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By Arthur W. Cooper

This paper contains a review of the development of blast furnace? slag handling and processing technology in the Ironmaking industry over the past 30 years, with an emphasis on economic and environmental factors. The requirements and practice of air-cooling slag for use as aggregate and of pelletizing and granulating slag for use in cement manufacture are described. The operation of slag pits, slag pots or ladles, the slag pelletizer and early granulation systems are compared with the new continuous .granulation, dewatering and handling systems developed in the past decade.

Jan 1, 1992

By W. Drummond

The cooling of smelter gases by air dilution, adiabatic evaporative cooling and indirect heat exchange is discussed with reference to the ,process, to the subsequent cleaning of the gas and to the use of the heat extracted from the gas. The method of reducing the effect of acidic ,sulphide formation on the corrosive properties of the gas and the dust and the development of surface cleaning mechanisms are discussed. The development of indirect recuperators using air, water or steam cooling, made 'possible by the control of surface fouling is traced. The application of the modern Waste Heat Boiler to the new sulphide smelting processes is discussed with respect to the natural and forced circulation concepts. Case histories are presented to illustrate mistakes made with respect to designs produced without recourse to sensitivity analysis and without an appreciation of "worst process conditions".

Jan 1, 1992

By C. M. Iheagwara

An overview of the scope and ramifications of scrap recycling in the Nigerian metallurgical industries has been presented in this paper. The modern state-of-the-art processing techniques and the operational strategies employed in the recycling plants are discussed. Optimization techniques for cost effective recycling operations are highlighted. As new units within existing metallurgical plants and new metal working plants approach commercial operations, expansion of existing recycling plants and the emergence of new ones have been showing to hold the key to their profitability from the raw material standpoint. The present economic predicament of the entire industrial sub-sector, lack of sufficient foreign exchange to procure new machineries and the emergence of a maintenance culture have triggered a phenomenal increase in the number of spin-off industries which depend on metal recycling activities. This, it is argued, widens the horizon for scrap processing/recycling.

Jan 1, 1992

By Deepak Malhotra

INTORDUCTION Mining operations are unique In that they handle large volumes of water (millions of gallons) daily. The water contains dissolved metals, processing chemicals, organics, and other contaminants, There are several sources of water contamination at mine sites: mines, mills, tailings ponds, and Industrial/utility complexes. Utility waste water generally represents a very small portion of the total process water utilized in a normal milling operation and hence will not be addressed in this paper. Mine drainage can represent a significant amount, thus having an Impact on the recovery of metals, especially In Industrial minerals operations, and may have to be treated separately. The National Pollutant Discharge Elimination System (NPDES) effluent limits are becoming more stringent, thereby requiring mining operations to treat process water prior to discharge to the environment. The general trend Is to move toward a closed-loop waste system and treat only that small fraction of process water which Is to be discharged to public lands. The following section discusses the reasons for waste water treatment and the existing and emerging technologies for meeting NPDES effluent limits. REASONS FOR WATER TREATMENT Due to the diverse nature of the mineral Industry, process/waste water contamination problems as well as processing flowsheets are site specific. However, certain generalizations can be made specific to processing of different minerals: • Acid mine drainage Is a problem at sulfide/coal mines. • Cyanide contamination of water Is a problem at gold processing plants. • Organics can be a problem at mines using flotation oils. • Tolling ponds are generally acidic at sites processing industrial minerals such as silica sand and feldspar. The cost for water treatment Is viewed as an added cost of production. Hence, large mines are moving toward dedicating personnel to management of water resources in order to minimize waste water for treatment. Very often, mines having closed-loop water systems will treat waste water for reasons other than meeting NPDES regulations. These Include situations where process requirements dictate use of high-quality water for separation of minerals, neutralization of acid mine drainage water, and portable water for the mill. WATER TREATMENT TECHNOLOGIES Water treatment process has to be cheap and simple because It has to process large volume, and It does not directly add to the bottom line, namely revenue. The water treatment process development has to be site specific because the contaminants In the water vary from site to site. and discharge limits for water vary from state to state. The current technologies for wastewater treatment have been divided Into the following three areas: • Removal of heavy metals • Cyanide destruction • Scale control A brief summary of the current technology In each area Is discussed below. Removal of Heavy Metals The physical and chemical processes for heavy metal removal are summarized in Table 1. The most common and cheapest approach has been the precipitation of hydroxides at high pH followed by sedimentation and thickening of solids. The remaining solids can be removed by filtration. The pH is adjusted back to neutral, and the water Is discharged. This process is most commonly used wastewater treatment technology in the mining industry. The basic processes can be modified by combining other operations in order to meet the objectives of the specific site as illustrated In the following examples: • AMAX's Mt. Emmons treatment facility uses Lectro Clear® process where the precipitated solids are removed by electroflotation. • AMAX's Climax Mine water treatment plant used Ion exchange columns to meet the discharge limits on molybdenum.

Jan 1, 1992

By W. Drummond

The cooling of smelter gases by air dilution, adiabatic evaporative cooling and indirect heat exchange is discussed with reference to the process, to the subsequent cleaning of the gas. and to the use of the heat extracted from the gas. The method of reducing the effect of acidic sulphide formation on the corrosive properties of the gas and the dust and the development of surface cleaning mechanisms?are discussed. The development of indirect recuperators using air, water or steam cooling, made possible by the control of surface fouling is traced. The application of the modern Waste Heat Boiler to the new sulphide smelting processes is discussed with respect to the natural and forced circulation concepts. Case histories are presented to illustrate mistakes made with respect to designs produced without recourse to sensitivity analysis and without an appreciation of "worst process? conditions".

Jan 1, 1992

By Van Deventer J S J

The first step in the design of a process to treat a possible economic precious metal deposit should be an examination of the mineralogy of the ore. Using this and other initial tests, the extractive metallurgist can design a process to treat the ore. In the field of precious metal metallurgy, little emphasis is placed on the mineralogical information available to the metallurgist. The information is of far more use to the geologist and the mining engineer. Diagnostic leaching was designed to open up the field of mineralogical analysis to the metallurgist. When a mineralogist looks at the deportment of gold in an ore, he is usually looking for an element which is present in parts per million, so that errors in sampling are multiplied dramatically. Diagnostic leaching offers a cheap, simple, practical alternative. In order to determine with which minerals the desired precious metal is associated, a specific mineral is first eliminated using a selective oxidative leach, and cyanidation is used to extract the precious metal (in this case gold and silver) liberated by the destruction of this mineral. The precious metal extracted can be measured in solution to give a fairly accurate record of the amount of the precious metal associated with that mineral. Furthermore, the residue from this first stage can be subjected to another selective acid leach, and the process repeated. The procedure can be varied to suit the mineralogy of the matrix material. At the end of this diagnostic leach the metallurgist is left with a complete record of the deportment of the precious metal. He can now use this information to design a metallurgical flowsheet to treat the ore. Diagnostic leaching is thus an analytical tool which can be used by the metallurgist not only to examine new ores, but also to look at problems occurring at existing plants. The procedure is not only limited to ores and residues but in fact can deal with any type of intermediary product that occurs on a plant. The information gained from analysing an intermediary product can give a useful indication of how well a unit process is working, eg flotation, roasting, etc.

Jan 1, 1992

By James A. Sommers

Hydrolysis of NbC15 is used to recover oxide values for ceramic and metals production. Reaction of NbC15 with water is rapid, exothermic and vigorous, yielding a gelatinous slurry. In contrast, dissolution of NbC15 in 12 N HCl is endothermic, resulting in a clear yellow solution. Such solutions can be de-hydrochlorinated by controlled contact with air, to precipitate a tantalum¬rich solids, depleting the liquid of its tantalum content. In this way, cheap, useful Nb-Ta partial separation is achieved. The separation is based upon differential oxide-chloride stability. Nb2O5 with <200 ppm Ta/Nb has obtained from starting levels of 2000 ppm. Observations are made on the different types of hydrolysis.

Jan 1, 1992

By R. R. Klimpel

This paper describes four new families of flotation products which are currently being introduced at the industrial level. A brief summary of the chemical basis behind each product family will be given. This is then followed by a selection of flotation examples which illustrate the more important use characteristics that have been observed to date. It is becoming more apparent with further testing that these four new product families can offer both technical and economic advantages to the industrial flotation process operator.

Jan 1, 1992

By J. L. Parks

Designs, installation procedures, and performance characteristics of martensitic cast steel concaves are reviewed. Longer wear life, fewer pieces to install, and eliminating the need to scarf joints are the principal benefits of using martensitic steel to replace austenitic 12% Mn (Hadfield&apos;s) steel, the traditional concave material for large gyratory crushers. Installation procedures that reduce the risk of breakage are described. Operating practices that affect concave performance are also discussed.

Jan 1, 1992

By Dan Mancuso

This case study is an example of how Encyle/Texas, Inc. (a subsidiary of ASARCO) responded to various socio-economic forces by converting an idle zinc hydrometallurgical refinery into a metals recycling facility. The facility accepts metal-laden process waste streams and produces various "synthetic ores" which are sold back to industry. Acceptance and reactions by industrial, political, economical and regulatory interests towards the project are also discussed.

Jan 1, 1992

By William J. McDonough

Advanced materials are polymers, metals, and ceramics fabricated as intermaterial compounds, alloys, or composites. The resultant components have higher strength-to-density ratios, greater hardness and wear resistance, and one or more superior thermal, electrical, or optical properties when compared with traditional materials. Advanced materials, the basis for many of today&apos;s emerging technologies, offer savings in total energy consumption, improved performance at reasonable cost, and less dependence on imports of strategic and critical mineral resources.

Jan 1, 1992

By R. G. Hite, R. G. Rowe

The Crandon deposit, located in northern Wisconsin, is a 65.8 million ton Precambrian volcanogenic massive sulfide deposit which averages 1.4% copper and 5.8% zinc. The deposit is classic in origin, mineralogy and shape. Comprehensive understanding of the geology of both the deposit and the project site has been fundamental to the credibility and success of project feasibility studies and regulatory permit preparation. Mine development in the current investment and regulatory climate requires thorough and timely application of geologic tools. From 1977-1980 geologic activities were focused on the typical objectives of orebody delineation, reserve estimation, depositional geology, and general site investigation. Results from these programs formed the basis for the project&apos;s preliminary feasibility studies. Since 1981 further geologic investigations have provided criteria for project design, site management, and operational permitting. Activities have included mine entry position definition drilling, devel reserve modeling, large diameter (150 mm) core drilling for mill pilot samples, rock mechanics testing, and evaluation of the glacial overburden/deposit geohydrology for computer simulation.

Jan 1, 1992

By May J. R

Exploration, including research, has fuelled the enormous expansion of the Australian mineral industry in the last three decades. Analysis of success and failure in exploration and research has therefore potentially powerful lessons and messages which may be used to influence the future shape and direction of the mineral industry. Research has been an integral part of organised corporate mineral exploration since its beginnings in Australia in the 1930s. In corporations, the activity generally called project generation or new project development is the main expression of exploration research but mostly it goes unidentified and poorly documented except perhaps when a successful discovery is made and reported on. The competitive nature of exploration means that extended and detailed analysis of corporate exploration research across the industry is impossible to achieve.

Jan 1, 1992

By AJ LYNCH

Broken Hill metallurgists have been responsible for some of the most important developments in mineral processing technology. These occurred mainly in two periods, 1902 - 15 and 1955 - 70. Mineral flotation was developed as an industrial process during the first period and this happened in two stages, the recovery of zinc minerals from the tailings dump accumulated during the gravity concentration of the oxidised ores and the selective recovery of galena and marmatite during flotation of the primary ores. During the second period fast accurate analytical procedures were developed to provide rapid assessment of process performance, and new means of controlling the process were devised which improved throughputs, grades and recoveries. These technological successes were due to the skills of the metallurgists and the commitment of the companies. They brought large financial returns. They were achieved under difficult circumstance. There are important lessons to be learnt from these successes.

Jan 1, 1992

By Manca PP, Lassandro R, Caranassios A, Massacci G, Ciccu R

The paper discusses the state of the progress reached in the development of the diamond wire tool for cutting hard rocks. To the advances of this relatively new technology a substantial contribution has been provided by the research being carried out at the University of Cagliari on samples of granite rocks from different Sardinian stone quarries. On the basis of field experiments and laboratory test data, the mechanism of diamond wire cutting has been assessed. In particular the influence of the rock features and operational variables on tool performance (cutting rate and bead wear) has been Elucidated.

Jan 1, 1992

By D. K. Steele

The U.S. Bureau of Mines has investigated the recovery of metals from copper industry wastes by sulfuric acid leaching in a semi-continuous, bench-scale system to solubilize arsenic, copper, and molybdenum. Leach residues contained approximately 40 wt pct PbSO4, suitable for processing at a lead smelter. Arsenic and molybdenum removal from leach solution was examined using solvent extraction with tri-n-butyl-phosphate (TBP), and copper was subsequently recovered by cementation. Bleed electrolyte from a copper refinery was determined to be a viable source of acid for the initial leach stage.

Jan 1, 1991

By P. M. Swash

This paper reviews the application of some mineralogical techniques in the evaluation of the Uitkomst Ni-Cu deposit, South Africa. The low grade of the ore necessitates detailed and representative characterisation in order to establish the prospects viability. The relevant mineralogical information is generated by using optical microscopy, magnetic and heavy liquid . separations, XRD. SEM and EMPA. Methods used are briefly reviewed. The cost savings and metallurgical understanding that is provided by the mineralogical work is described especially with regard to milling, flotation and the presence of by-products (PGMs and chromite).

Jan 1, 1991

By Roe-Hoan Yoon

INTRODUCTION In 1960, coal accounted for 49% of the world energy consumption, an amount that was reduced to 29% in 1973 because of the availability of cheap oil. At that time, it seemed that oil would remain available for a long time in unlimited quantities. However, this situation changed drastically in 1973/74 when a series of closely spaced price increases from $3 per to $12 per bbl by mid-1974 hit both industrialized and developing countries. Another sharp price increase in 1979/80 to the $34 to $38 per bbl level also hit the world economy hard and, at the same time, set in motion powerful technology development forces for increased coal utilization. At this point, the price of coal was approximately $1.50 per MM Btu, while that of oil approached $6.00 per MM Btu. This huge price differential offered an incentive for developing new coal technologies including liquefaction, gasification, fluidized bed combustion, coal-water mixture (CWM), etc. The CWM technology was of particular interest to the utility industry, which consumes more than 80% of the coal mined in the US for power generation. In this technology, a powdered coal is mixed with water to produce a stable slurry that can be stored for an extended period of time without settling and is readily pumpable. Various reagents in the amount of approximately 1% by weight of the coal are added to inhibit sedimentation during storage and to reduce the viscosity for atomization in burners. The coal loading is in the range of 50 to 80% solids, depending on the particle size and its distribution. With very fine particles, it is difficult to increase the coal loading above 50%, and a binomial distribution helps increase the coal loading. The presence of water consumes a relatively small amount of the heating value of the coal during combustion; for a coal-water slurry containing 30% water, less than 5% of the calorific value of coal is usually consumed due to evaporation. The major advantage of burning coal as a slurry is that many of the oil-burning furnaces can be converted to coal-burning with a minimum retrofit cost. Considering the substantial price margin between coal and oil, the pay- back period for retrofit costs can be relatively short. Nevertheless, the retrofit cost can be further reduced if low-ash coals are used as feedstocks for CWM; there will be savings in the capital cost of installing bag filters or electrostatic precipitators that are designed to remove the ash from the combustion gases. Furthermore, the use of low-ash coals can minimize derating of boilers because the velocity of the combustion gases can be maximized without creating erosion

Jan 1, 1991

By Peter J. Nicholson

The methods of reinforcement to be discussed in this paper are all insitu methods, ones that can be used on the soil structure as it exists in the ground, and do not rely on excavation and replacement of the soil. Current practice in the United States, as well as new ideas and methods, will be discussed as they relate to slope stability, retaining walls, and to other uses such as control of mine or cavity related subsidence and to liquefaction control under existing structures. The method is based on the concept of "nailing" or reinforcing the soil in place, and thereby causing a mass of soil to act as a coherent unit. When performed properly, a true gravity structure can be constructed, one that will remain intact under both horizontal and vertical loadings and that will also resist vibrational and seismic loadings.

Jan 1, 1991

One does not need to travel too far back in time to find that the manpower requirements for new projects were focused mainly on: ò plentifulness of supply; ò cheapness of use; and ò fitness for use. These were primarily quantitative considerations and corresponded with the dominant view of labour as a commodity. Qualitative considerations were not very evident with the exception of judgements of industrial militancy. It was not unusual for areas of known militancy to be excluded from the recruitment net (eg Captain&apos;s Flat, Broken Hill, Pilbara).

Jan 1, 1991