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By H. Hearnden

Whereas in the past, ladles were simply a means of transferring molten products from furnace tapholes to points of discharge be they casting pans or waste dumps, the ladle is now becoming a more integral and versatile piece of equipment in the pyrometallurgical plant. The drive behind this development is the need for continuous improvement in performance where better, faster and cheaper means remaining competitive in the global market. This paper will explore the technologies available for the rendering of a costly and otherwise cumbersome piece of pyrometallurgical equipment more efficient and versatile in adding value to the final product. Essentially it all revolves around heat and more importantly the loss of it when tapping. The common practice is to move the molten product to its point of discharge quickly with the minimum of interruption to prevent skulling and hence the cost associated with clearing it. The advances in Oxy-fuel burners, AC or DC ladle furnaces, converters, gas purging and high velocity, bath injection systems has increased the versatility of processes and enhanced the potential for adding value to intermediate products through down stream practices such as granulation and atomisation.

Jan 1, 2004

By Gordon King

The site of the First Quality Tissue plant is located on a previous paper production facility in Lock Haven, Pennsylvania. The new development, which included the construction of a tissue machine building, baled building, converting building, various storage buildings and an electrical switchgear building, required the use of deep foundation systems to transfer loads below compressible fill and alluvial soils. Loading details provided by Jacobs Engineering, the project structural engineer, detailed braced steel frame buildings with typical column loads ranging from 75 to 150 kips and slab live loads of 250 to 300 psf. As an exception to this, however, the tissue machine and stock preparation building, which had a roof height ranging up to 85 feet, had column loads ranging up to 800 kips in addition to high dynamic loads. The First Tissue plant is located in a river valley in the hills of Western Pennsylvania. To evaluate the proposed site conditions and to formulate recommendations for the structure foundations, a geotechnical study was performed by the owner. Approximately 30 borings were advanced to bedrock, with wire-line coring performed in the tissue machine building. The borings disclosed a soil profile comprising of the following:

Jan 1, 2004

The quantity, quality and detail of project information increases as project development moves from initial scoping level studies, to pre-feasibility and option studies, then definitive feasibility study and basic engineering stages. Data accumulates from metallurgical and vendor testing from various ore types and composites carried out to assess physical characteristics and processing responses of the ore. Over-simplification or assumptions about the orebody for flow sheet development can result in using æaverageÆ information for design. Use of averages of data can have adverse implications on sizing of plant and equipment and consequently on definitive study cost estimates and detailed engineering. In practice, the treatment plant workforce is faced with managing a non-homogeneous or non-average orebody in a variable operating environment that is not always predictable. This paper presents views on how to use the data generated from testwork in project development and for process and plant design. Examples of process design risk or operating risk are presented. Although this topic is applicable to the broad range of process design decision making in the minerals industry, this discussion references comminution, flotation and extraction processes for gold and base metal ores.

Jan 1, 2004

By F. W. Brackebusch, R. O. Sack

"A method for determining the fineness of Au in electrum from the composition of fahlore coexisting with pyrite and chalcopyrite is presented. This method is based on previously published experimental brackets and activitycomposition models for electrum and fahlore, and it is potentially useful for defining temperatures of hydrothermal mineralization and retrograde evolution of precious metals deposits. The authors demonstrate that it successfully predicts compositions of electrum reported for this assemblage in the literature and illustrate its application for three gold-quartz vein deposits from the Coeur d’Alene mining district, Idaho, that are prospects of the New Jersey Mining Company, the Coleman vein, High-Grade prospect, and Silver Strand mine. Temperatures calculated from average electrum compositions estimated from gravity concentrates (molar Au/(Au+Ag) = 0.76-0.39) and from microprobe analyses of the fahlores (molar Ag/(Ag+Cu) = 0.039 ± 0.004, Zn/(Zn+Fe) = 0.57 ± 0.03, As/(As+Sb) = 0.23 ± 0.02) from the Coleman vein indicate that the electrums underwent retrograde re-equilibration to temperatures between about 80°C and 240°C, roughly 80°C below the temperature of hydrothermal mineralization and 10°C to 40°C above the temperature inferred for retrograde equilibration of Fe and Zn between sphalerite and fahlore. Fahlores from the High-Grade prospect [molar Ag/(Ag+Cu) = 0.009 ± 0.004, Zn/(Zn+Fe) = 0.55 ± 0.11, and As/(As+Sb) = 0.04 ± 0.03] and Silver Strand mineralized zone [molar Ag/(Ag+Cu) = 0.10 ± 0.04, Zn/(Zn+Fe) = 0.63 ± 0.02, and As/(As+Sb) = 0.06 ± 0.02] exhibit strong core to rim depletions in Ag due to retrograde operation of the reaction1/10Cu10Fe2Sb4S13 + Ag + FeS2 =Cu-fahlore electrum pyriteCuFeS2 + 1/10Ag10Fe2Sb4S13chalcopyrite Ag-fahlorewhich proceeds to the left with decreasing temperature. Electrum inclusions in arsenopyrite from the High-Grade prospect [molar Au/(Au+Ag) = 0.90 ± 0.02] define a minimum bound on the temperature of hydrothermal mineralization of 273°C, and the temperatureelectrum composition curve constructed for the most Ag-rich fahlore in the Silver Strand mine indicates that the fineness of its electrum is significantly less than in the other deposits."

Jan 1, 2004

By B. McLaughlin

"The Penna shaft is the deepest single-lift shaft in North America. Agnico-Eagle started sinking the Penna shaft in 1995 with a hoisting plant capable of hoisting 1800 t/d from a 2240-m deep shaft. Exploration success at depth led to the replacement of the existing double drum hoist by another double drum hoist capable of hoisting 7000 t/d. The use of another double drum hoist, instead of a Blair multi-rope winder, to hoist 24.5 t skips was only made possible by lowering the safety factor.This paper describes recent experiences at Penna and in South Africa, and examines the possibility of extending the double drum hoisting system to a depth of 3 km. IntroductionThe original Penna production hoist was a 4.88 m (16 ft) diameter double drum and single clutch machine. Béliveau (1996) and Scott (1996) have described this hoisting plant. In 1998, a decision was made to increase mining capacity from 1800 t to 4500 t of ore per day from the shaft bottom. Final capacity had to include an allowance of 1800 t of waste per day for future capital projects. While daily capacity was to be 6300 t, it would, by taking into account the different rock densities, be equivalent to hoisting 7000 t of ore.The steps taken to lower the safety factor were presented by McLaughlin and Scott"

Jan 1, 2004

By P. R. Scheller

Reactions between metal and slag are of decisive importance for metallurgical processing. In the continuous casting process, where metal solidifies at the metal-slag interface, reaction products can cause surface defects, with quality damages of the cast products as a consequence. These investigations are focused on the contact area between casting flux and metal. The samples were taken from the mould during the casting process. The results show that layers up to approximately 300 nm from the slag/metal interface represent a specific reaction space. Sodium in this layer on the slag side plays a specific role, which is explained on the basis of experimental results. The transport of oxygen near the interface and the charge transfer is explained on the basis of the ionic character of the slag. The mass transfer rate of oxygen crossing the interface is calculated from measured data, and conclusions concerning the stability of the interfacial tension are made. Keywords: mass exchange, metal slag reaction, interface, ion transport, oxygen transfer, oxidation, casting slag, flux, sodium

Jan 1, 2004

By John C. Wilmot, Robert E. Brewer, Royce J. Smith

In March 2003, Phelps Dodge started up an innovative pressure leach facility for processing copper concentrates at the Bagdad mine in Arizona. This paper describes the development of the concentrate leaching plant at Bagdad and the operational results from start up to present. Optimization efforts and an approach to mineralogical modeling of the concentrate to calculate oxygen utilization are also presented.

Jan 1, 2004

By J. I. Schoenherr, G. Schubert, T. A. Baloun

The currently known and used plastics and rubber recycling or sorting processes cannot be applied efficiently and economically due to large amounts and different numbers of plastics types as well as of fine bulky materials (<4mm). These wastes are mostly given to land-fill sites. Thermal adhesion seems to be a great means to efficiently separate plastics mixes. Tests carried out at a special lab-scale testing unit (TaA1) confirm the effectiveness and feasibility of the separating mechanism. The thermal properties of the individual types of plastics differ from each other to a sufficient degree so that special products or product mixes of high material purity can be obtained according to the respective requirements. For this reason, plastics mixes such as PE and PP can be sorted with very good results. The separation efficiency is influenced only by different contact surfaces. The contact period can be adjusted to a short period of time so that sorting large amounts of fine dispersed plastics seems feasible. Sorting processes in feed streams were shown to be technologically effective when applying appropriate technologies. For the time being, the technological application of a thermal adhesion drum separator (TaTr1) is suitable. First tests on such a pilot-scale unit provided good separation results.

Jan 1, 2004

By A. McLean, M. Iwase, K. Wakimoto, K. Katogi

For many decades control strategies have been based upon samples taken from liquid steel, molten slag and gas phase as well as from solid products. Because of recent developments in the areas of dynamic control models, artificial intelligence and expert systems, there is an increasing incentive to develop diagnostic sensors, which permit in-situ rapid determinations of concentrations of various elements in molten steel. In this paper, an overview is given on recent developments in the areas of sensors for use in ferroalloy and steel production. Particular emphasis will be given on (i) innovative application of sensors for on-line determinations of dissolved elements, Si, P, N, H and Cr in molten iron and ferroalloys, (ii) evaluation of inclusions in liquid metal and (iii) rapid determinations of slag compositions.

Jan 1, 2004

By J. Budac, R. Krentz, P. Cordingley, G. Freeman, M. E. Chalkley, H. Scheie

Pressure hydrometallurgical unit operations have been in commercial use at the Fort Saskatchewan refinery of Sherritt International Corporation for fifty years. This paper traces the history of Sherritt from its origins in northern Manitoba, and the development of the first hydrometallurgical nickel-cobalt refinery in 1954, utilizing pressure hydrometallurgy, to the modern day refinery. Sherritt&apos;s involvement with pressure hydrometallurgy during the past 50 years has included the operation of the refinery, the development and licensing of technology, incorporating pressure hydrometallurgical unit operations, to more than 30 companies worldwide, the joint venture at Moa, Cuba involving both leaching and precipitation at elevated temperature and pressure, and the production of specialty metal powders. Developments in each of these areas are reviewed.

Jan 1, 2004

By Carlos F. Perucca, Maria Virginia Ramírez A.

"Chile based SQM S.A., exploits potassium chloride rich salts at the Salar de Atacama, in northern Chile. The process includes the solar evaporation of natural brines existing in the Salar salt bed, followed by conventional flotation to recover Muriate of Potash (MOP) for fertilizer use.This paper describes a structured method developed to aid in understanding the metallurgical response of the solar evaporated salts to conventional flotation. The method uses classical metallurgical data analysis combined with laboratory and plant-scale testing, and rudimentary mineralogical studies.As a result of the study, several changes were made to the flotation circuit which produced an operation that is much more consistent and easier to control, and has an increased recovery. An optimized circuit, currently being financially evaluated, has also been conceptually designed based on the findings of this work.INTRODUCTIONSQM S.A. is the world’s largest producer and distributor of specialty fertilizers, iodine, lithium, as well as a wide array of industrial and specialty chemicals. SQM is a public corporation whose shares are traded in the Santiago and the New York Stock Exchanges.SQM S.A. exploits the mineral rights at the Salar de Atacama in northern Chile. Its production processes involve the solar evaporation of natural brines existing in the Salar salt bed, aimed at the recovery of Potassium, Lithium and Boron compounds."

Jan 1, 2004

By F. Melo, M. Pawlik

Fine coal aggregation in concentrated coal-water suspensions was studied through steady-state rheological measurements. The wettability of coal particles was modified by dry oxidation of a bituminous coal. The degree of hydrophobicity was monitored using film flotation. The rheological measurements revealed that hydrophobic coal particles aggregate in aqueous suspensions, over a wide pH range, and produce slurries with high yield stresses. As the degree of coal oxidation increases, the coal particles become more hydrophilic and such suspensions exhibit lower yield stresses values. The yield stress values for suspensions prepared from oxidized/hydrophilic coal become a strong function of pH and correlate well with the surface charge as determined through electroacoustic measurements. These results indicate that the yield stress of aqueous suspensions of coal, and hence coal particles aggregation, is strongly affected by the wettability of coal particles.

Jan 1, 2004

By Stephen L. Chryssoulis, Stamen Dimov

"Preg-robbing has been known for many years, where increased losses are suffered because dissolved gold is removed from solution by adsorption onto carbonaceous matter. In direct cyanidation circuits it is reasonable to conclude that the preg-robbed gold is either in a gold cyanide [Au(CN) - 2, AuCN] or metallic [Au°] form. However, in circuits with a pre-oxidation step possibilities increase and multiply even further because of water recycle streams containing apparent and not-so-apparent gold ligands. It is in these circuits where speciation of sorbed gold, i.e. the identification of the gold compound, is useful. The importance arises from the fact that proper identification of the sorbed gold species can be used to determine how, when, where and why gold was removed from solution, thereby identifying the exact cause of the problem and providing clues as to how it may be rectified.INTRODUCTIONTo the best of our knowledge, this is the first attempt ever to speciate gold preg-robbed by carbonaceous matter using a surface sensitive microbeam technique. This approach enables the direct determination of gold species sorbed on carbonaceous particulates, opening an entirely new field in the understanding of the chemistry of gold sorption on carbon. The reasoning behind this effort was to add to the current knowledge of the detrimental effect chloride ions have on gold recovery by the pressure oxidation and in particular why in the ensuing CIL step, gold is not being desorbed from the surface of the carbonaceous particles (Table 1)."

Jan 1, 2004

The effect of composition on electrical conductivity (resistivity), viscosity and liquidus temperature of the slags encountered in electric smelting of PGM-containing suphide concentrates is reviewed along with the relationsip between slag composition, slag-matte separation and metal losses to slag. Optimization of slag composition at furnace temperature is attempted on the basis of opposite and parabolic trends of the viscosity-conductivity relationships of the slags. The importance of surface tension of slags is emphasized using available and estimated information, which are grouped into a useful correlation. These values are coupled with or incorporated into slag viscosity plots to illustrate the correlation between the two factors which influence slag-matte separation as well as refractory attack. The electrode in the slag-resistance furnace is the central factor in the design and operation of the furnace by its role of conveying the smelting power. The obvious parameters are the size and positioning in the slag bath, which are defined by slag resistivity, furnace resistance, cell constant and power input. The flow of heat generated by the electrode current determines the energy distribution and furnace dimensions creating viscosity profiles, which in turn affect flow conditions. Thus the flow of slag and matte isdiscussed in conjunction with the furnace geometry, stirring action of the electrodes, buoyancy and electromagnetic effects. The action of the electric furnace as a settler is discussed. The rectangular furnace is considered as a channel reactor in this analysis and the action of the electrodes is described to indicate a balanced settling rate in the area of electrode action. Discussion of the design and production capacity of the electric furnace with reference to operating current, power input, furnace dimensions and electrode size are based on considerations derived mainly from slag properties such as its resistivity, viscosity and liquidus temperature.

Jan 1, 2004

By Charles R. Barnhart

The Nitrogen Dioxide Cloud: After one year of testing it can be stated that we do know and understand a great deal about why the nitrogen dioxide formation is exacerbated in cast blasting. Picture 1 is an example of how concentrated the NOx can be from a cast blast. It has long been felt that 300 or more milliseconds of timing needs to be put between each row of detonations to allow the rock a maximum time of flight so the cast percentage is high. Our experiments have found that higher cast percentages can make with timing between 150 to 200 milliseconds between rows. Picture 2 show a definite improvement in nitrogen dioxide concentration and most of that was the result of shooting a previously shot end of the cast pattern that had not been dug, thus no confinement of the powder columns.

Jan 1, 2004

Barrick Gold plans to have four new gold mines in production by 2006. Together, the mines would increase the company’s output by 40 percent. The projects include Veladero in Argentina, Alto Chicama in Peru, Cowal in Australia and Tulawaka in Tanzania. All of them are scheduled to begin production between the first quarter of 2005 and the first quarter of 2006. They are expected to drive Barrick Gold’s growth profile to a target of 211.5 to 217.7 t (6.8 million to 7 mil-lion oz) of gold production in 2007. The company’s projected output for 2004 is 152.4 to 155.5 t (4.9 million to 5million oz) in 2004. Overall, higher production and lower costs are expected in the early years from the new mines.

Jan 1, 2004

By E. Milke, A. Arnold, B. Friedrich, A. Sydykov

CaF2is often used as a fluoride addition to the chloride salt flux in the melting of aluminium scrap. The solubility of CaF2in the chloride salt system is limited. Dissolved CaF2is considered to improve the properties of salt fluxes. Experimental investigations indicated that the solubility ofCaF2in 70 wt % NaCl/30 wt % KCl, German salt flux used in aluminium scrap melting, might be lower than expected according to literature data. The pseudo binary section CaF2-(70 wt % NaCl-30 wt % KCl) was investigated by differential thermal analysis (DTA). The determined solubility of CaF2appeared to be considerably lower than presented in the literature. The pseudo binary section calculated using thermodynamic data partially confirmed the results. DTA allowed us alsoto determine the crystallization temperature interval of the two phase eutectic consisting of the solid solution NaCl-KCl and CaF2. Keywords: aluminium recycling, phase system, salt flux, CaF2, NaCl, KCl, solubility

Jan 1, 2004

By N. R. Shoko, J. Chirasha

Zimbabwe Alloys has been producing Low Carbon Ferrochrome since 1953. A number of operational and technical advances have been made since then. Some of these advances improved production significantly. Process control, however, remained a challenge not only in the production process itself but also in the handling of finished product. In addition the handling of the slag created an environmental problem. Process control issues were addressed by Zimbabwe Alloys Limited and Japan Metal & Chemicals (JMC) entering into a Technical Transfer Agreement. The aim of the technical transfer was to improve production, alloy quality and, thereby, the financial performance of Zimbabwe Alloys. In addition, the Low Carbon Ferrochrome production process was made environmentally friendlier by modifying the final slag handling methodology. The aspects that are covered and discussed in this paper are, ladle refractory lining changes, improved control of the process, changes in the alloy casting methodology and granulation of the final slag. The improved control of the process was enhanced by the conversion from ladle duplexing to argon purging, introduction of on-line sampling and introduction of second stage process. The combined effect of the above was a significant improvement on on-grade material production, production efficiencies, unit cost of production and a cleaner working environment.

Jan 1, 2004

By Bonifacio Degay, Mike Lovitt

PT Freeport Indonesia is a block cave mine that now utilizes an advanced undercut method to set up the min in the Deep Ore Zone (DOZ). In this method a slice of rock (undercut) is broken such that it sits on top of the drawbell level. The drawbells are developed to channel the broken ore into the extraction level and to enable the caving orebody to be drawn out in an even and controlled manner. These drawbells are difficult to form due to the small amount of void that can be developed in the low strength rock before firing. Starting with two rises of 2m square, the void ratio for the entire drawbell around 6%, which would normally result in a frozen and unproductive blast. Orica -Mining Services have worked with PT Freeport in a collaborative effort to find a solution to the mining problem. With excellent control of timing of the blasting it is possible to get fluid flow of blasted rock out of the draw points such that more void can be made available for blasting the remaining parts of the drawbell. The i-konTM electronic blasting system gives the exacting control of timing within the blast to achieve this Dynamic Void Generation (DVG). The solution stops the need to charge close to brows in the drawbells and reduces the cost and time related to developing initial blast voidage. This paper identifies the results of the trials including design, photographic evidence and vibration analysis. The flexibility and accurate timing of this electronic blasting system has enabled single hole initiation rather than 4 or more holes being initiated together, thereby reducing the damaging vibrations to the extraction level.

Jan 1, 2004

By R. Dippenaar

The emergence of new steel grades is largely driven by the need to produce high quality steel at a competitive price. The principal aims are to attain ultra-high purity, (especially low interstitial elements) and ultra-cleanliness (by the control of the inclusion content and size). Whereas the steel used to build the Titanic contained 650 ppm sulphur, resulting in MnS stringer-inclusions 25 mm in length, modern quality requirements for arctic pipelines would only allow 10 ppm of sulphur and inclusions in ball-bearing steels must be smaller than 5µm. Most developments are aimed at hot-metal treatment before refining and ladle treatment after decarburisation. Because ferroalloys are added during or after the refining step, it is the secondary (ladle) refining production technologies that are of specific interest to the ferroalloy producer. Through ladle treatment, hydrogen and nitrogen contents are reduced, ultra-low levels of solute impurities are attained and the shapes as well as the composition of inclusions are modified. Steelmakers are concerned about the cost effectiveness of the use of ferroalloys such as consistent product analysis and delivery, improved financing arrangements and technical support. Minimal variation in product sizing is vital because it impacts on handling problems and because particle size determines the rate of particle dissolution. The required ferroalloy product quality depends on the specific use but in general sulphur, phosphorous and nitrogen contents are of concern. Apart from the presence of trace and impurity elements, ferroalloys also contain inclusions. For example, ferromanganese may contain MnO-MnS-SiO2 inclusions while high-carbon ferro-chrome may contain different kinds of Cr-Mn-spinels. The presence of these impurities and inclusions has a significant impact on steel production techniques and cost and hence, on the selection and use of ferroalloys. The interrelationship between ferroalloy quality and steel production technology is plant and product specific and hence, effective communication between ferroalloy suppliers and steel producers is essential.

Jan 1, 2004