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By Lanny Pasternak

"This article is directed at plant production, engineering and maintenance personnel. Seldom does any industrial operation take the time to study the costs involved in the generation of what is probably their most expensive plant utility energy source.IntroductionIn the typical industrial plant in Canada, a 200 hp, 900 cfm, air compressor costs about $60,000* per year to operate (Fig. 1). In 1989 when BC Hydro embarked on their industrial energy management program Airflow Energy Ltd. were asked to spearhead the “Efficiency Compressed Air” portion of that program with a mandate to perform onsite overview surveys and physical hands-on testing of some 300 selected industrial plants throughout British Columbia for compressor efficiencies and wasteful air leaks (Fig. 2). The program duration lasted until 1995, during which time a tremendous amount of data were amassed relating to equipment types, clients’ operating habits, end-use applications and operating costs.During the past six years, Airflow Energy also performed somewhat similar surveys but on a smaller scale in Alberta, Ontario, the United States and the Republic of China. It was no surprise to find some inherent equipment concerns related to efficiency as well as neglected energy wasteful air leaks, so British Columbia was not alone and the problems appear somewhat universal."

Jan 1, 1996

By James M. Barker

Industrial minerals are critical to most aspects of modern society. They are pervasive in both industry and in everyone's lives (McVey, 1989; Barsotti, 1993). They are also the dominant class of minerals produced in the United States but this fact is little known outside the industry. For example, in 1993 (U.S. Bureau of Mines, 1995, table 1) industrial mineral dollar value was double that of metals ($20.86 billion vs. $10.88 billion) and employment levels were nearly so (74,000 vs. 40,000). A further difference is that transportation tends to dominate production costs (FOB end user) whereas they are much less significant in other mining ventures or other industries. Finally, metal mines are more concentrated west of the Mississippi; industrial mineral operations are more prevalent to the east (U.S. Bureau of Mines, 1995, p. 16-17). The significance of transport cost is discussed in Part 2, which is essentially Barker and Austin, 1995. Part 1 will update and expand portions of Barker and Austin (1995) and provide a more detailed discussion of import/export relationships using a China/United States reference point because of China's dramatic influence on some industrial mineral markets since the mid-1980s (barite, etc.).

Jan 1, 1996

By S. J. Taylor

The siting, grading and fill usage for leach pads are important aspects of leach pad design. A method is presented that optimizes the cut and fill quantities (i.e. minimizes the cost) required to grade a leach pad with parallel cells; given the desired pad characteristics of maximum and minimum pad slopes, maximum cut and fill depths, etc. and the cut and fill costs. The method allows the variation of the cut and fill costs with depth, which allows the accurate modeling of the cost savings practice of using cheaper fill towards the bottom of a thick fill. This optimization could be incorporated into a CAD package, enabling a designer to simply draw a desired pad shape on a site plan, input the pad and heap characteristics (required heap volume, heap height, heap sideslopes, etc.) and then have the computer report both the adequacy of the pad area and the optimum grading for the particular pad shape. Using this, a designer could quickly and accurately assess the optimum, or cheapest, grading of many shapes and positions for a leach pad. This would be especially useful for large pads that need to be sited on rough terrain.

Jan 1, 1996

Physical and chemical properties of the salt flux phase play a significant role in the recycling of UBC in Aluminum melting processes. Particularly knowledge of several properties such as salt vapor pressure, melting temperature, loss of aluminum, corrosion of refractories are useful for the process control decisions in order to attain a good quality of aluminum produced. A literature review and analysis of several salt flux systems for the selection of a flux for the Aluminum melter (low temperature natural gas bath melting) process were made. Based on these analysis two salt flux systems are recommended for further studies. These are NaCl?KCl?LiF system and NaF?LiF?KCl system with small amounts of other salt additives. Application of these fluxes to Al industrial processes are discussed.

Jan 1, 1996

By H. Eccles

BNFL, an internationally acclaimed company noted for its nuclear fuel cycle services and waste management technologies, collaborated with Viridian BioProcessing Ltd, a small company acknowledged for developing environmental biological processes, and an internationally recognised professor of biological sciences, to develop an unique bioremediation process for treating toxic, heavy metal contaminated land. This paper describes the process, with particular reference to the problem and scope of land contamination with toxic, heavy metals and the current available technologies. The process technologies are based on using indigenous, soil micro-organisms which can be stimulated to produce acid or sulphide ions to mobilise or precipitate the heavy metals respectively. Laboratory studies have indicated metal removal efficiencies of greater than 90 % can be achieved, whilst recovery efficiencies from the metal loaded leachate are even higher at approximately 95%.

Jan 1, 1996

By G. Laird, N. B. Gray, N. Lawson

"Photographic, video, laser, hot film and conductivity methods are used in the experimental study of gas-liquid flows. A discussion of their capabilities and limitations are given in this paper illustrating the wide range of phenomena that can be studied. Most of these methods are limited to physical models at room temperature with transparent fluids, although they can be extended for use with opaque and hot fluids. A number of these techniques have been used by the GKW CRC in studies on industrial plants and their usage is increasing although a number of technical difficulties still need to be overcome. An in-depth discussion of the laser doppler anemometry (LDA) and particle image velocimetry (PIV) methods is given with experimental results on the flow field of an air plume in water based on advanced development of the techniques and studies carried out at the GKW CRC. The LDA method provides high resolution data on the velocity profiles, while the PIV method provides an overall view of the complex flow structure occurring at the gas-liquid regions. These two methods complement each other in providing experimental data for validating numerical models and exploring the complexities of multi phase flows.IntroductionThe injection of gases into melts is an important operation in the metallurgical industry. It is used in converters, anode furnaces, blast furnaces, ladles, bath smelters, zinc fumers and many other smelting processes. In many of these processes, the gas is injected into a molten bath resulting in the formation of bubbles that promote reaction, mixing, alloying and heat transfer. The study of gas-liquid systems presents enormous challenges to the researcher due to the complexity of the mathematical and physical modelling which require innovative numerical and experimental skills."

Jan 1, 1996

By C. G. Anderson

The treatment of materials for the recovery of the precious metals imposes many processing and environmental challenges. Sunshine Mining and Refining Company has developed hydrometallurgical technology for recovery of values from refractory precious metal materials. At Sunshine, the industrial focus of these processes has been for the direct recovery of silver without cyanidation. However, recent work has indicated that these technologies can provide a means for treating complex, refractory gold concentrates. This will be the focus of this paper. The practice of pretreating ores and concentrates to make them more amenable to cyanidation is becoming more common. Several pretreatment options for sulfide concentrates containing gold include roasting, bio-leaching, direct pressure oxidation and nitrogen species catalyzed pressure oxidation. The industrial use of nitrogen species catalyzed pressure oxidation has been limited to the Sunshine refinery where its focus has been for the treatment of silver concentrates. Much of the reluctance, outside of Sunshine, to use this type of technology may be based on the perception that high costs are associated with using nitrogen species (e.g. nitric acid, sodium nitrite) to leach. Also, the use of nitrogen species catalyzed pressure oxidation on an industrial scale is unfamiliar to most metallurgical professionals. A summary of pressure leaching processes which utilize nitrogen species as a catalyst is presented in Tables 1 and 2.

Jan 1, 1996

By L. M. Luckevich

Gypsum is a product from the neutralization of sulfuric acid by lime or limestone. This paper will discuss specifications for gypsum used in wallboard, cement and agriculture and the factors affecting its utilization potential. Process conditions during the neutralization which enhance or inhibit utilization potential will be included. In addition, this paper provides a technical and economic perspective of the gypsum industry in North America with a view to the factors affecting the utilization of synthetic gypsum in traditional applications. Current production and consumption of natural and synthetic gypsum in Nonh America are described and the impact of their differences on utilization options are discussed.

Jan 1, 1996

By Corby G. Anderson

Hydrometallurgical technology for the pretreatment of refractory gold concentrates has been developed at Sunshine Mining and Refining Company. It employs a patented nitrous-sulfuric acid pressure leaching process which' was proven industrially at the Sunshine refinery. Additionally, pretreatment for removal of antimony and some other impurities is done with alkaline sulfide leaching. This paper will discuss the successful application of these two technologies for pretreatment of a refractory gold concentrate prior to CIL gold recovery. A complex gold concentrate composed of pyrite, arsenopyrite and stibnite was tested. Results of antimony leaching in alkaline sulfide media will be discussed including some details of a novel and selective recovery method for gold leached by polysulfide or thiosulfate" Also, the factors important in and the results of the application of nitrogen species catalyzed pressure leaching to refractory gold concentrates will be detailed.

Jan 1, 1996

By Donald R. Sadoway

Molten salt electrolysis is a proven technology for the extraction of metals -- all the world's primary aluminum is produced in this manner. The unique properties of molten salts, also make them excellent media in which to treat a variety of forms of waste. Of special .note in this regard is electrolysis in molten oxides, a .concept put forward by. the author, initially as a ."clean technology" for producing primary metal. However, in the context of waste treatment, electroly-sis in molten oxides is a process offering the prospect of changing the. valence of dissolved heavy metals while making pure oxygen gas as the main by-product .Laboratory tests conducted at a temperature of 1550°C on chromate sludge dissolved in an melt composed of Al2O3 and MgO have confirmed electrochemical production of oxygen on a carbon-free anode.

Jan 1, 1996

By J. R. Parga

A shortage of landfill space and growing environmental concerns in Mexico are renewing interest in the recyclability of scrap from automobiles. This work describes a pyroumetallurgical process for the recovery of metallic lead from waste lead paste. Argentopyrite concentrate is commingled with lead paste residue and smelted in a fuming process thereby transferring the precious metals into lead bullion. The process consists of smelting lead paste and argentopyrite, sodium carbonate, and metallic iron at smelting temperatures of about 1100 T. The reaction products are slag and molten lead bullion enriched with precious metals. A major feature of this process is the removal of precious metals from the bullion by means of zinc, whereby a silver-zinc intermetallic compound is formed and floats out of the lead. The recoveries of precious metals are about 98%.

Jan 1, 1996

By A.M. Wala

A new radioactive tracer method to measure airflow in inaccessible airways has been developed for situations when studies of the mine ventilation system are not possible using conventional flowmeters (anemometers). The new method has been tested in the ventilation laboratory at the University of Kentucky and in the Experimental Underground Coal Mine at the U.S. Bureau of Mines. This new tracer method has been utilized in leakage, dilution and flow velocity measurements in laboratory and field (mine) experiments.

Jan 1, 1996

By Bjoern R. Petterson, Lars Haakon Siem

The world's longest highway-tunnel -- the Aurland Tunnel in western Norway -- is scheduled to be opened in the year 2000. A project to build a main highway between Oslo and Bergen with no ferry connections was approved by the Norwegian Parliament in January 1995. Construction of the five-year blasting project was started by the Norwegian Highway Authority in mid-March 1995, with an expected completion date of November-December 1999.

Jan 1, 1996

Diversity; what a wonderful topic. Diversity; the condition or quality of being diverse, different, varied to the point that the very word diversity means different things to different people. As one example of diversity the American Science Magazine (April, 1994) contained a light-hearted interview with Dr Noitall who was pushing his case for diversity.

Jan 1, 1996

By Jones M

The concept of precise, accurate timing with Electronic Delay Detonators (EDDs) was first seriously addressed in the mid-1980s and much was made of the cheapness and profusion of digital watches in terms of the likelihood of EDDs also being cheap and easy to produce. Ten years later, with every major explosives company and many electronics groups having instituted projects to capitalise on the promise of these devices, production devices are still to come into general use. In South Africa, Expert Explosives units have been used in most applications during proving trials and more recently for production blasting in underground ring stoping and open cast coal. The outcome has been valuable learning both as to the benefits and technical requirements for electronic delay blasting, and especially, safety aspects. Examples are shown of production blasts which utilised the power of EDDs. It is evident that it is not delay accuracy alone which determines the value of these systems, but the whole robustness, flexibility and ease of delay allocation when harnessing blast engineering knowledge. Muckpile movement and shape, fragmentation and vibration frequencies have shown to be greatly influenced by designs which can be implemented no other way. The flexibility of a system and the power of the software controlling it are crucial in capitalising on blasting potential, which lies in integrating control of blast timing with other developing electronic Technologies.

Jan 1, 1995

By Fred L. Stanley, Ricky Q. Honaker, Michael J. Mankosa

Spiral concentration has gained a great deal of popularity as a cheap, effective method for recovering fine coal (8x100 mesh). Typically, 6-turn, wide-profile spirals are used in either a single pass, open- circuit configuration or in combination with a middlings retreat circuit. Recent work conducted at Carpco, however, has indicated that a split feed scenario and/or hydraulic classification in advance of spiral concentration offers significant advantages in both capacity and metallurgical performance. In addition, it has also been shown that the apparent density separation which naturally occurs in a hydraulic classifier provides significant up-grading in terms of pyrite and ash rejection. The results from this study will be presented in comparison with those obtained from open-circuit spiral testing.

Jan 1, 1995

By M. Spangler

FirstMiss Gold installed a supervisory control system based on Pavilion Technology's Process Insights neural network software and Oil System's PI data historian. The primary goal of the system was to control the acid preconditioning circuit. However, our first successful control loop was on the limestone feed rate to the neutralization circuit. The information gained by modeling these circuits and the better control provided by the system has resulted in reagent savings of over $80,000 per month.

Jan 1, 1995

By Ronald Erdmann

Today the BOF filter dusts and sludges are mainly dumped due to their zinc contents. By typically ranging from 2 to 5 % they prevent the filter dusts and sludges from beeing recycled via the blast furnace route. Based on the different discharge kinetics of Iron and zinc during the main blowing period In a bottom stirred BOF a simple and efficient system for recovery allow zinc fractions has been developed. The obtained material Is suitable for recycling without nsc of shell formation In the blast furnace. Different subsequent development steps have been performed. By starling with a very simple lime dependent model the sludge from the BOF off gas cleaning system was collected in two different sludge channel systems. This model based an the fact that most of the scrap based zinc Is discharged from the melt within the first eight to ten minutes of the BOF process. To Improve the system a spectroscope zinc sensor was Installed at the hot section of the off gas cleaning system to get more reliable informations on the actual zinc concentation of the BOF dust. By use of the system up to 50 % of the BOF sludge can be recycled.

Jan 1, 1995

By Dale A. Zuck

Recovery of aluminum metal from drosses? is a major factor in the recyclability success story enjoyed by the United States aluminum industry. Today's modern dross processor uses the latest technology to maximize metal recovery at the lowest cost while complying with all environmental laws and regulations. Most dross processors, however, pay little attention to the resulting saltcake, the end residual of dross recyCling, and rely on landfills for .disposition of this material.. The alternative is to recycle the saltcake, but the success of this technology is dependent on the development of reliable outlets for each of the saltcake constituents. This paper discusses the evolution of an aluminum dross oxide processing technology that ,produces an economically attractive source of alumina for the production of portland cement.

Jan 1, 1995

By Michael D. Fenton

Bauxite resources were primarily in Africa, Asia, Oceania, and South America. Only five countries combined, Australia, Brazil, Guinea, India, and Jamaica, contained most of the total world reserves available for extraction under current economic conditions and accounted for nearly 80 % of world production of bauxite. World bauxite and alumina production declined and prices for smelter-grade alumina remained below the $200/mt level during 1993 because of growing aluminum inventories on international markets and declining worldwide demand. The United States imported bauxite primarily from Australia, Brazil, Guinea, and Jamaica. U.S. alumina plant capacity remained essentially unchanged throughout 1993, but apparent capacity utilization decreased by the close of 1993. Chromium Most of the world's known resources and reserves of chromite are located in India, Kazakhstan, South Africa, and Zimbabwe. India, Kazakhstan, and South Africa accounted for 73 % of world production of chromite. The two largest producers of chromite, Kazakhstan and South Africa, were in the process of major economic and political change during 1993. South Africa's production and exports of chromite continued to fall during 1993, because of weak international demand and a flood of cheap metal from the former U.S.S.R. and China into world markets. Despite a significant increase in production, South Africa's ferrochrome producers continued to operate below capacity in 1993. Prior o the dissolution of the U.S.S.R., Kazakhstan was a major internal supplier of chromite ore to the U.S.S.R. consumer, but subsequent decline in demand led to a downward trend of chromite production in Kazakhstan and increasing exports to Europe during 1992 and 1993. The United States consumed, about 10% of world chromite ore production in various forms of imported materials. The United States imported nearly one-half of its required chromium contained in chromite ore and chromium ferroalloys and metal from South Africa; the remainder was from the minor producers Turkey, Yugoslavia, Zimbabwe, and others.

Jan 1, 1995