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The comminution circuit at Tarkwa Gold Mine was commissioned as a Single Stage SAG mill operated in closed circuit with hydrocyclones designed to process 4Mtpa. The circuit was later expanded by adding a secondary ball mill in closed circuit with hydrocyclones with a view to treat 12Mtpa. The change in the circuit configuration and assigning the low aspect ratio SAG mill for primary grinding application makes the Tarkwa experience unique in terms the optimisation strategy and operating philosophy. This paper reports the findings from a series of surveys performed on this plant. The surveys reported include data obtained when the SAG mill was operated as a single stage mill in closed circuit with hydrocyclones and also SABC mode under two different feed conditions. The differences in operating philosophy between the initial single stage SAG circuit and the current SAG/Ball mill circuit are discussed.

Jan 1, 2012

By Subrata Dutta

Sindesar Khurd Mine is situated in Rajasthan, India, and operated by Hindustan Zinc Ltd, under Vedanta Group. The base metal mine is high in reserves of Lead, Zinc and silver and has been producing since 2007 with initial production of 0.3 mtpa. Recently the mine has gained prominence as a base metal underground mine in introduction of latest mining techniques and achieving high production at lowest costs. The promising Lead-Zinc reserves of Sindesar Khurd Mine (SKM) and high-tech exploration adopted by Hindustan Zinc Ltd (HZL), (Vedanta Group), raising the reserves and resources from a meager 9 Mt (1997) to 81 Mt (2012), has prompted HZL management to ramp up the mine production from 0.3 mtpa (2006-07) to 2 mtpa by 2013-14 with ambitious plans to reach 3.5mtpa subsequently (presently largest underground metal mine in India). The complete trackless system underground mine, recently equipped with latest leaky feeder communication system (unique in India), utilize modern drilling, mucking and hauling equipment aided with various utility/service vehicles. Excavation optimization and quality recovery maximization from the open and post filled stoping methods, continual expert analysis and feedback from International consultants like AMC (Australia) and SRK (UK), and involvement of renowned bodies in management excellence, have lead the mine towards highest productivity and lowest mine operating cost, earning the mine a prominent place in the global base metal industry. The paper deals with how the various challenges in mine planning and designing, mine development, operator skill, equipment introduction and maintenance, expertise availability, provide training and exposure to officials, prompt and effective communication/service, control of ground vibrations, maintain ventilation standards etc are faced in attaining high operational excellence and thus attain a record mine output/man shift (OMS) of 14 ton/man shift with targets to reach 20 ton/man /shift. Scientific designing using 2D/3D numerical mine-modeling techniques, faster stope sequencing with introduction of paste filling ( first time in India),latest leaky feeder communication system, control ground vibration to stringent standards using electronic delay system, faster raising techniques using raise borers to enhance development and ventilation, cavity scanners to monitor large stope voids, fast shaft sinking at 100 m/month(Chinese expertise) and maintaining adequate ventilation with close software monitoring are some of the highlights discussed in the paper towards achieving the targets.

Aug 1, 2013

By S. Demetrio

China has a traditional segment of Copper Smelters with its own Chinese technology, typically small in size from 20.000 to 50.000 tCu/a, and they are responsible for the processing and production of more than 600,000 tonnes of blister copper per year. For occidental experts, like one of the authors, it is not so easy to believe that they are profitable, because the size and the use of old Blast Furnaces, but they are with simple and effective production lines. The authors are convinced that China has a good alternative to improve theses old copper production lines with small innovative changes in its process arrangement, jumping to higher level technology, more efficient in production, productivity and cost, assuring copper as a raw material for the country and its high speed development. The key to improve that the traditional Chinese Copper Smelter is white metal as an extra raw material as a first step doubling the copper production from raw materials and the complete replacement of concentrates by white metal (WM) in a second step increasing it four times or more as the final goal. It is not so difficult nor expensive to make it happen, but there are a couple of questions for implementing this innovation in the copper smelter industry: 1 - Will the old fashioned mentality be open to this new direction for China being the biggest copper consumer on one side, and the biggest copper Primary Producers on the other hand? and 2 - Will they be open to follow this "win-win" strategic way for both ends of the copper market? We don't know if anybody will take up the challenge to improve it but our responsibility as a consulting expert and a university professor is to put the alternative on table for others to decide whether to implement it.

Jan 1, 2007

By Luc Harnois, Gabriel Voicu, Marc Bardoux, Robert Crépeau

"Abstract-Detailed petrographical and geochemical studies have been carried out on the igneous and sedimentary rocks in the Omai area, part of the Paleoproterozoic Barama-Mazaruni greenstone belt, Guyana. The stratigraphic succession at Omai begins with basalts, associated with mafic-ultramafic intrusives and poorly-sorted conglomerates; these are overlain by andesites and quartzfeldspar porphyries, with pelites and tuffaceous sediments at the top. The volcanic-sedimentary succession was intruded by a quartz-monzodioritic stock (Omai stock) and granophyric rhyolite dikes. Several generations of mafic dikes were intruded discontinuously from the Mesoproterozoic to the Permo-Triassic. Volcanic rocks range in composition from subalkaline basalt to high-silica rhyolites, with a gap between 60% to 70% SiO2, which suggests the suite is bimodal. Major, trace, and rare earth element criteria were used to subdivide the rocks into tholeiitic and calc-alkaline types. The tholeiitic rocks are characterized by flat to moderately sloping chondrite-normalized REE patterns. On the basis of immobile trace-element ratios, the tholeiitic mafic rocks from Omai have characteristics of immature intra-oceanic island arcs, or of E-MORB basalts affected by a strong arc signature, as is commonly reported for back-arc basin basalts. The andesites, quartz-feldspar porphyries, rhyolites and quartz monzodioritic stock are calc-alkaline, with strongly sloping REE patterns, enrichments in the large-ion lithophile elements, and depletions in the heavy REE and high-field-strength elements, features which are typical of more mature island-arc settings.At Omai, two types of gold-bearing veins can be distinguished: vein sets (± stockworks) and tension veins, both post-dating the regional metamorphic peak at the level they were emplaced. The relationship between the gold mineralization and its host lithologies does not seem to be genetic. Rather, the emplacement of mineralization was strongly influenced by the rheological contrasts between the intrusive/subvolcanic bodies and the volcanic/sedimentary country rocks. These contrasts helped to focus the regional stress upon the more competent intrusive subvolcanic bodies, resulting in brittle fracturing, and therefore in greatly enhanced permeability to hydrothermal fluids. The Omai gold mineralization can be classified as late tectonic, with its emplacement controlled by the last brittle to brittle-ductile stages of the Trans-Amazonian orogeny."

Jan 1, 1997

By Gabriel Voicu, Harnois Luc, Marc Bardoux, Robert Crépeau

"Detailed petrographical and geochemical studies have been carried out on the igneous and sedimentary rocks in the Omai area, part of the Paleoproterozoic Barama-Mazaruni greenstonebelt, Guyana. The stratigraphic succession at Omai begins with basalts, associated with ma?c-ultrama?c intrusives and poorly-sorted conglomerates; these are overlain by andesites and quartz-feldspar porphyries, with pelites and tuffaceous sediments at the top. The volcanic-sedimentary succession was intruded by a quartz-monzodioritic stock (Omai stock) and granophyric rhyolitedikes. Several generations of ma?c dikes were intruded discontinuously from the Mesoproterozoicto the Permo-Triassic. Volcanic rocks range in composition from subalkaline basalt to high-silicarhyolites, with a gap between 60% to 70% SiO2, which suggests the suite is bimodal. Major, trace, and rare earth element criteria were used to subdivide the rocks into tholeiitic and calc-alkaline types. The tholeiitic rocks are characterized by ?at to moderately sloping chondrite-normalized REE patterns. On the basis of immobile trace-element ratios, the tholeiitic ma?c rocks from Omai have characteristics of immature intra-oceanic island arcs, or of E-MORB basalts affected by a strong arcsignature, as is commonly reported for back-arc basin basalts. The andesites, quartz-feldspar porphyries, rhyolites and quartz monzodioritic stock are calc-alkaline, with strongly sloping REE pat-terns, enrichments in the large-ion lithophile elements, and depletions in the heavy REE and high-?eld-strength elements, features which are typical of more mature island-arc settings.At Omai, two types of gold-bearing veins can be distinguished: vein sets (± stockworks) and tension veins, both post-dating the regional metamorphic peak at the level they were emplaced. The relationship between the gold mineralization and its host lithologies does not seem to be genetic. Rather, the emplacement of mineralization was strongly in?uenced by the rheological contrasts between the intrusive/subvolcanic bodies and the volcanic/sedimentary country rocks. These con-trasts helped to focus the regional stress upon the more competent intrusive subvolcanic bodies,resulting in brittle fracturing, and therefore in greatly enhanced permeability to hydrothermal ?uids.The Omai gold mineralization can be classi?ed as late tectonic, with its emplacement controlled by the last brittle to brittle-ductile stages of the Trans-Amazonian orogeny."

Jan 1, 1997

By A. Roca, V. A. Quezada, O. A. Benavente, M. Cruells

The leaching pretreatment of copper ores is widely used in the Chilean mining industry. Agglomeration and acid curing have been identified as the most useful pretreatments. Of these, acid curing was recognized as beneficial in the dissolution of copper minerals, even in sulphides such as chalcopyrite. Extensive acid curing times have an impact on copper extraction, generate a homogeneous acid distribution in the mineral bed and benefit the inhibition of aluminum-silicate minerals (acid consumers). This document describes some of the theoretical background and results regarding the effect of acid curing in a chalcopyrite sample with 74% purity according to Qemscan analysis and a 28.5% of total copper. Leaching tests are carried out at 25, 50 and 70°C, evaluating the effect of a pretreatment on the chalcopyrite dissolution. The original sample and products generated were characterized by X-ray diffraction analysis and Scanning Electron Microscopy (SEM). The performed experiments indicate a direct relation between the effect of curing time and temperature in copper extraction. 92% of copper can be extracted in a leaching at 70°C and with 15 days of curing. Elemental sulfur, jarosite and copper polysulfide (CuS2) have been detected in leaching products. INTRODUCTION The copper extraction from minerals is a technique that has been developed for hundreds of years in the world. In 2017, the largest copper producer was Chile, exported 5.5 million tons (COCHILCO, 2018). However, in order to preserve this production level means overcoming multiple challenges. In the case of the Chilean copper deposits, the average copper grade in 2016 was 0.65%, lower than the 1% declared in 2004 (Consejo Minero, 2018). This is mainly due to the deeper of the deposits reaching sulfide mineral zones, mainly chalcopyrite. Traditionally, these sulfurized zones ore are treated through concentration by flotation and subsequent pyrometallurgical treatments. However, for some copper companies it is complex to process by this alternative, due to the high costs and high rates of water consumption. The mineral resources of these companies are known as "low-grade sulfides" and do not allow, economically, the treatment of these minerals through concentration by flotation. This is how hydrometallurgy becomes an alternative for the treatment of this type of deposits. In addition, several companies have hydrometallurgical plants, which would allow the operational continuity of these plants.

Jan 1, 2019

By A. Mcdonald

"An X-Met Analyzer was purchased from Outokumpu in late 1983for use in the Hudson Bay Mining and Smelting smelter. Its first use was in the fuming plant to give zinc assays of each charge of slag tapped from the fuming furnaces. This quickly told the operators exactly when each charge had reached its economic tap-out point, and gave supervision a fool-proof method of identifying good operation. These and other factors led to major improvements in coal utilization in the fumers and to major increases in zinc oxide production. A second unit was later purchased for the reverberatory furnace to give silica and iron assays of the slag, and these were used to make adjustments in the feed composition to maintain the desired SiO2:Fe ratio in the slag. Since purchasing the units for the furnace, the oil consumption and copper content of the slag have dropped significantly. IntroductionSmelters have lagged far behind concentrators in process control by mean s of rapid product analysis. The on-stream X-ray analyzer was developed about seventeen years ago, and soon concentrators around the world were getting assays of the incoming ore, .concentrates and tailings every fifteen minutes, and using these to control reagent additions and other process variables. Almost always, the concentrate grade and recovery improved.In smelters, product streams are solids or molten materials, not the more easily handled slurries, and until seven years ago no inexpensive equipment was available to provide rapid analysis of this type of material. In approximately 1980, several companies developed instruments based on irradiating solid samples with low-intensity gamma rays from radio-isotope sources, and measuring the secondary X-rays emitted from different elements in the sample to provide an analysis of the elements desired.The smelter staff had a close look at what was needed and listed the following points as being critical:1. ability to provide Zn assays of a sample of slag within 15 minutes of taking it, in order to achieve optimum fuming times (zinc fuming , being a batch process, had the greatest potential benefit from rapid slag analysis);2. ability to give Cu and Fe assays on the slag, and on other smelter products, such as matte and converter slag;3. ability to give Si02 assays since the SiO2 content of the slag has a strong effect on fuming rate; and4. ability to stand up to an industrial atmosphere such as exists in the fuming plant."

Jan 1, 1987

By J. D. Corbett

The spatial coincidence of the seven anomalies is obvious, even though the self-potential is offset northward. Because the ratio, as an indicator of conductivity, is a relative estimate at best, concise interpretation is limited in almost every instance to the location of a conductor or conductor axis. When related to the initial phase of an exploration program, magnitudes and ratios similar to those obtained from any one of the methods described, would be sufficiently attractive to warrant further investigation. The compilation shown is an empirical comparison of actual field results and no emphasis has intentionally been placed on the relative merits of one method in respect to another. Too many additional factors, i.e., size, depth and conductivity of overburden, etc., that cannot unequivocally be answered, enter into such a comparison before a relative evaluation can be made.

Jan 1, 1961

By J. Kalynchuk, R. Poulin, R. Pakalnis, D. Peterson

"A market survey of all underground mines in Canada (Fig. 1) was completed to determine the ex1ent to which cable bolts are being used as ground support. One hundred and nine questionnaires were distributed with 65% of them being returned completed. As a result, the quantity, types and locations of cable bolt installations have been determined. In addition, the grout pumps used, time required and cost of installations have been addressed. The popularity of other support types used in underground mines is summarized.IntroductionRock reinforcement consists of installing support within the rock mass (internal) or within the excavation (external). Within the past twenty-five years several new types of ground support have been introduced within the mining industry. Cable bolts were first introduced to the Canadian mining industry in the 19605 (Gramoli, 1975).Cable bolts have gained increased acceptance as a method of ground support during the past decade. The cable bolt is comprised of one central wire surrounded by six slightly smaller outside wires and typically having an over-all diameter of 15.2 nun to 15.9 nun (0.6 in. to 0.625 in.). The cable wires are made from high-strength steel with an ultimate strength of 26 tonnes (58 000 Ibs) (Goris, 1990). Current cable bolting practice consists of cement grouting one or more steel cables within a drill hole in order to reinforce the surrounding rock mass. Cable bolts are a form of internal support and are generally used in open stoping and cut-and-fill mining methods (Fig. 2).They can be either tensioned (active support) or untensioned (passive support) and may be of any length, though for underground mining applications, they are generally less than 20 m (65.5 ft) and are untensioned. A major advantage compared to previously used ground support is that the cables are flexible and can be coiled to approximately 1 m (3.3 ft) diameter coils allowing relatively long support to be installed in areas with limited head room (1.8 m).With the advent of bulk mining methods which require comparatively large stopes, it has necessitated the use of relatively long support tendons to stabilize the large spans being created. As a result, the use of cable bolts for ground support in mines has increased significantly within the past decade."

Jan 1, 1995

By G. Binks

In 1997, the Zinifex Hobart Smelter ceased ocean disposal of jarosite and the flowsheet was converted to reject iron as paragoethite. This paper describes the evolution of the flowsheet since the changeover and considers future flowsheet developments. The major change to the flowsheet has been an increase in the silica content of the calcine resulting from treating increasing levels of Century concentrate. The high silica levels impacted on the paragoethite precipitation stage, causing a deterioration in the settling and filtration characteristics of the paragoethite and an increase in the contained zinc level. The implementation of a two stage neutral leach step has enabled the flowsheet to cope with the higher input silica levels. Future developments include an understanding of the form of the zinc in the paragoethite and options to lower the zinc level to improve the overall zinc recovery.

Jan 1, 2006

By B. W. Williams

The crack propagation behaviour of Zr-2.5Nb pressure tube material was studied through comparison of the measured behaviour with the predicted response from finite element analysis. Three-dimensional finite element simulations of compact tension specimens were performed using the crack tip opening angle as a fracture criterion to allow for crack propagation. To obtain reasonable agreement with the measured behaviour, it was important to capture both the anisotropic plastic deformation behaviour of the Zr-2.5Nb material through use of the Hill-48 yield criterion and damage due to void growth, nucleation, and coalescence through the use of a Gurson-based constitutive model in the simulations.

Jan 1, 2010

By M. L. F. Paullo, S. Cristian Mejia, D. Roehl

"Rock fracture simulation most often presents non-linear behaviour due to loss of material integrity and strain concentration in the fracture zone. These strains generate local instabilities that propagate to the global system of equilibrium equations, generating convergence problems of the numerical solution. Often, in such cases, analyses in the post-critical regime are unfeasible. To overcome the numerical difficulties associated with problems of stiffness loss in the post-critical regime control methods, also called continuation methods, are employed. Among them are the arc-length method, the energy control method and the indirect displacement control method. These methods are employed in conjunction with a Newton- Raphson scheme for the solution of non-linear systems of equations. However, depending on the system instability, convergence in not guaranteed even with very small increments. In the present work these control techniques are investigated in combination with cohesive elements to simulate rock fracture. The constitutive model employed with the cohesive elements represents stiffness degradation through a damage law, which leads to serious convergence difficulties as reported in the literature. Here the continuation methods mentioned are applied to a Mode I rock fracture problem and to hydraulic fracture simulations. The effectiveness of the different continuation methods is compared.INTRODUCTIONThe process of rock fracture induced by the fluid pressure is called hydraulic fracturing. The propagation of a hydraulic fracture is a complex process, which is basically defined by the mechanical deformation of the rock, the fluid flow within the fracture and the fracture propagation itself (Mokryakov, 2011). In the works of Bendezu et al. (2013), Chen (2012) and Carrier et al. (2012), vertical hydraulic fracture propagation is modeled by cohesive elements with traction-separation law. The softening behavior of rock in post-critical regime is demonstrated by experimental testing and is characterized mainly by high strains and low stresses (Crowder and Bawden, 2004). This nonlinear behaviour can arise due to material nonlinearity, such as micro-cracking and damage, leading to softening behaviour (Chandrakant, S.D., 2012). The cohesive fracture model considers in its formulation the softening behaviour that most rocks present in post-critical regime with propagation criteria."

Jan 1, 2015

By John Clancy, Andrew J. Freyman

"Trends in world coal markets indicate that the next twenty years could be a period of intensive development for British Columbia's coal resource. This paper examines demand projections for metallurgical, thermal and chemical feedstock coals, with particular reference to domestic and Pacific Rim markets. Supply possibilities, from the point of view of British Columbia's competitive position, are explored, with emphasis on the interaction of such factors as capital, labour, port and transportation requirements.The paper concludes with an examination of British Columbia's strategies in light of the foregoing, and comments on the government's role in ensuring that development of the coal resource be attained in a manner consistent with over-all provincial goals and objectives.IntroductionFor the purposes of this paper the Pacific Rim is defined as including, in addition to Canada, the following: Japan, Korea, the People 's Republic of China, Hong Kong, Taiwan, the countries of the Indonesian Archipelago, Australia, New Zealand and the Pacific-bordering countries of South America and Mexico. The United States has been excluded in this definition in order to better illustrate the economic growth potential for British Columbia coal in the Pacific Rim economies.In the past decade, the Pacific Rim economies have grown faster than most other economies in the rest of the world; economic growth rates of 10 per cent were common in the region prior to the 1974 slowdown and the average rate of economic expansion in the mid-1970s has exceeded 6 per cent. Rapid expansion of international trade in the region has been a major stimulus in this process. By 1979, Pacific Rim two-way trade has reached an estimated $550 billion-about 20 per cent of world trade."

Jan 1, 1982

By B. R. MacKay

Introduction Of all Canada's mineral resources, its coal deposits have probably received the most continued attention by the Geological Survey since its inception ninety years ago. A casual review of the many geological maps of coal areas by the Geological Survey will show how geological and topographical detail on the maps has gradually increased to meet the ever urgent demands of the mining industry. In the early stages of exploration, the mapping done, especially in the coalfields of the Rocky mountains, was largely of a reconnaissance nature. On these maps the topographical relief, where shown, is indicated by form lines or by hachures, the boundaries of the coal-bearing formations are only approximately defined, and the geological structure of the coal seams is illustrated by one or more generalized cross-sections. Once mining development on a coal area began, there arose a demand for more detailed maps. To meet this need, topographical and geological maps on a scale of one inch to a mile were made, in which the ?topographical relief is shown by contour lines having generally an interval of 100 or 200feet. On the geological maps, the boundaries of the formations are accurately delineated, and the geological structure of the area is illustrated by one or more structure sections drawn across the area, which show the position and attitude of fault lines, the crests and troughs of folds, and the attitude of the various formations (See maps of Costigan Coal Field, 1905, and Cascade Coal Basin, 1907, by D. B. Dowling).

Jan 1, 1932

By T. ?kre, O. M. Dotterud, S. Haarberg, J. Thonstad, G. M. Haarberg

An electrowinning pilot plant has been constructed at Falconbridge Nikkelverk A/S, Kristiansand, Norway. The equipment consists of a mixing tank where the electrolyte composition and temperature are controlled, an electrowinning tank equipped with five cathodes and six anodes of commercial size and design and a dechlorination facility. Electrowinning experiments were carried out in this pilot plant using acid cobalt chloride solution from the cobalt tankhouse. Key parameters were varied to obtain an improved understanding of the cobalt electrowinning process, focusing on the detrimental deposition of cobalt oxide on dimensionally stable anodes. The extent of anode scaling was found to be dependent on the electrowinning conditions. Low pH, temperature and cobalt concentration resulted in less scale being formed, however at the expense of cobalt current efficiency and cell voltage, adversely affecting electrowinning production capacity and energy consumption. When operating at high acidity, pH in the anolyte was higher than in the catholyte, which is believed to be due to H+ ions taking part in the current transport across the diaphragm, migrating out of the bags surrounding each anode.

Jan 1, 2005

By A. Hussain

PAPER NOT SUBMITTED FOR PUBLICATION

Jan 1, 1987

By Matej Petružálek, Tomáš Svitek, Tomáš Lokajícek

"Migmatite from the Skalka region (Czech Republic) was chosen as the experimental rock material. It has macroscopically visible plane parallel structure (foliation). The foliation was caused mainly by biotite grains arrangement. The cylindrical samples of migmatite with subhorizontal, subvertical and oblique foliation were uniaxially loaded up to the failure. Network of 8 broad band sensors was employed for acoustic emission monitoring and ultrasonic sounding. A grid search method with anisotropic velocity model was used for AE hypocenters localization. The source types of successfully localized events were determined from the average first arrival amplitude. Structural anisotropy of tested rock material caused the anisotropy of its mechanical properties (peak strength, Young’s modulus) as well as a different way of fracturing process in dependence on the angle between axial stress and foliation plane. The combination of splitting, shearing and sliding was found to control the fracturing of sample with subhorizontal foliation. The shearing and sliding was dominant in fracturing of samples with oblique foliation. With greater dip of foliation, the role of sliding increased at the expense of shearing. Due to the favorably oriented system of microcracks already present, the shearing and splitting was at the same level during fracturing of the sample with subvertical foliation before nucleation began.INTRODUCTIONThe process of failure of low porosity rocks depends on their mechanical properties and actual stress and temperature condition. At the low pressure and low temperature, the most common way is brittle failure, which is a progressive process requiring the initiation, growth and coalescence of cracks (Lockner, 1993). Stress strain behavior of low porosity crystalline rocks, during the laboratory compression experiments, is divided into four characteristic stages: crack closure, elastic region, stable crack growth and unstable crack growth which leads to the brittle failure, Brace et al. (1966) , Bieniawski (1967), Lajtai (1974), Cai et al. (2004), Nicksiar and Martin, 2012 and 2013.The fracturing process of stressed rock begins with the crack initiation (sci), which for low porosity rocks occurs approximately at 40-50% of peak strength (sp) (Cai et al., 2004; Nicksiar and Martin, 2013). After the sci, the dilatancy begins and stable crack growth follows up to the crack damage threshold (scd), which is approximately at 80% of sp (Cai et al., 2004). After crossing the crack damage level, there is an unstable crack growth accompanied with nucleation of fault plane (sn) at 97-100% of sp. (Rao et al., 2011). The stress drop accompanied with formation of macro scale shear failure plane follows after peak stress is crossed."

Jan 1, 2015

By M. Maccagni, J. Nielsen

"The recovery of lead from battery paste has been investigated for a long time and with the use of many different electrolytes. A number of processes have been presented, but none of them reached even the demonstration step. Engitec has developed a new concept for the battery paste electrowinning using a chloride electrolyte fed through a very innovative flow cell. The process has passed the lab and the demo scale and it is ready to be introduced on the market. In this paper, a description of the process will be provided.INTRODUCTIONThe need for improved energy storage systems as well as the introduction of commercially viable electric vehicles is providing a strong compulsion toward the research of new batteries. The lead battery is playing an important role because it is inexpensive, reliable and it is the most recycled material. This last aspect marks the lead acid battery as quite peculiar making it both the primary lead based product and the main raw material for lead production.In the last years the legislative pressure has become very strong and has forced the lead production to react through the introduction of important process innovations and market changes. The dispersive products, such as additives for paints and for fuel as well as bullets, have been practically banned all over the world while the battery market continues to grow. The lead acid battery remains the cheapest and most integrated energy storage system available and is improving to meet the new technical challenges. This is testified by the news coming from the development of new and more efficient lead acid batteries which are confirming their leading position.Unfortunately, the image of lead is very negative in the public opinion and some important actions are required to try changing this sentiment. Among them, better information to the market and users and the introduction of new and cleaner technologies in the production of lead can help."

Jan 1, 2016

By G. J. Kipouros, W. Judge

"The prevalent metal extraction processes for most reactive metals are fused salt electrolysis and metallothermic reduction. The feed material for both of these processes is the anhydrous chloride of the metal under consideration. Dehydration of the feed material is then a critical step in the production of most reactive metals and requires rigorous thermodynamic analysis. Thermodynamic data for most of the reactive metal chloride hydrates have not been measured. Improper dehydration of the metal chloride may lead to a prohibitive amount of hydroxychloride, oxychloride, and oxide. To prevent hydrolysis a certain pressure of hydrogen chloride is required. An estimation and prediction model is presented for the vapour pressures of reactive metal chloride hydrates in an attempt to deduce the conditions necessary for dehydration to proceed without hydrolysis. Thermodynamic data including heat capacities, standard entropies, and standard enthalpies are estimated/predicted for all conceivable intermediate hydrate compounds. Estimations are based on published data as well as trends proven in similar systems. The thermodynamic estimations and predictions are presented for the magnesium, neodymium, praseodymium, and dysprosium chloride hydrates. INTRODUCTIONThe high reactivity of metals such as the alkalis, alkaline earths, and lanthanides prevents their reduction by traditional pyro- or hydrometallurgy. In their elemental form, these metals are raw materials in the manufacture of intermediate products such as alloys and electronic components. Currently the only two viable metal production methods are fused salt electrolysis and metallothermic reduction. Various feed materials have been proposed for these processes. Using the chloride of the metal as a feed material offers advantages in separation and purity of the final product, as well as lower energy input. Chlorides, however, are hygroscopic and must be dehydrated before use. Improper dehydration will lead to a prohibitive amount of oxychloride which will lower efficiencies and contaminate the final product.Optimum conditions for proper dehydration of MgCl2•6H2O to produce pure MgCl2 without hydrolysis have been calculated from existent thermodynamic data and have been reported previously (Kipouros, 1987; 2001). Calculations were also performed for the case of production of pure anhydrous NdCl3 from NdCl3•6H2O (Roy, 1997)] and the mechanism of dehydration was elucidated. Some thermodynamic studies on the dehydration of chlorides of the rare earths have also been conducted (Sundstrom, 1997; Hong, 1997; Aschcroft, 1968; Haeseler, 1965; Ukraintseya, 1989)."

Jan 1, 2012

By G. V. Sirianni, G. E. Viens, R. A. Campbell, G. N. Banks, R. L. Sachdeva

"A combined shaft-electric furnace for the smelting of ores and the melting of metallized iron pellets is being developed. The materials are preheated, and in some cases pre-reduced, in the shaft before being transferred to the electric furnace, where melting or smelting is completed. It has been demonstrated that this combination of equipment will enable much of the relatively expensive electrical energy to be replaced by cheaper energy in the form of oil or natural gas, and preliminary experiments indicate that the total energy requirements for a melting or smelting operation are significantly reduced. Projections based on results obtained from the preliminary experiments indicate that further improvements will be possible when certain modifications to the equipment are completed."

Jan 1, 1968