Search Documents

By Stephen M. Jasinski

This report describes the materials flow of mercury in the United States. It examines the mining and production of mercury and the manufacturing, uses, and ultimate disposal of mercury. Materials flowcharts were prepared for 1989 and 1990. An effort was made to include estimates for all major anthropogenic sources including fossil fuel combustion, waste incineration, and nonferrous metal mining operations. Mining and mineral processing released about 100 mt/yr of mercury to the environment in both 1989 and 1990. The combustion o ii fu1s released 175 mt/yr in the same years. The manufacturing, use, and disposal of products containing mercury accounted fix the release of 1,037 mt of mercury in 1989 and 938 mt in 1990. The manufacture of chlorine and caustic soda was a major source of recycled mercury, but it was all reused within the industry. Recovery from all waste products accounted for 36% of reported consumption in 1989 and 42% in 1990. The losses from manufacturing and end use have been declining, whereas mercury emitted from combustion sources has not been strictly regulated and will likely become the largest source of mercury releases to the environment.

Jan 1, 1994

By Tatsuo Inoue, Marnoru Mizuno, Toru Matsuoka, Kenichiro Abe

"The distribution of particle reinforcements and the residual stresses in metal matrix composite are simulated by considering the motion of particles and the solidification of matrix associated with temperature variation in the course of centrifugal casting process. In the analysis, a heat conduction equation including heat generation due to latent heat and also mechanical work as well as heat input from successively accumulated element on the air/metal boundary is solved by the finite element technique. After the movement of particles subjected to the centrifugal force and drag are analyzed, the residual stresses are elucidated by using a unified constitutive equation which can describe the behavior both in liquid and solid states. Results of the simulation are compared with the experimental data, and the validity and utility of the procedure is confirmed.IntroductionProcess simulation of metal matrix composite (MMC) is required to determine the mechanical properties of the materials and the efficient process and conditions of the fabrication. Properties of bonding matrix with reinforcements in the course of the processing, for example, affects the strength of the composite, while the final costs of the productions depends on the efficiency of fabrication. Therefore, the simulation of processing of MMC is prerequisite in order to clarify the mechanism to fabricate the material which has been expected to maintain high mechanical properties and the cost performance.Some techniques of processing MMC[l] have been developed so far. Among them, the centrifugal casting technique [2-5] has many attractive characteristics as processing of the MMC: The centrifugal casting technique makes the reinforcements such as particles or short fibers to be distributed in the radial direction by the centrifugal force acting on reinforcements due to the difference in density between reinforcements and matrix. Since the distribution of reinforcements affect the mechanical properties of MMC, the composite with functionally gradient mechanical properties can be provided by the centrifugal casting technique."

Jan 1, 1994

By A. Durnan

Barrick Goldstrike Mines Inc. (Goldstrike) operates a six circuit (train) pressure oxidation plant for the pretreatment of gold bearing sulfide ores. The property is located 27 miles north of Carlin, Nevada. Since the commissioning and start-up of the first circuit in 1990 until the present total plant availabilities have exceeded 90%. The discussion that follows will detail the maintenance practices employed to consistently achieve this goal.

Jan 1, 1994

By T. J. Fenner

Research conducted in South African mines has demonstrated the benefit of ground penetrating radar for the detection of geologic features and hazards. This is crucial for safety and production considerations in underground mines that are as much as 4 kilometers deep. This paper describes a new ground penetrating radar system designed specifically for high quality data acquisition, in the harsh conditions of deep underground environments, for use by operators with minimal geophysical experience. Design criteria included automated functions, intrinsic safety, light weight and minimal power requirements. Data is processed on the ground surface by geoscientists using a PC.

Jan 1, 1994

By Harold R. Kokal, Madhu G. Ranade

A metallurgical/flux is a substance that is added to combine with gangue (unwanted minerals) during ore smelting, with impurities in a molten metal, or with other additives in metal refining processes to form a slag that can be separated from the metal. Because slags are immiscible with the metallic melt and are of lower density, a separation of the slag and metal occurs if the viscosity and surface tension are of the proper values. The chemistries of slags are adjusted to provide the proper melting point, viscosity, surface tension, conductivity, specific heat, density, or chemical properties to effect the desired task. In addition to absorbing impurities from the metal, the purposes of the slag are to thermally insulate the metal bath, protect the molten metal from the atmosphere, and control the chemical potential of the system. Several excellent references on slags and metallurgical fluxes are available (Boynton, 1980, Lankford, Jr., et al., 1985, Turkdogan, 1983, Rosenqvist, 1974, Fine and Gaskell, 1984). The function of the slag might vary at different stages within a process prior to final melting. For example, the slag composition and behavior will change as materials descend in the iron blast furnace, or as they melt in the early stages of formation of steel- making slags. Selection of the chemistry for a slag might be influenced by factors outside the primary function as when blast furnace slags are used to make cement, rock wool insulation, or fertilizer supplements. Sometimes slags contain a sufficient amount of valuable recoverable elements to be sold as raw materials for other processes. Fluxes are often referred to as acid, basic, or neutral. Acid fluxes are those that generally form acids in water and bases are those that would generally form bases in water. Typical acid fluxes are silica, alumina, and phosphorus, although alumina can function as either an acid or base. Typical basic fluxes are lime and magnesia. Fluorspar, or calcium fluoride, is a neutral substance because it can be viewed as the reaction product of a base and an acid. The degree of acidity (ratio of acids to bases) or basicity (ratio of bases to acids) is often specified to characterize the slag chemistry for a particular system. The system might also be referred to as acid or basic depending on the choice of slag, for example, basic steelmaking uses slags with more bases (lime and magnesia) than acids (silica and alumina). Many forms of minerals and compounds have been used as fluxes depending on the process requirements, availability, costs, requirements for recycling of intermediate products, and environmental concerns. Because slags are most often mixtures of oxides and silicates, fluxes are usually oxides, carbonates (which decompose to oxides) and silicates. Slags comprising phosphates, borates, sulfides, carbides, or halides have also been used (Rosenqvist, 1974, Moore, 1981, Szekely et al., 1989). In ironmaking and steelmaking, some acidic components are sometimes added. In nonferrous processes slags and fluxes are acidic with silica as the primary component, and although the use of basic flux such as limestone or lime is not extensive, some amount is used to modify slag properties and some refining slags are lime based. The production of iron is accomplished by smelting of ores, pellets, and sinter in blast furnaces with subsequent refining of molten iron and scrap in oxygen-blown processes. The electric furnace is used to make steel, stainless steels, ferroalloys, and special alloys, whereas ferromanganese is often made in blast furnaces. Fluxes are used in all of these processes, and either limestone or lime is the major flux component with some dolomite, dolomitic lime, silica, alumina, and fluorspar being used. In ironmaking, the flux is added either by direct charging or through sinter and fluxed pellets. In steel refining by the basic oxygen process, flux is added as lime and dolomitic lime that are either charged as lumps or injected as fines. Some small amount of limestone is sometimes used. Fluorspar is often added as lumps or mixed with other fine materials in briquettes. Alumina is sometimes added to blast furnaces either by direct charging of sized lumps or through sinter. Typical acid fluxes are sand, gravel, quartz rock, used silica brick, or raw siliceous ore (Lankford, Jr., et al., 1985). Olivine, which is a magnesium-silicate mineral, has been added to iron blast furnaces to enhance removal of alkalis (Lankford, Jr., et al., 1985). Alumina in the form of bauxite, aluminiferous clay, and recycled alumina brick has been used as flux. Alumina can function amphoterically as either an acid or base, for example it can form aluminum silicate in high silica slags or calcium aluminate in lime-bearing slags (Lankford, Jr., et al., 1985). Limestone (calcium carbonate) and dolomite (magnesium-calcium carbonate), or fluxstones as they are sometimes called (Boynton, 1980), and their calcined forms, lime and dolomitic lime are the major basic fluxes. In the latter cases, the carbonates are de- composed in a kiln-type process to drive off carbon dioxide that might otherwise interfere with the subsequent smelting or refining process or require expensive forms of energy to effect the decomposition (e.g., by combustion of coke in the iron blast furnace). Limestone is considerably less expensive than lime because it is not calcined; however, lime is far more difficult to handle and reacts readily with water. Dolomite and dolomitic lime are used for their magnesia content. Fluorspar is a neutral flux often used as an additive in steel- making slags to improve fluidity, but it has also been used in combination with lime as a primary slag in electroslag refining (Duckworth and Hoyle, 1969). Fluorspar is available in several grades, with the lowest grade often used for steelmaking. When the price of fluorspar has risen, substitutes including aluminum smelting dross, borax, manganese ore, titania, iron oxides, silica sand, and

Jan 1, 1994

Studies of Theological effects in grinding hold promise for improving this energy-intensive process. Six surveys of the Hellyer ball mill were conducted. The stream and sizing data from these surveys were balanced by JKMbal to compare the mill

Jan 1, 1994

By J. R. Koehler

The U.S. Bureau of Mines (USBM) ground control research program includes several projects focused on developing design criteria for yielding-pillar-based longwall gate road systems. As part of this program, mining practices at the Sunnyside Mines, Sunnyside Reclamation and Salvage Co., Sunnyside, UT, are being documented to preserve the long history of yield pillar system evolution on the property. Published information describing the specific in-mine performance of the numerous gate road configurations utilized at the Sunnyside Mines is very limited. To overcome this deficit, USBM personnel interviewed 30 longtime mine employees representing nearly 700 years of mining experience at the Sunnyside operations. Mining conditions in 12 specific areas in the Nos. 1, 2, and 3 Mines were discussed in the interviews. Also, broad topics such as general mining practices, safety, and geology were often addressed during the discussions. Comprising the body of this report is an extensive record of the events and conditions experienced while mining the identified areas. In addition, eight significant conclusions were developed that accurately summarize the general opinions of the interviewed personnel regarding mining conditions and practices at Sunnyside.

Jan 1, 1994

One of the biggest drawbacks of deciding upon a heap leach method of treating gold ore is the risk associated with the full-scale production heaps not performing as predicted by the testwork. This paper examines the key decisions that are taken in the design of a heap leach project, and suggests ways in which exposure to these risks can be minimised. It also looks at monitoring techniques to give early warning of problems and possible remedial actions.

Jan 1, 1994

By James C. Duchon

The use of extended workdays (regular shift lengths of 10 or 12 h (hour), while still maintaining a 4O-h workweek) in mining operations is attracting growing interest in the United States. There is very little doubt that extended workdays is a very popular alternative among the work force because of the significant increase in days off, including weekends, especially when compared with traditional rotation schedules of working seven straight shifts or having only one weekend off every 4 to 6 weeks. However, there are some serious concerns by management, workers, unions, and various governmental policymakers that working 10-or 12-h days may create an added risk of accidents and health problems. The U.S. Bureau of Mines reviewed the literature studies related to the safety and performance issues of extended workdays. This report presents a summary of those findings. The studies examined in this review are divided into three sections: (1) laboratory, (2) field, and (3) accident and injury analysis. In general, results are inconclusive. Studies have shown both positive and negative effects. It is concluded, therefore, that in industries such as mining where accidents are a serious concern, special measures and evaluation in the use of extended workdays be considered.

Jan 1, 1994

By D. Malhotra

Metallurgists are continuously striving to improve recovery. But optimization of profits and/or revenue dictates that recovery can be sacrificed at the expense of throughput. However, recently there has been significant interest in the concept of retreatment of tailings to enhance recovery and hence revenue while maintaining high throughput. The authors discuss the technical and economic factors that need to be considered in evaluation of the feasibility of retreatment of tailings including the potential feed streams (i.e., rougher tailings, cleaner tailings, etc.) and processing options (i.e., physical beneficiation, chemical processing, etc.). A case study for base metals is discussed.

Jan 1, 1994

By J. A. M. Cano

Pot Grate tests were carried out in the pilot plant at Samarco producing pellets containing SiO2 between 2.0% and 2.2% in a wide range of basicity to be used in blast furnace. These pellets were submitted to tests in Samarco's laboratory and another laboratory in Germany to evaluate the metallurgical properties. The pellets in the binary basicity range (CaO/SiO2) from 0,87 to 0,95 were those that presented the best results in the Pot Grate tests. Based on the results, these pellets are being routinely produced?on industrial-scale confirming the results observed in laboratory tests.?

Jan 1, 1994

By L. N. Hill

The classifiers on the primary grinding circuit at Cyprus Sierrita have been upgraded from 0.66 m (26 in) diameter hydrocyclones to 0.84 m (33 in) diameter hydrocyclones. This has resulted in a 4.3 % (11 t/h) (12 standard tons/hour) increase in mill throughput while producing a flotation feed which contains 4.8% less +300 micron (48 mesh Tyler screen size) material. This reduction in flotation feed particle size has increased copper (CU) recovery by 0.8 %. Various grinding circuit relationships were evaluated. These relationships include circulating load versus throughput, horizontal versus vertical cyclone configuration, and the effect of cyclone components on performance. We conclude that the improvements achieved are due to a shift in the overflow size distribution created by a cyclone diameter more suited to our operation, and by eliminating the cyclone capacity constraint in the grinding circuit.

Jan 1, 1994

By A. Kar, J. Mazumder

"Laser ablation is a process that can be used to synthesize novel nanoscale particles as well as to deposit thin films of various materials. Usually, nanoscale particles and thin films are formed at relatively high and low pressures, respectively, inside the ablation chamber. This paper presents a mathematical model to predict the particle size distribution in the plasma generated during laser ablation. The model is developed by considering the effects of the laser-matter and laser-plasma interactions, the Stefan condition, and the discontinuity across the Knudsen layer. The nanoscale particles are found to be located at the central region of the plasma near the target. The particles have very high velocity and temperature. A good qualitative agreement is observed between the results of this model and experimental data. IntroductionRapid solidification produces novel microstructures whose atomic arrangements and/or chemical compositions are different from those of conventional materials. The conventional materials are either crystalline or amorphous. The crystalline materials have both short- and long-range orders, whereas the amorphous materials have only the shortrange order. The nanocrystalline materials have neither short- nor long-range orders, and for this reason, they exhibit novel properties which are important for synthesizing new materials. The atoms of a nanocrystal can be classified as ""crystal atoms"" and ""boundary atoms"", where the ""crystal atoms"" have the nearest-neighbor configurations similar to the lattice configuration, whereas the nearest-neighbor configurations of the ""boundary atoms"" differ from the lattice configurations 1. Various aspects of the nanoscale materials have been discussed in Refs. [1-7]."

Jan 1, 1994

By John B. Cocanour

The U.S. Bureau of Mines (USBM) has developed a laboratory-scale on-line analysis and process control system for a decopperization electrolytic circuit. This system is software driven, running on a 486DX-33 personal computer (PC) utilizing a portable energy- dispersive x-ray fluorescence (XRF) spectrometer as the sample analyzer. The XRF copper reading obtained was used as the control variable through an RS-232 serial interface to the PC for software-based control of feed flowrates. When the copper concentration in the electrolytic cell (as measured by the XRF) deviated from the set point, the feed flowrate to the cell was automatically altered using software-based proportional-integral-differential (PID) computer control to yield the desired copper concentration at the electrolytic cell outlet.

Jan 1, 1994

By Daniel L. Hanson

This paper presents a case history of the design, installation and performance of a tied-back tangent caisson retaining wall which was constructed as part of the Third Harbor Tunnel project currently underway in Boston, Massachusetts. The Third Harbor Tunnel project consists of a large multi-lane transportation tunnel which is being constructed by the sunken tube method. In this type of construction, the tunnel alignment, slopes and bedding are excavated and installed underwater and the tunnel sections floated over the proper alignment and sunk in place. The tangent caisson retaining wall discussed in this paper was constructed to provide support of the upper portions of the tunnel excavation at the East Boston Portal where the tunnel exited from below the harbor and continued underground on shore. A portion of the tangent caisson retaining wall was also utilized to provide earth support for the barge unloading facility where spoil from the tunnel excavation was transferred to surface vehicles for removal from the site. PROJECT BACKGROUND The tangent caisson retaining wall was constructed by The Millgard Corporation (TMC) as a subcontractor to the Boston Third Harbor Tunnel Contractors, a Joint Venture which consisted of the firms of Morrison-Knudsen Corporation, Interbeton Inc., and J.F. White Contracting Company. The entire project team is listed below on Table 1. The design of the tangent caisson wall system was performed by Hanson Engineering, P.C. (HE) acting as design consultant to TMC. The retaining wall system incorporated a single row of pressure injected earth anchors (tie-backs) as part of the design. The earth anchors were designed and installed by Drill Tech as a subcontractor to TMC.

Jan 1, 1994

By Frank M. Kimmerle

Spent Potlining (SPL) contains recoverable chemical elements (C, F, Na and Al) which are lost in stabilization or immobilization processes primarily aimed at eliminating cyanides and reducing leach rates of soluble fluorides prior to landfiling. They can be recovered in a variety of mineral forms for recycling in the aluminum industry and elsewhere. Alcan has developed a cost-effective hydrometallurgical route, combining a number of proven unit processes to destroy cyanides, recycle the chemical values and provide a zero-discharge process. Pilot plant studies of this Low Caustic Leach and Liming (LCL&L) Process prove that the fluoride scan be converted to acid grade fluorspar, while the sodium and aluminum are recovered as a sodium aluminate and caustic feed to the Bayer Plant operations. The remaining brick and carbon fraction constitutes a high ash solid fuel which meets TCLP leach criteria and whose reduced sodium content enhances its value as a chemical reducing agent.

Jan 1, 1994

Portfolio management tends to separate the functions of Asset Allocation and Stock Selection, so the person responsible for reviewing an expert's report on a company would typically be choosing between companies rather than between a company and cash or bonds. How these choices are made depends on the investment time horizon, philosophy and style. Two styles, momentum investing and value investing are contrasted and the role of valuation methods within the framework of each style is evaluated. Finally, pricing is distinguished from valuation.

Jan 1, 1994

By Nicholas Kyriazi, John P. Shubilla

A joint effort by the U.S. Bureau of Mines (USBM) and the US. Mine Safety and Health Administration (MSHA) was undertaken to determine how well self-contained self-rescuers (SCSR's), deployed in accordance with Federal regulations (30 CFR 75.1714), held up in the underground environment with regard to both physical damage and aging. This report presents findings regarding laboratory-tested SCSR's in the fourth phase of testing from 1989 to 1993. The SCSRYs were tested on human subjects and on a breathing and metabolic simulator (BMS). These results indicate that most of the apparatus, if they pass their inspection criteria, perform as expected except units with manufacturing defects. However, when the apparatus are carried in and out of the mine daily and stored at the working section, they may suffer abuse. Physical signs of abuse, unless extremely obvious, are frequently not detected by the miners or mine operators. In addition, some apparatus collected for this study had not been returned to the manufacturer in a recall effort for correction of a manufacturing defect. In both cases, the apparatus would have presented problems in emergency use. Recommendations include improved training in inspection procedures and better enforcement of recall notices.

Jan 1, 1994

By O. D. Staman

The risk assessment project examines the likelihood of inorganic contaminants from copper dump-leaching operations to contaminate domestic water supplies. The project examines contaminant transport by modeling contaminant movement from the base of a leach pile through the unsaturated zone and into the saturated zone. The modeling effort is unique in that it models infiltration, contaminant transport in the unsaturated and saturated zone combined with geochemical modeling of the unsaturated zone. The project incorporates probability theory to reflect the uncertainty of hydrogeologic parameters.

Jan 1, 1994

By J. D. Miller

The fossil resins of certain western coals are of significance and of sufficient value as a chemical commodity to justify a fossil resin industry. At the present time these valuable fossil resin resources, worth more than $0.50/lb as a chemical commodity, are being burned as fuel for electric power generation. This waste of our fossil resin resources corresponds to a loss in revenue of $200 million per year -equivalent to the value of the coal itself! Improved process technology for the recovery of fossil resin is under development and includes selective flotation of fossil resin from fine coal streams and solvent refining of the fossil resin flotation concentrate to produce a premium resin product. The most recent developments in process technologies are discussed with respect to separation efficiency and product quality. It is clear that the development of a fossil resin industry should not be limited by process technology.

Jan 1, 1994