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By D. R. Nagaraj

Secondary Ion Mass Spectroscopy (SIMS) was used to study adsorption of sulfide collectors such as modified thionocarbamates and thioureas, xanthate, dithiophosphate, and dithiophosphinate, on galena, chalcocite, chalcopyrite, and quartz under flotation related conditions. In the case of the adsorption of modified thiourea on chalcopyrite, chalcocite and Cu-activated quartz, and of dithiophosphinate on galena, SIMS measurements have provided direct evidence for the presence of metal-collector (1:1) complexes on surfaces. In the other systems, only the collector molecular ion and its fragments were detected. The distribution of adsorbed species on the surfaces was obtained by using SIMS in the imaging mode. On chalcopyrite, only the copper-collector complex was found; there was no evidence for iron-collector complex. In the case of quartz, adsorption of selective collectors was observed only after activation by copper ions.

Jan 1, 1996

By J. R. Donald

Surface and interfacial phenomena play a significant role in refractory performance. For example, the wettability of the refractory material with slag, matte, and metal influences infiltration and interfacial reactions. Yet, very little fundamental information regarding the surface properties of refractory materials and slag is available. Thus, in the present work, the sessile drop technique incorporating a high temperature furnace equipped with X-ray fluorescope was employed to investigate the surface and interfacial phenomena of fayalite-type slags on solid alumina at 1200?C. The iron to silica (Fe/SiO,) ratios employed were 1.4 and 2.0, and the oxygen potentials used were log p02 =-11 and log p02=-9 atmospheres. The contact angle between the fayalite-type slags and the alumina were determined to be relatively low, at about 16.9 to 19.6 degrees under the experimental conditions. The surface tension of fayalite slag (Fe/SiO2=1.4) at an oxygen potential of log -11 was 0.298, which agreed with the work of previous researchers. The surface tension of the fayalite was observed to increase with time. The spinel FeAl2O4. was determined to be the product of the interfacial reaction, and 8.8 to 15.8 mass percent alumina was dissolved into the slag after 40 minutes.

Jan 1, 1996

By V. I. Lakshmanan

"Historically flowsheets are developed for efficient separation of metals for economic recovery. With increasing emphasis on reduction, reuse and recycle (3Rs) efficient methods are sought to recover values from a variety of feeds where cost of collection, transportation, local consumer behaviour and regulatory guidelines dictate the development of economically viable flowsheets. Innovative understanding of potential market applications can provide means to develop value added end products. The paper with examples will discuss the use of innovative-separation technologies to obtain value added end use materials from secondary sources.IntroductionFlowsheets are developed for the efficient separation of materials of value for economic recovery. However with increasing societal pressures and regulatory initiatives for stricter environmental guidelines, there is strong need to provide focus to recover materials efficiently and economically in an environmentally accepted manner. North American industries are increasingly caught between demands for high technology value added products and responsibility for environment. An aspect that is receiving increasing attention is Design for Environment'. This incorporates a system wide approach for product design and incorporates environmentally preferable features such as recyclability, disassembly, maintainability, reusability and use of safe materials as part of a product's design objectives.The present paper with case histories will address innovative flowsheet development to convert wastes into recyclables value added products or for minimising generation of waste materials. Case HistoriesProcess for Separating Fibres from Composite Materials 1In the automotive industry, sheet molded compound (SMC) is used to produce panels, bumpers and the like. During the manufacture and at the end of life, considerable waste materials are generated which are potentially recyclable. Fibre reinforced plastics where fibre substrate impregnated with thermosetting resin, find applications in several manufacturing processes and are potentially recyclable at the end of life."

Jan 1, 1996

By R. Mensah-Biney

The kinetics of gold-bromide loading onto activated carbon has been investigated in a batch stirred reactor. The amount of gold adsorbed by the carbon was correlated with time based on a second-order equation. The rate constant for gold-bromide species onto activated carbon ranged from 0.27 to 1.2 x 10-3 (kg/t)-l(min)-l from a solution containing 25 ppm of Au, with 0.8 g carbon per liter of solution at 30° C. The equilibrium saturation capacity (Q.) was 36±3.0 kg/t from the same system. The rate of loading increased with decreasing particle size, decreasing pH, increasing temperature, and decreasing concentration of gold in solution. The calculated activation energy E. was 8.8 kcal/mole, significantly higher than those reported for physical adsorption. The equilibrium saturation capacity (Q.) increased with increasing concentration of gold in solution, but was independent of other variables such as temperature, agitation speed, particle size and pH. These rate constants and equilibrium saturation capacity for the gold-bromide species are higher than those reported for the gold-cyanide systems.

Jan 1, 1996

By Dennis R. Dolinar

Controlling coal mine roofs subjected to high-horizontal stress conditions has always been difficult and uncertain. Traditional supports such as wooden cribs and posts, concrete donut cribs, and standing supports collapse and fail when the roof and floor move horizontally as mining progresses. The former U.S. Bureau of Mines (USBM) (currently the U.S. Department of Energy (DOE)), in cooperation with Western Fuels-Utah, Incorporated, conducted research to provide an alternative for traditional secondary support systems in a 3-entry gate road system subjected to high horizontal movements. The support system used in several other coal mine operations, consisted of internal high-strength galvanized resin-grouted cable supports. The system virtually eliminates the necessity for external crib, timber, or concrete supports. The support system consisted of 2.4 m (8 ft) full-column resin grouted bolts and 4.8 m (16 ft) long cable supports installed in conjunction with wire mesh and "Monster-Mats." Cable loading and roof deformations were monitored to evaluate the behavior of the immediate and main roofs during first and second panel extractions. Additionally, cable trusses were installed on the longwall headgate to protect the coal conveyance system from roof and pillar falls created by the formation of cutters and gutters. The test results indicated that the designed support system successfully maintained the roof during the extraction of two longwall panels and dramatically reduced the cost of secondary support. This paper describes the theory of high-horizontal roof movements, the advantages of vertical cable supports and cable trusses, and presents the roof and cable measurements made to assess the support performance during longwall retreat mining.

Jan 1, 1996

By M. J. Hrebar

A study was conducted to evaluate the applicability of large wheel loaders (Cat 994 class) as primary loading equipment in open pit iron ore operations. Field visits were made to taconite and gold mines that used large wheel loaders. Data were gathered on loader selection rationale; operating and maintenance experience; and production, availability, and cost information. Brief time studies were conducted to indicate machine performance and utilization. The paper summarizes the field data and includes economic comparisons of wheel loaders versus cable shovels in an iron ore application.

Jan 1, 1996

By L. R. Stace

Arguably, one of the most significant technological breakthroughs that had been experienced during the period when British Coal was the major coalmine operating company in the UK, the use of rockbolts as principal support in underground roadways brought with it the need to re-assess the technical knowledge, management controls and legislative frameworks associated with the support of mine workings. Following a major roof fall in a roadway supported principally using rockbolts in which fatalities occurred, the process of the design of rockbolted support and the systems and procedures that had been put in place to control its use in the UK were further reviewed. The paper discusses the outcome of these reviews, and how the incident initiated a major new interest in strata control research in the UK against the background of the fragmentation of the ownership of the mines following the sale of the former British Coal assets at the end of 1994, together with the proposed introduction of new strata control legislation in 1996.

Jan 1, 1996

By C. L. Karr

Researchers at the University of Alabama have developed a method for producing fuzzy linguistic models of mineral processing equipment directly from engineering data. These fuzzy linguistic models rely exclusively on data collected from the processing systems being modeled and do not presuppose an understanding of the physics of the system. The fuzzy linguistic models use descriptive rules and explicit membership functions that provide a precise, nonmathematical description of the processing equipment. A genetic algorithm is employed to simultaneously select rules and tune membership functions used in the fuzzy models. The result is an extremely flexible approach to modelling that is applicable in a variety of linear and nonlinear systems. The effectiveness of this approach to modelling is demonstrated using a four-input, two-output model of a grinding circuit.

Jan 1, 1996

By A. K. Kyllo

A study has been carried out on the dusts from Hudson Bay Mining and Smelting's Flin Flon copper smelter. The aim of the work was to determine the mechanisms of dust formation and the deportment of the various constituents. The work concentrated on the copper converters, but the electrostatic precipitators and baghouse also clean the reverberatory furnace off gas, so some mixing will have occurred. The dust composition was found to vary with distance from the furnace, and to be made up of three major components: solidified droplets, unreacted flux, and condensed particles. The solidified droplets were formed from material ejected from the converter during blowing, while the flux was blown out of the converters immediately after charging. The condensed particles contained the majority of the lead and zinc, as well as the volatile impurities. There was also a significant soluble content of the dusts, increasing with distance from the furnace. The condensed material may be separated from the remainder by a simple washing and sizing technique.

Jan 1, 1996

By B. I. Hop

The f10wfield set up by the standard Hydro gas purging unit has been predicted by a numerical model. In addition turbulent trajectories of gas bubbles released from the rotor are predicted. Here the deposition rate of inclusions on the bubble surface is allowed to depend on local conditions. Bubbles passing regions with strong pressure gradients, such as close to the rotor, will experience large slip velocities and large deposition rates. This model can deal with any distribution of bubble sizes and inclusions. The results found from the multidimensional flow predictions are discussed in relation to what can be obtained from a much simpler metallurgical engineering approach. The differences between these two approaches to predict the same process will be discussed. The model predictions are compared to experimental results for removal of SiC-particles from aluminium.

Jan 1, 1996

By L. H. Michaud

A mining company plans to extend its surface coal-mining operations in central Pennsylvania. Although the proposed site contains pyritic material, the results of the acid-base accountings for the site shows an overall Neutralization Potential to Maximum Potential Acidity Ratio (NP:MPA) of 4.26:1 for the entire site. The pyritic material is, however, associated with the lower of the three seams to be mined. If traditional dragline-mining methods are used, this would result in the acidic material being placed at the top of the spoil piles, exposing it to air and water, and therefore to the formation of acid mine drainage (AMD). Further concerns are associated with the fact that the alkaline material is not distributed evenly over the mine site. To prevent the formation of AMD, the company has proposed to mine the area using truck-shovel mining methods. This technique offers a more flexible alternative for cut sequencing and for the selective placement of waste material. Working with the Department of Mineral Engineering at The Pennsylvania State University, amine plan was developed for this site. This plan results in the layering of the alkaline and acidic spoil to achieve an overall net alkalinity in all spoil areas. Therefore, mining this site should not result in the formation of AMD.

Jan 1, 1996

By G. A. Doyle

The quality of water in mine pit lakes depends in part on the physical limnology (Le. stratification, turnover, and development of anoxic conditions with depth) of the lake. Limnologic data collected from four existing pit lakes indicate that pit lakes develop a thermocline, or temperature stratification, in the upper 10m to 30 m of the water column. Two of the pit lakes (26 m and 55 m deep) undergo seasonal turnover of the entire water column, whereas two deeper pit lakes (110 m and 240 m) undergo seasonal turnover of only the upper portion of the water column. In the deeper lakes, seasonal mixing does not extend through the entire water column and a distinct chemocline develops with depth.

Jan 1, 1996

By William J. Miles

Bentonite Corporation decided to pursue ISO-9002 Registration for our bentonite production for many reasons. We wanted to improve our current Quality System to encompass all business aspects, not just Quality Assurance. We wanted this system to build supplier/customer confidence and provide our customers with all the services that they needed for their business functions: such as Quality Assurance for their needs; appropriate shipping and delivery; appropriate billing; and appropriate sales, technical and management support of our product. These objectives of our Quality System are addressed by the ISO 9000 clauses and requirements. There were additional reasons and expectations for implementing an ISO 9000 Quality System. ISO 9000 registration would develop and aid international sales since the ISO system is a basic requirement in many parts of the world such as Europe and the Far East. It would bring acceptance of bentonite products by new customers and markets Another objective was to develop better trained employees. We hoped that the ISO Quality System would help us reduce costly non-conformances and reduce overall production and operating costs. We hoped to achieve ISO 900 registration before our major customers required it. For example, our major market is use of bentonite as a binder in foundry mold sand systems. The foundries in North America primarily service the automobile manufacturers who have individual Quality System requirements that are being merged with ISO 9000 Standards. As the foundries addressed the automobile manufacturer?s needs, Bentonite Corporation received numerous inquiries and surveys of our Quality System and its conformance with ISO 9000 Standards. Eventually, ISO 9000 Registration will become a requirement to directly or indirectly service this market.

Jan 1, 1996

By C. Ramasamy

The tariff reductions on imports, as a part of on-going liberalisation process in India, has fueled competition within and outside India and has, in turn provided an opportunity to reach global markets. This change calls for quality upgrades and cost-competitiveness without impairing the environment. In this context, gas based processes, contributing to improvement in quality and environment as well as processes where controls are applied when gases inimical to environment are involved, are discussed in a remelt/cast-house scenario. The impact of such processes on fabrication cost of sheet ingot is seen alongwith consumption and cost of materials and compared with a world class standard plant in North America.

Jan 1, 1996

By N. A. Warner

Fundamental studies on the reaction of limestone or dolomite at high temperature with S02 are extended to the realm of large scale primary copper smelting. Whereas flue gas desulfurisation in the electric power utility industry is concerned with S02 concentrations normally less than 0.5 percent, high temperature smelting gases can have S02 levels approaching 100 percent. The reaction involved is very exothermic so proposals are made in this paper for returning the heat generated in sulfur fixation directly back to the copper smelting process. This integration leads to metal production with lower energy requirements than current technology. The anhydrite reaction product can either be disposed of locally with minimum adverse environmental impact or upgraded to a value-added product. It is assumed, of course, that no viable market exists to support sulfuric acid production.

Jan 1, 1996

By Jan Yaozhong

The composition and the possible utilization of Ti bearing blast furnace from a titanomagnetite blast furnace smelter were studied. The slag contained about 20% Ti02 and trace Sc. The mineralogical analysis indicated that Ti in the slag is mainly as perovskite. By means of magnetite separation, the Ti containing phase could not be enriched. An effective hydrometallurgical approach was proposed with sulphuric acid leaching. The method proposed for processing the studied slag renders product Ti02 and SC203. Besides the recovery ofTiO2 and SC2O3' the leaching process yields fine grained residues which can used as additives for making cement.

Jan 1, 1996

By Evangelos Spyridonos, Thomas Frommer, Wolfdietrich Skala, René Prissang

Operational grade modelling is a technique that uses production data to run daily updates of property models. It will enable mining engineers to use property predictions based on the most recently acquired data as support for quality control and decision making. The approach necessitates that the properties of the run- of-mine material can always be attributed to individual mining blocks or charges. The software employed must be highly reliable, because a system failure or the loss of data could seriously affect the mine's quality management. An operational grade modelling system has been developed for the Breitenau magnesite mine. It makes use of the Linear Octree Based Property Modelling system which was conceived and realised at the Free University of Berlin. This paper describes the system design and gives an account of the experiences during the first six months since system start-up.

Jan 1, 1996

Rhyolitic rocks are volumetrically significant in the eastern part of the Coromandel gold province, yet deposits hosted by rhyolite (Kapowai, Broken Hills, Neavesville, Wharekirauponga and Waihi Beach) are generally low grade and subeconomic, especially compared with andesite-hosted deposits. In contrast, rhyolitic volcanic centres in Nevada host a number of economically significant epithermal gold deposits such as Round Mountain, Sleeper and Bullfrog. The Nevada deposits are associated with 27-20 Ma continental arc volcanics dominated by ignimbrites (eg Round Mountain), or younger 17-9 Ma bimodal rhyolite-basalt volcanism related to extensional basin-and-range tectonics (eg Sleeper). The Round Mountain deposit is localised on a caldera boundary fault and the mineralisation was deposited soon after eruption of the host rhyodacitic ignimbrite. In other Nevada deposits, hydrothermal systems are linked to the closing stages of flow-dome complexes and mineralisation is localised along normal faults associated with extensional basin-and-range tectonism. The style and composition of the mineralisation is similar in both the Coromandel and Nevada deposits and consists of sheeted and stockwork quartz veins, containing electrum as the main ore mineral and only minor sulphides (mainly pyrite) Likewise, the vein minerals were deposited from low salinity hydrothermal fluids in the temperature range of 200-270¦C. Both the Neavesville and Round Mountain deposits are geochemically anomalous in molybdenum. The deep oxidation of the Nevada gold deposits, dry climate and low level of competing land uses combine to make it economic to mine and process very low grade ore (0.2 - 2.0 g/t Au) by heap-leaching with cyanide solutions in most areas of Nevada. Although extensive low grade gold mineralisation is known at deposits such as Wharekirauponga and Neavesville, it is sub-economic because of shallow oxidation and land use conditions that are unfavourable for open pit mining and heap leaching.

Jan 1, 1996

By Richard S. Dennis

Acid recovery employs ion exchange (I-X) resin as separation media for inorganic acids from dissolved metallic salts by physical adsorption and without the use of chemicals. This technology has been used for years on spent etching and plating liquors to recover acid for reuse in the bath and to reduce waste acid neutralization costs. It is also used for electrolyte treatment to facilitate valuable metal recovery via acidity reduction. TETRA's ccrxr'" I-X contactor has been used successfully for acid separation from its metallic salt counterpart in a simple, continuous operating mode using strong base anion resins. Efficient separation is enhanced by acid reconcentration to nearly its original strength or as high as 14-20%. Continuous treatment also recovers heat to the tankhouse or bath and improves metal quality due to consistent acid quality. Conventional fixed bed ion exchange (I-X) systems are impractical for acid recovery because of complex control design and large resin inventories needed to process very low liquid-to-resin treatment ratios associated with strong acid concentrations.

Jan 1, 1996

By Abishev D. N, Balakirev V. F, Davydov G. I

The problem of recovery of cobalt products from poorly oxidised nickel ores (Kempirsaisk deposit) and pyrite concentrates with a low content of cobalt (Sokolovsk-Sarbaisky deposit) has not been solved to the present time in Kazakstan. The balance reserves of nickel ore of the Kempirsaisky deposit make up more than 35 million tons with a nickel content of 1.13 per cent and cobalt content of 0.05 per cent; besides there are 110 millions tons of out-balance ores (Anon, 1995). In a tailing dump of Sokolovsk-Sarbaisk Mining and Productional Association more than 320 million tons of tailings of wet magnetic separation have accumulated, which contain 7.2 per cent of sulphur, 0.022 per cent of cobalt, 0.012 per cent of nickel, 0.094 per cent of copper, 0.079 per cent of zinc, 16.45 per cent of iron, and from which a high quality pyrite concentrate car) he separated through flotation, containing 48 - 50 per cent of sulphur, 44.15 per cent of iron, 0.141 per cent of cobalt, 0.07 per cent of nickel, and 0.10 per cent of copper. The well-known technological flow charts for cobalt and nickel recovery from the tailings of sulphide-magnetite ores dressing (to give pyrite concentrate) and from oxidised nickel ores, are not profitable at the existing prices for metals, but are not worthless and require significant capital investments for the realisation of their value. The flow chart `sulphate roasting - leaching - solution processing' is used widely for combined processing of cobalt-containing pyrite ores and concentrates.

Jan 1, 1996