field is about 1.75 million ounces, at the surprising average recovered grade of 28 g/t. The last significant mine closed in 1926: since then there has been no comprehensive exploration program, though Lone Star Exploration NL tested part of the field for shallow open-pittable resources in the 1970s and Carpentaria Exploration Company Pty Ltd carried out widely-spaced drilling on the three main reefs from 1979 to 1982. Diamin (1983 - 1994) commenced a careful compilation of old mine records and newspaper clippings, and drilled several cored holes.

Jan 1, 1996

By B. Denby, D. J. McMlarnon

During the ongoing research into the possible applications of Virtual Reality in underground operations, the AIMS Research Unit has developed a user-interface driven program which enables a user to input the geometry of underground mines, and add equipment and working processes in order to produce an accurate simulation of their operation. This paper describes the main features of this system (VR-MINE). Virtual Reality is a field which has grown out of three dimensional computer graphics techniques, and allows a user to move freely around a model held within the computer's memory. Movement around this model is carried out by the use of intuitive peripherals such as joysticks, with the user's view from their position within the model being produced in real time on a computer monitor or other device (such as a headset). This enables a user to interact with any three dimensional model and see the results of their actions immediately. VR-MINE is broken into two separate programs, both running under Microsoft Windows 3.1 or above. The first, the editor, allows the user to develop the mine layout and add equipment and personnel. The mine geometry is considered to be made up of various types of objects, for example a straight roadway segment which can be inclined, a junction roadway segment, and a turning segment. The geometry can then saved into a file to be loaded in by the second program of VR-MINE, the viewer. This generates a real- istic representation of the mine, with undulating floors and walls. It also has the ability to display multiple windows on the mine at the same time, which are arranged interactively. The simulation occurs within this program, with the user traversing the model in real time to examine possible areas of improvement in operations. This paper gives a number of examples of how the AIMS Re- search Unit has applied this technology to a range of underground mining scenarios to improve the safety of workers in the under- ground environment. The application discussed include computer graphics and Virtual Reality systems to training, risk analysis, visualisation, simulation, accident investigation and major hazard planning.

Jan 1, 1996

By João M. S. Rodrigues

The use of sandblasting as a treatment method for conditioning anodes for zinc electro-winning was investigated and compared with conventional fluoride preconditioning. The anodes were made from two different lead-based alloys (Pb-Ag-Ca and Pb-Ag). Laboratory results showed that sandblasting and preconditioning both minimize lead contamination in the zinc and sludge generation. Sandblasting was found to have no aggravating effect on the anode corrosion. The sandblasting treatment was tested on Pb- Ag-Ca anodes on an industrial scale in the celJhouse of a local zinc producer. An unexpected finding of the large-scale tests was that the sandblasting appeared to strengthen the anodes, resulting in reduced warping during handling and operation.

Jan 1, 1996

By Garg. D.

Premixed bronze powders are widely used to produce a wide variety of P/M components including bearings and bushings by the powder metal industry. The physical and mechanical properties of sintered bronze components such as dimensions, strength, microstructural characteristics, and sintered density are well known to change with sinlering furnace design, particle size distribution in powders, green density, preheating and sinlering time" and temperature, and protective atmosphere flow rate. " However, not much is known about the effect of protective atmosphere composition on physical and mechanical properties of sintered bronze components; This paper describes effects of protective atmosphere composition and sintering temperature on physical and mechanical properties of sintered bronze components

Jan 1, 1996

By Paul Worsey, Ron Ecklecamp, Scott G. Giltner, Ronnie Inman, Terry Drechsler

A blast monitoring program conducted at Chemical Lime Companys new lime calcining facility near Ste. Genevieve, Missouri is discussed. The purpose was to develop blasting criteria for the construction and operation of the lime plant within the quarry operated by Tower Rock Stone. Further, it was imperative to accommodate production requirements into the blasting criteria. The major concern was the effect of blasting on the curing of green concrete during the construction of the storage silos and kiln stacks. In addition to discussing the susceptibility of curing concrete to blast vibrations, the paper also details how this varies with time.

Jan 1, 1996

By Michael Honerkamp, Clemens Mann

A quarry is not a static, but a dynamic structure that greatly affects the appearance of the surrounding area. Excellent planning is required today to cope with this continual change. In this paper several case studies are presented where computerized three-dimensional visualization has been successfully applied.

Jan 1, 1996

By Louis J. Cabri

The ion microprobe (dynamic SIMS technique) is a very sensitive instrument for the quantitative determination of trace concentrations of precious metals (often at the ppb level) occurring in common sulfide minerals, either chemically-bound or as discrete particles too small for resolution by SEM. The technique involves sputtering a 250 x 250 Jim area of the grains to a depth of about one ILm and analysing the secondary ions emitted from a circular central region in the sputter crater with a 62.5 I'm diameter. The combination of quantitative mineral-specific sub-ppm analyses together with depth-profiling and the ability to produce secondary ion maps of trace precious metals makes this a very powerful technique in quantifying the precious metal distribution in refractory and other sulfide ores and process products. The technique is particularly well-established for analysis of gold-and platinum-bearing ores and process products.

Jan 1, 1996

By G. White

Traditional atmospheres used for Aluminum annealing have been air, exothermic gas, and cryogenic purity Nitrogen. Air and exothermic gas have several problems associated with them such as surface discoloration, toxic emissions, and explosion hazards. High Oxygen levels can cause Magnesium streaking and oil staining, and therefore pure Nitrogen has been the atmosphere of choice for high quality Aluminum coils. A comparative study was made on key Aluminum alloys annealed in Nitrogen with different Oxygen concentrations to determine the effect on surface quality. The atmosphere composition inside the furnace was analyzed during the purge and heat cycle to determine its effects on purge times and exhaust emissions. The Aluminum coils after annealing were visually inspected for surface staining before and after rolling. The lab study revealed that Nitrogen with up to 1.0% Oxygen is acceptable, and did not adversely effects the surface quality or any of the other processing variables. However it isbelieved that higher Oxygen concentrations are acceptable depending on the rolling oils and alloy systems.

Jan 1, 1996

By R. J. McLaughlin

Acid mine drainage (AMD) can occur as a natural phenomenon through oxidation of sulfide minerals. Oxidation by air and water can be exacerbated by mining. Because AMD can exhibit low pH, it is capable of extracting heavy metals from mineral deposits. The result is highly acidic drainage with elevated heavy metal concentrations -the combination of which can cause extensive environmental damage. Because of the importance of these factors, this paper is focused on sulfate based AMD. Due to widespread mining, the occurrence of AMD is ubiquitous. As a result, several approaches to treatment have been developed. Chemical treatment using alkali is most commonly employed to treat AMD. There are alternative methods of treatment, as well as alternative ways of handling treatment sludges or concentrates. Dewatering of sludge or concentrates is beyond the scope of this paper.

Jan 1, 1996