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By H. Arima, Y. Kudo

In general, the iron content of zinc leach residue produced by sulphuric acid leaching from calcine is disposed as jarosite or goethite into a tailing dam. More recently, these iron residues have been treated pyrometallurgically to avoid waste disposal. The Iijima refinery selected a different zinc leach residue treatment process for iron control when it was established in 1971. The Iijima refinery is the only plant in the world that has processed a zinc leach residue by the combination of SO2 pressure leaching and O2 pressure hematite precipitation. The process enhances zinc recovery and recovers gold, silver, copper, lead and rare metals in saleable by-products. This paper focuses on the two stages of autoclave application in the zinc leach residue treatment process. The detailed flowsheet and recent advancements to improve the quality of by-products are discussed.

Jan 1, 2004

Viscosity measurements were carried out on slags in the CaO-Cu2O-CuO-MgO-SiO2systemcontaining ~ 63 wt% SiO2in air. The experimental work was carried out over a range of temperatures where the slags were completely liquid. Initial measurements were on a binary CaO-SiO2slag to which incremental additions of CuxO-MgO-SiO2slag with the same silica mole fraction were made. The viscosity-temperature relationship was measured for slags with‘Cu2O’contents of 0.02, 0.19, 0.38, 0.79, 1.69, 2.47, 3.01, 5.31 and 10.0 wt%. The proportions of Cu+and Cu2+in the slags were determined. The oxidation state of Cushifted from predominantly Cu+to Cu2+, with the Cu+/Cu2+ratio of approximately 0.3 for slag with a Cu content above 2 wt%. This is equivalent to Cu1.13O. The trends observed for changes of Cu2+/Cu+redox ratio with slag chemistry were consistent with the literature. Decreasing the CaO content by substituting copper oxide resulted in a decrease in the Cu+/Cu2+redox ratio. The change in ratio corresponded to a shift of the value of x in CuxO from an initial value of 1.8 to 1.1,when the slags contained 10% ‘Cu2O’. In this study, the SiO2content of the slags varied between 64 and 60 wt% as the Cu content increased. The viscosity of the slag containing 10 wt% CuxO was nearly 4.5 times lower than the binary CaO-SiO2slag. As the silica mole fraction (xSiO2) actually stayed constant (0.61±0.009),the results show that CuxO acted as a network breaker. Comparison with other ternary slags with similar silica mole fractions suggest that that addition of CuxO to silicate slags has a stronger effect on lowering the viscosity than FeO or MnO has on a molar basis. Keywords: viscosity, copper, silicate, slags

Jan 1, 2004

By Frederick C. Rhyner

Drilled shafts have become an economical foundation choice for bridges in the northeast United States, especially when they can be constructed over water without the use of cofferdams. For the Boscawen-Canterbury Bridge over the Merrimack River in New Hampshire, an unusual design was used to avoid the use of cofferdams and avoid the need for pier caps at the waterline. This design used a pair of integral drilled shaft ? columns to form a bent type of substructure for support. Drilled shafts were 8-foot diameter, about 90 feet deep, with 16-foot long rock sockets. These are integrally constructed with 6-foot diameter reinforced concrete columns extending 37 feet from the waterline to the superstructure. Design load cases focused on lateral loads from ice flows, stream flows, wind and seismic events. Alternative analyses using different methods were made to check the design results. This paper discusses the subsurface conditions, design of the drilled shafts and columns, rebar and joint detailing issues, and construction of the drilled shafts.

Jan 1, 2004

By Z. F. Zhou, X. Y. Zhou, V. G. Papangelakis, Z. D. Jankovic, S. M. Ulyanov, S. N. Lvov

Recently developed flow-through electrochemical techniques (1,2) were employed for measuring pH in high concentration aqueous solutions and geothermal brines. The pH values of (1) 5.0 mol kg-1 NaCl + x mol kg-1 HCl, (2) 3.0 mol kg-1 of NaCl + 0.5 mol kg -1 of KCl + 1.0 mol kg-1 of CaCl2 + x mol kg-1 HCl (x < 0.1 mol kg-1), and (3) mixtures of Al2(SO4)3-H2SO4-H2O, MgSO4-H2SO4-H2O, and NiSO4-H2SO4-H2O solutions have been measured at temperatures from 100 to 280°C. The obtained experimental data and their thermodynamic analysis demonstrated that the electrochemical system can be used for on-line pH monitoring of high concentration aqueous solutions with an accuracy of ±0.1-0.3 pH units over a wide range of temperatures. Greater deviation exists in real laterite leach solution measurements due to in situ precipitation of Na-alunite. The system is excellent for research and process development work. Further work is needed to ensure robust operation under pressure leach conditions of laterites.

Jan 1, 2004

By P. J. Brereton-Stiles, M. S. Rennie, N. Singh

Ferroalloy producers are large-scale users of electrical energy, which in many countries is in short supply and increasingly expensive. Preheating and/or pre-reduction using natural gas, recycled furnace gas or coal fines have lowered the specific use of electricity, but the high energy concentration necessary for most reduction processes can be achieved only by the use of high electric currents. Most countries have insufficient electricity to supply the demands of industry and the domestic consumer, particularly during certain periods of the day and certain times of the year. The generation and distribution of electricity is a large-scale expensive business, which is financed and managed directly or indirectly by government bodies in most countries. Both economic and political imperatives determine how much electrical energy is made available to whom and at what price. In South Africa demand is set to outstrip supply within the next few years, and the local supplier Eskom has moved from a traditional demand tariff pricing structure to a time-of-use tariff pricing so as to limit peak demand usage. This will mean a substantial increase in electricity cost to those users unable or unwilling to reduce consumption during peak periods. The optimal use of the available electrical energy depends both on the process, the furnace size, the configuration and infrastructure of each plant and its cost structure. As the cost and availability of electricity is set to change dynamically, the management of the situation becomes a real time control and optimisation problem. This paper discusses some the process and operational constraints associated with low- or no-load conditions and how to manage the situation. Electrode management will be one of the key issues.

Jan 1, 2004

By J. Robison, H. Pieterse, C. C. Smith, M. Luque, S. Chipman

Phase change during pressure let down releases significant amounts of energy that must be controlled to avoid undo wear and tear on equipment. Hydrometallurgical slurries require flow control equipment (valves and tanks) made of expensive materials to withstand the abrasive, and often corrosive nature of the slurry. Presented is a model of the nozzle of a let-down choke which is designed to control the flow pattern that exits the choke (valve) as it enters the receiving tank. This model can be used to design chokes which allow for the dissipation of the energy released during pressure let down by spreading the stream over a significant portion of the slurry pool in the receiving tank to minimize wear on equipment near the nozzle exit and the bottom of the slurry tank. An example uses the model to choose the nozzle expansion (area) ratio to select the outlet slurry velocity and slurry expansion angle.

Jan 1, 2004

By J. L. van Niekerk

The proposed Gautrain Rapid Rail Link (GRRL) will require approximately 15 km of double or twin high-speed rail track tunnels located for the greater part beneath the northern suburbs of Johannesburg, including Houghton, Rosebank and Sandton. During the Environmental Impact Assessment (EIA) it became clear that potential surface vibration above and in the vicinity of the tunnels was a matter of serious concern to the residents of the affected properties and that the impact required assessment. The general method proposed is based on a US Department of Transportation, 1998, publication in which abase vibration curve derived for typical high-speed passenger trains is adjusted for the topological, geological and other features to predict the surface vibration and the associated ground-borne noise. The predictions indicate that some isolated areas might be impacted but that the impact will likely be limited, and it is possible to mitigate the impact using suitable track construction methods and track support systems.

Jan 1, 2004

By Steve Dillingham

Whenever misfired holes or portions of misfired holes remain after a blast is fired, a hazardous situation exists until the unfired explosive materials have been disposed of properly. Yet, there are so many factors that can contribute to misfires that it is impossible to give blanket instructions on how to handle them. To complicate matters, misfires today are rare due to reliable blasting products. As such, it isn’t very surprising that many blasters have never had to deal with a misf i re condition. While the likelihood of a misfire occurrence is minimal, you should always be pre p a red to handle a misfire should you be involved in such an event. To begin, every blaster and blasting org a n i z a t i o n should develop a misfire policy which contains the company’s safe operating pro c e d u res, emergency contact list, as well as any regulatory compliance re q u i re m e n t s . Tailgate and/or company-wide safety meetings should communicate the company’s contingent misfire pro c ed u res and any special site-specific precautions BEFORE the start of any project.

Jan 1, 2004

By Hämäläinen M., O. Hyvärinen, E. Jääskeläinen

HydroCopperTM is a new hydrometallurgical process for the treatment of copper sulphide concentrates, which has been developed by Outokumpu. The process includes chloride leaching of copper concentrate, solution purification and precipitation of copper(I) oxide, an intermediate product, which is reduced and cast into copper products. The reduction can be carried out by pyrometallurgical methods or hydrometallurgically in an autoclave. This paper discusses the thermodynamic and kinetic aspects of the hydrogen reduction of copper(I) oxide in an autoclave. The results of the laboratory tests are presented and discussed. Finally, the autoclave method is compared with other options.

Jan 1, 2004

By A. C. du Preez

The separation of nickel and cobalt from calcium, magnesium and manganese by solvent extraction using synergistic mixtures of carboxylic acids was studied. Addition of certain viable synergists to commercially available tertiary branched carboxylic acids, such as Versatic 10 (Shell) or Neodecanoic acid (Exxon), produced large synergistic shifts (?pH50) in the pH50values for nickel, and small antagonistic shifts (negative ?pH50values) in the extraction of calcium. Under the initial test conditions used (0.50 M each of Neodecanoic acid and the Mintek synergist, in xylene) a large separation (pH50Ca? pH50Ni= 3.09 pH units) between nickel and calcium in their extraction from 1.00 M sodium nitrate solutions was obtained, compared with only 1.11 pH units in the absence of the synergist. The selectivity series for the extraction of divalent base metals from 0.333 M sodium sulphate solutions by 0.50 M Neodecanoic acid and 0.25 M of the Mintek synergist in C12-C13aliphatic diluent was found to lie in the order (with pH50values in parentheses): Cu(3.42) > Ni (5.08) > Zn (5.58) > Co (5.73) > Mn (6.62) > Ca (7.48) >Mg (8.25). In batch counter current experiments, a simulated leach liquor containing (in gL-1): Ni 5, Mg 5, Mn 2, Co 0.5, Ca 0.5, Cu 0.1and Zn 0.1 was contacted with the mixed extractant in three stages at unit phase ratio and an equilibrium pH of 5.9. The recovery of nickel was 99.9 per cent and that of cobalt was 84.7 per cent, whilst the co-extractions of manganese, calcium and magnesium were 2.7,1.5 and 0.04 per cent, respectively. The recovery of cobalt can be enhanced by employing a slightly higher pH, although this will also increase the extraction of manganese, calcium and magnesium somewhat. Nearly quantitative stripping (99 per cent) of nickel from the loaded organic phase was achieved in a single contact at an organic-to-aqueous phase ratio of 4 using a simulated spent electrolyte containing 39 gL-1sulphuric acid and 33 gL-1nickel,thereby producing an ?advance electrolyte? containing 57 gL-1nickelat pH 3.5. Loading of acid into the organic phase was very slight, amounting to only 0.002 M H+in contact with the above-mentioned spent electrolyte. Keywords: solvent extraction; synergism; nickel; calcium; carboxylic acids.

Jan 1, 2004

By V. Tathavadkar

Worldwide TiO2is extracted from natural ilmenite, rutile, and anatase minerals via the sulphateand chloride processes. The sulphate process generates large volumes of less toxic wastes, whereas the chloride process, including the ilmenite-chloride process of DuPont, yields much lower volume of wastes, which are highly toxic and hazardous. The treatment and disposal of such hazardous chloride wastes is both expensive and difficult in terms of long-term monitoring. Besides the waste management and disposal, there is also a shortage of high-grade titanium dioxide minerals in nature, which consequently yields much larger tonnages of sulphate and chloride wastes. In the present investigation we report the results of an alternative titaniferous mineral beneficiation process based on soda ash roasting of minerals. Compared to the conventional processes for beneficiation of TiO2- ores, the alkali roasting of titaniferous offers several advantages including the zero process wastes. In the soda ash roasting process, the mineral is mixed with sodium carbonate and heated above 1023 K in air. The oxidative roasting of ores yields several complex alkali compounds, some of which produce a liquid mixture above 1123 K. In this paper, we have attempted to characterize the composition and physical chemistry of alkali-rich liquid phase. The phase equilibria in the Ti-(M:Fe)-Na-O system are evaluated and compared with the phases formed as a result of roasting reaction. The experimental results revealed that the composition of complex alkali liquid at the reaction interface plays an important role in determining the transport of O2-ions and decomposition of ilmenite. The roles of the crystal structure of mineral phases and their energetics are also emphasized in controlling their decomposition during alkali roasting. The presence of molten alkali in controlling the partitioning of water-soluble alkali salts and insoluble sodium titanate is also explained. Keywords: ilmenite, anatase, alkali roasting, phase equilibria.

Jan 1, 2004

By M. Görnerup, A. Kapilashrami, Seetharaman. S., A. K. Lahiri

Simultaneous reduction and foaming of chromium-rich slag have been studied in a laboratory furnace equipped with X-ray image analysis. Reduction of the metal oxides by graphite generated CO, which caused the melt to foam. The slag composition continuously changed due to reactions and dissolution of lining. Gas generation rate, foam height, and gas bubble size were studied and correlated to slag composition. Viscosity increased significantly during the experiments due to a change in slag composition. Bubble sizes varied little during the progress of reactions but differed considerably for different slags. Bubble sizes were largest for V2O5 containing slag, which is contrary to the general understanding that the presence of strong surface active agents reduces the bubble size. The foaming index did not follow expected trends for bubble size and viscosity, suggesting that foaming index is not a suitable parameter for discussion of foams under dynamic conditions. Keywords: slag, foaming, dynamic conditions

Jan 1, 2004

By V. Riihimäki, M. Luotamo

The Unit of Toxicological Risk Assessment of the Finnish Institute of Occupational Health (FIOH) is conducting a &apos;Health Risk Assessment for Metallic Chromium and Trivalent Chromium&apos; under the sponsorship of the International Chromium Development Association (ICDA) and the International Stainless Steel Forum (ISSF). This risk assessment will be conducted in accordance with the current European Union legislation in force (Council Regulation 793/93/EEC, Commission Regulation 1488/94/EEC, Dir. 67/548/EEC), but also to meet the regulatory obligations as set out in the European Commission REACH legislation proposal (Consultation Document, the Registration, Evaluation, Authorisation and Restrictions of CHemicals). Further aims include outlining the criteria for the setting of occupational exposure limits for metallic chromium and trivalent chromium compounds. Human Health Risk Assessment according to the current legislation shall entail hazard identification of the toxic end points (acute toxicity, irritation/corrosivity, sensitisation, repeated dose toxicity, mutagenicity, carcinogenicity, reproductive toxicity) including, as appropriate, dose (concentration) - response assessment, and derivation of the N(L)OAELs (No (Lowest) Observed Adverse Effect Level) and/or DNELs (Derived No Effect Level). Exposure assessments for workers, consumers and humans exposed via the environment take into account all the known intended uses. Risk characterisation will compare the typical and/or reasonable worst case exposure estimates to the N(L)OAELs or DNELs to determine Margins of Safety (MOS) for all human populations by each exposure scenario and type of effect, followed by conclusions about the presence or absence of risk. Although all of the key elements of existing legislation remain in REACH, the principal change is that, the burden of proof will be transferred from the member state authorities to industry. The new proposed format of Chemical Safety Report (CSR) will include Risk Management Measures (RMM) as an essential part of the report in addition to the risk assessment. The RMM plays a role in the evaluation of further testing needs and advocating reasons for possible waiwer of requirements. The research programme started in March 2002 and will be completed within the time frame of two years.

Jan 1, 2004

By R. Burger, M. Masukawa

Cato Ridge Alloys (CRA) is a joint venture company between Assmang of South Africa, Mizushima Ferro Alloy Company (MZK) and Sumitomo Corporation from Japan. Negotiations for the formation of the company started in 1992 with the joint venture agreement signed on the 19th September 1996. MZK was to supply the technical know how for the production of Medium and Low Carbon FeMn while Assmang was to manage the day to day activities of the company. Sumitomo Corporation was to act as facilitator between Assmang and MZK and, together with Ore and Metal are responsible for the marketing of the refined products. The conceptual design of the plant started in December 1996 and the first charge of molten high carbon ferromanganese metal was charged on the 19th January 1998. Problems experienced during the initial startup period were addressed resulting in substantial operational improvements. A build-up in the stock of fine metal was addressed through the development of a process to remelt the fine metal, the development of a market for fine metal and the upgrading of the crushing and screening plant to reduce the generation of fine metal. The mass yield from High Carbon Ferromanganese to Refined Ferromanganese was increased through the implementation of statistical process control, changes to the blowing patterns and the development of a sampling device for taking samples during the process. Converter refractory consumption was reduced. This was achieved on the converter by improving the cooling of the converters with the installation of cooling fans and cooling fins. The heating schedule of the converters was changed for improved refractory life. Production schedules were modified to allow cooling of the refractory between low carbon erromanganese charges. Additional changes made to improve operations were: ? Changing from mehanite casting trays to metal fines beds. ? Installation of sonic horns in the baghouse to prevent the bridging of dust. ? Improved welding on the lance tips.

Jan 1, 2004

Paper written on project work carried out in partial fulfilment of B. Eng (Metallurgical Engineering) degree Electrowinning is an attractive method to recover gold from the relatively concentrated aurodicyanide solutions produced by the elution of loaded carbon, provided that the plated gold can be easily removed using high pressure water sprays. In practice, difficulty with the removal of the gold is occasionally experienced and has been correlated with the presence of high concentrations of copper in the eluate. In this work, the influence of copper on the electro-plating of gold was further investigated using a laboratory electrowinning cell with a rotating disc cathode, polarization, and adhesion tests. It was found that the reduction of copper will compete with gold electrowinning at high copper tenors and that the adhesion of the precipitated gold is also increased under these conditions. Keywords: reduction, adhesion, morphology, current efficiency, limiting current.

Jan 1, 2004

By J. Alexis, G. Ye, E. Burström

Over the past twenty years the 3 MW DC arc furnace at MEFOS has been frequently used for development of new processes. These processes include recovery of valuable metals from slag, sludge and dust from steel and other metallurgical industry, treatment of ashes from power plant and incinerators, smelting reduction of minerals and zinc recovery from EAF dust. The process characteristics of the DC arc furnace operation in terms of: ? selective reduction, ? total reduction, ? process stability and flexibility, ? dust carry-over, ? thermodynamic conditions provided in the hot spot area, ? precision in composing slag products These are analysed and described in this paper based on technical results from selected test campaigns over the years and thermodynamic considerations. The electromagnetic properties of DC arcs beneath the electrode have been studied by CFD simulation. The calculated result enables us to understand some interesting technical phenomena observed. The heat balance has also been considered based on data obtained from test campaigns and heat balance calculation.

Jan 1, 2004

By S. Sridhar, R. E. Aune, M. Hayashi

Thermophysical properties of silicate melts are strongly structure dependent. It is well known that the viscosities of slags increase with increasing the degree of polymerization of silicate anions. Even the thermodynamic properties of slags are dependent on the types of species and the population of the same in the melt. Thus, a link between the thermophysical and thermochemical properties of silicate melts is logically expected. The present paper elucidates the salient features of Darken?s excess stability approach to the Gibbs energies of solutions as applied to the viscosities of silicate melts. It is demonstrated, that the second derivatives of the viscosities of binary silicate melts with respect to composition indicate a maxima corresponding to the existence of stable compounds in these systems. The concept was successfully applied to the following systems: Al2O3-SiO2, CaO-SiO2, FeO-SiO2, MgO-SiO2and MnO-SiO2. In all the cases, the second derivative plots of viscosities with respect to composition showed peaks corresponding to the metasilicates. The second derivatives of the activation energies of viscous flow with respect to temperature has earlier been shown to reflect the formation of associates/embryos in the homogeneous silicate melts, indicating the readiness of the melt to separate a solid phase. Thermodynamic coupling of thermal diffusivities in the case of the system CaO-Al2O3-SiO2from the laser-flash measurements of these slags as a function of temperature are examined as part of the present study. Densities are estimated from integral molar enthalpies in the case of silicate systems and the results are presented. Keywords: silicate melts, viscosity; activation energy, thermal diffusivity; density

Jan 1, 2004

By T. Vandergrift, J. Sturgill, W. Gerhard, J. Carrick

As surface minable coal is depleted, many operators look to high-wall mining to extend reserve life. Recent advances in highwall mining equipment have greatly improved productivity, clean coal recovery, and attainable penetration beneath the highwall. Somewhat lagging have been systematic design approaches for ensuring web pillar and overall highwall stability. This paper presents an overview of the design, planning, and field performance of a multiple-seam highwall mining application in southwest Wyoming. The safety and efficiency obtained to date is attributable to the careful geotechnical and operational planning described herein. Field confirmation of performance and suggestions for improvement are also discussed.

Jan 1, 2004

By Robert Hopler

DESCENT INTO A COAL MINE From “The Playbook of Metals, including Personal Narratives of Visits to Coal, Lead, Copper, and Tin Mines,” by John Henry Pepper. Published by Routledge, Wa rne, and Routledge, London, 1862 ENGINEERING NEWS New Yor k January 22, 1903 THE BEGINNING OF THE END OF DYNAMITE. In another part of this issue we have reported the results of some test results made upon one of the safety powders. It will pay every c o n t r a c t o r, miner, or user of explosives in any form to carefully re a d the article re f e r red to. Dynamite has done a gre a t work in the service of man, as did black powder before it; but its i n h e rent dangers are admitted by all and are proved by the long list of deaths and injuries, and destruction to property which annually occur through its use. Why should we continue to use an explosive that annually kills and maims hund reds of men, when others are available which are equally powerful, no more expensive and far less liable to accidental discharg e ? Dynamite when first manufacture d is pure and comparatively safe; but most unfortunately it does not always stay pure; it “rots,” and then it is exceedingly dangerous. More than this, the explosive part of dynamite is a liquid, nitro - g l y c e rine, which is absorbed or soaked up by sawdust, wood pulp or the like. So long as this liquid nitro - glycerine remains pure and remains “soaked up,” or absorbed t h e re is little danger. It has been found, however, that the nitro - g l y cerine leaks under certain conditions. During thawing it fre q u e n t l y leaks out of the stick, or if it becomes wet the water causes the n i t ro-glycerine to leak out. In either case free liquid nitro - g l y c e r i n e escapes, and in that free state it may be exploded by any very slight shock. Nor is this all, if a stick of frozen dynamite be bro k e n a c ross it has been found by tests that the frozen nitro - g l y c e r i n e w h e re thus broken is very sensitive to shocks afterward .

Jan 1, 2004

This paper describes results of an investigation of fracture during tube expansion of 5052 and 5754 aluminum seam-welded tubes to optimize the forming of aluminum tubes during hydroforming. The tubes were produced in laboratory by press forming of tubular blanks and pilot-scale high frequency induction welding. The effect of property mismatch between the weld and base metal has been investigated. The material work-hardening was obtained by roll forming of sheet blanks in the 0-temper and H32 temper condition. The results showed that a significant work-hardening can be present in aluminum tube without causing weld fracture during tube expansion. The work-hardening increases the yield-strength mismatch between base metal and weld. Annealing reduces the hardness of base metal leading to more uniform deformation during tube expansion. As a result the occurrence of weld fracture is reduced. The study showed significant deformation of the welds during tube expansion. Weld thinning can be as large as parent-material thinning before fracture. To avoid fracture at the weld joint, good formability and high yield strength of the weld is needed. FEM simulation showed that minimizing the width of the weld joint can reduce thinning of the weld.

Jan 1, 2004