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By Woodcock JT

This paper reviews the chemistry of flotation pulps with the aim of gaining a better understanding of the effect of chemical environment in flotation and ap- plying the knowledge to improving the con- trol of reagent additions. Theories of flotation are considered briefly, but they are only of limited help in specifying an appropriate chemical environment and in establishing control techniques. The chemical nature of flotation pulps is reviewed. Four distinct phases are present - solids, an aqueous liquor con- taining many dissolved reactive sub- stances, organic liquids, and gases. All of these vary in many ways and interact with each other. It has now been estab- lished that there are many previously- unsuspected materials present in plant pulps that can or might affect flotation. Concentration profiles of selected para- meters in operating plants are given to show some typical changes that occur. Recent advances in collector chemistry, especially that of xanthate and related species, are reviewed. Modes of decompo- sition and/or formation in pulps of xan- thate, dixanthogen, perxanthate, xanthyl thiosulphate, and monothiocarbonate are reviewed, and their W absorption spectra are compared. Some relevant information on dithiophosphates, mercaptobenzothia- zole, and thionocarbamate is summarized, and some speculative comments are made about reactions of these collectors.

Jan 1, 1984

By Maurice L. Madden

An investigation was undertaken for a ground water discharge plan for the Chino mining complex near Hurley, New Mexico. Operations which impact ground water include dump leaching, storage reservoirs, and tailings seepage. The investigation included both hydrogeological data collection and laboratory analysis. A conceptual understanding of surface water and ground water was then developed. Surface water and ground water models were used to match existing conditions and predict the impact of operational modifications. The study concluded that runoff and resulting leach reservoir overflows were primarily responsible for the ground water degradation. Tailings seepage represents a smaller part of the impact.

Jan 1, 1984

By H. W. Kilau

The Bureau of Mines tested chromium-bearing waste slags from industrial stainless steel and other chrome alloy operations to determine their chromium leachability characteristics under acid precipitation conditions and to devise measures to prevent any pollution originating from this source. Two critical slag composition factors were found to control the chromium leachability: (1) CaO:Si02 ratio and (2) magnesium content. Above a 2.0 CaO:Si02 ratio, chromium exists in slag as CaO·Cr203, which can be vulnerable to leaching by acid precipitation especially if oxi-dized to CaCr04 when exposed to the environment over an extended period. Maximum chromium leachability from industrial slags occurred when the composition of the slag had about a 2.0 CaO:Si02 ratio. Between a 1.0 and 2.0 CaO:Si02 ratio, in the presence of sufficient magnesium, MgO ·Cr203 was formed, which is very resistant to oxidation and to dissolution by simulated acid precipitation. Addition of magnesium silicates to molten slag to fix the chromium in the MgO·Cr203 form was successful in preventing chromium leaching in simulated acid rain solutions. Experiments showed olivine and waste taconite tailings were suitable for this purpose. Olivine addition to a waste slag having a composition vulnerable to leaching (CaO:Si02 > 2) reduced the chromium leachability more than 80 pct.

Jan 1, 1984

By Maynard O. Serbousek

The mechanics of load transfer of fully-grouted roof bolts in coal mines has been investigated in laboratory and analytical studies. The purpose of this research is to increase the understanding and better interpret data from pull tests which are routinely performed in the field. Laboratory work includes variation of bolt length, hole diameter and grout type in pull tests. Four-foot bolts were tested in holes of 1- and 1-3/8-inch diameters. Both polyester resins and inorganic grouts were used as the anchorage medium. The bolts were strain gauged at six locations to observe the rate of load transfer from the bolt to the rock mass when a force was applied at the bolt end using standard Jack pull testing procedures and equipment. Analytical studies using closed form solutions and finite-element techniques were compared to experimental results. The models are for the elastic regime only but do include slip elements. A detailed analysis of the load transfer mechanisms from the bolts through the grout to the rock mass is presented.

Jan 1, 1984

By David Butts

Completion of a railroad to the high Tibetan Plateau in Central China has now made it economical to exploit its mineral reserves. Lead and zinc mines are now being established. A potash plant to produce 40,000 tons per year KC1 is now in operation. Plans to produce 200,000 tons per year by 1987 are being implemented. Pilot drilling for oil and natural gas have proved up reserves. Slaughter houses are being constructed to ship yak, mutton and beef from the endless grasslands on the plateau. Research Centers in Xining and Golmud have been completed for the sole purpose of increasing technology and exploitation of the Tsaidam Basin and surrounding area.

Jan 1, 1984

By David Butts

Solar ponding to crystdlize sodium chloride has been used for thousands of years.1 The systems used were inefficient and usually small compared to the large 25,000 acre pond areas seen today. It has only been in the last 25 years that any real effort has been applied to develop solar ponding technology. Many large solar pond systems have been constructed without much thought to efficient and optimum production rates. The recent high costs of labor, of equipment and of energy have forced producers to take a closer look at their solar pond systems in an attempt to squeeze out the highest possible yields. Other companies such as the Arab Potash Company, the Dead Sea Works, Texas Gulf (Moab, Utah) and San Francisco Salt Companies have no more land area in which to expand and therefore efficient ponds are essential. This paper is written to show how the subdivision of solar ponds can result in production increases of up to 20% and beyond.

Jan 1, 1984

By J. S. Dunning

Recent developments in energy conversion, mining and minerals processing, pollution control, and chemical equipment have placed in-creased demands on heat-resistant alloys. Higher corrosion rates from oxidation, hot corrosion, and sulfidation have increased consumption of materials that contain critical and strategic minerals and in many cases have limited productivity. The Bureau of Mines is conducting re-search on substitute materials having greater resistance to high-temperature corrosive atmospheres above 6000 C compared to austenitic stainless steels such as AISI 304, 316, and 310, with the goal of conserving critical metals such as Cr and Ni. The substitute materials are based on Fe-Cr-Ni-Al compositions. Aluminum additions to Fe-Cr-Ni alloys significantly improve high-temperature corrosion resistance, particularly sulfidation resistance. In the alloy, devised by Bureau researchers, aluminum additions are held in the form of a second-phase precipitate, 8NiAl. Minor additions of Ti, Mn, and Si improve workability.

Jan 1, 1984

By J. A. Meech, R. J. Tucker

"Since the establishment of froth flotation as an effective method of mineral beneficiation there has been both academic and industrial interest in the levels of the various reagents required to perform the desired separations. Academic interest was spurred by a desire to understand the mechanisms involved - industrial interest by a need to improve the efficiency of the process. These efficiency improvements can take two forms: cost reductions due to reduced reagent consumption and/or improved separation efficiencies. The latter are indicated by either improved grade-recovery relationships for removal of a valuable mineral from gangue, or improved separation of two similar valuable minerals.The processing of lower grade ore bodies at higher tonnage rates has necessitated increased interest in both reagent consumption and metal recovery. Furthermore, the development of accurate and functional on-stream analysis equipment in the 1960's and 1970's has allowed for a better understanding of the dynamic processes involved in a flotation circuit and has required a more concrete statement of the relationships and reactions between the minerals and chemicals in the flotation pulp. Development of these relationships is necessary in order to make use of on-stream analysis to control the process at, or near its more efficient level."

Jan 1, 1984

Reduce dust generated during bagging at minerals processing facilities, such as silica sand operations. Approach Installation of a new type of bag nozzle system eliminates the major dust sources during the bag filling process. How It Works The drawing illustrates components of the new bag nozzle system. The system differs in several ways from the conventional nozzle system. An improved bag clamp reduces the amount of blow-back during bag filling, because it has direct contact with approximately 80 per-cent of the nozzle. A two nozzle arrangement includes an inner or "fill" nozzle surrounded by another nozzle, which is designed to exhaust excess pressure from the bag after it has been filled. The exhaust is powered by an eductor, which uses a venturi effect to exhaust the bag at approximately 50 cfm. The exhaust exits into a bucket elevator and is recycled. A pinch valve automatically opens and closes the exhaust system to the bag.

Jan 1, 1984

By L. G. Austin

The procedure for scaling breakage parameters determined in a laboratory mill to values for a full-scale mill is briefly presented. A simulation model of a closed circuit mill also requires a model of residence time distribution, a mass transfer law to predict over-filling as a function of flow rate through the mill, and a model to describe classification action. For fine dry grinding, or viscous slurry grinding, it is necessary to allow for slowing-down of breakage rates for a fine mill charge. Four examples of comparing simulation models to actual plant data are presented. The first is wet grinding of copper ore in normal closed circuit at 50 tph (metric) production, under conditions where the mill does not overfill. The second is the wet grinding of copper ore in reversed closed circuit at production of 87, 102 and 108 tph, with flow through the mill of approximately 150, 200 and 300 tph. The third is dry grinding of coal with a hot air sweeping stream to remove all of the coal as air-borne material, in open and normal closed circuit. The fourth is grinding of cement clinker in a two-compartment, air-swept tube mill in normal closed circuit with two different classifiers, producing 120 tph of 3250 Blaine cement. In all cases the simulated capacities and product size distributions were in reasonable agreement with actual plant performance.

Jan 1, 1984

By B. Pina

The conversion of maf coal to pyridine solubles and gas was investigated in a microautoclave batch reactor for two Kentucky washed coal samples (Ky. #9 and Ky. #11). Solvent hydrogen donor strength was controlled by the tetralin content of a mixed 1-methyl naphthalene-tetralin solvent. Primary liquefaction conversions greater than 90% in 10 minutes of reaction time at 427°C were achieved in liquefaction solvents with moderate hydrogen-donor strength (circa 40% tetralin). A modified irreversible first order rate expression, containing a parameter (a) to account for the intrinsic reactives of the maf coal, described the experimental kinetic data rather well. The integrated form of this rate expression is -k1e x = a (a- ß)e (eq. 1) Parameter ß in equation (I) is the pyridine solubility of the starting maf feed coal, x is the primary liquefaction fractional number of conversion, k1 is the specific reaction velocity constant and ? is reaction time. Primary liquefaction rate was found to be quite temperature sensitive and independent of coal when a liquefaction solvent containing 40% or more tetralin was employed. Primary liquefaction rate appears to depend on liquefaction solvent hydrogen donor strength for solvents containing = 40 wt.% tetralin. The intrinsic reactives in the maf feed coal or a appear to depend mainly on the inertinite group maceral content of the coal for the two coals studied in liquefaction solvents containing 3 40wt.% tetralin. In contrast, a appears to decrease in liquefaction solvents of low donor strength., i.e; solvents with less than 40wt.% tetralin.

Jan 1, 1984

By R. L. Weigel

As Florida phosphate mining gradually moves from the Bone Valley formation to the Hawthorn formation, a greater portion of the minable deposit contains dolomitic diluents which result in lower product grades that can be detrimental to the production of phosphoric acid for fertilizer uses. One beneficiation technique found applicable to the phosphate pebble size range (3 X 16 mesh) is heavy media separation using suspensions of magnetite and ferrosilicon. As part of an ongoing investigation of dolomite removal technology, a pilot heavy media cyclone system was constructed by IMC and used in the testing of a variety of drill core composites and hulk samples. The results of these tests were used to develop a predictive model for heavy media cyclone separation based on pebble fraction assays and heavy media operating parameters. This model is currently being used in the evaluation of specific future mining areas.

Jan 1, 1984

By J. A. Eisele, G. E. McClelland, M. D. Wroblewski

The Bureau of Mines is conducting research at its Reno Research Center to develop a staged agglomeration-heap leaching system and to electrowin the dissolved precious metals from the pregnant leaching solution. For direct electro- winning to be successful, the pregnant solutions generated during the Initial stages of leaching must be higher grade than obtained by conventional heap leaching. The precious metal concentration of the pregnant solution can be Increased by agglomeration pretreatment with cyanide solution which starts the leaching process during the curing period, by leaching with small volumes of solution and by cycling the leaching solution through more than one heap in a staged manner. The resulting pregnant solution is passed directly through an electrowinning circuit. The barren solution from electrowinning is recycled to the leaching circuit. Bench-scale research on the development of the staged leaching system and on the development of an efficient electrowinning cell are described. The Bureau of Mines developed agglomeration- heap leaching technology. This technology was readily adopted by the mining Industry for heap leaching crushed ores and mine wastes. Current research involves the application of this technology to finely ground feed materials such as precious metal-bearing milled tailings. Tailings agglomeration-heap leaching has also been used commercially.

Jan 1, 1984

By Dean S. Rogers

The conventional role of exploration, development and grade control is examined in this paper within the context of the many and varied types of gold occurrences which are found at the Dome Nine. The account endeavours to trace the development of the total ore evaluation process, from diamond drilling through the exploration and drifting stage, to the stope development and planning phase of the operation, with an emphasis on sampling techniques and assaying procedure. The concept of ore reserve calculations is developed and the practice of grade control is described. In summary, the role of the geological, the engineering and the mining department is presented in relation to the contribution each has to make in the evaluation and exploitation of ore from one of the world's classic Archean gold deposits.

Jan 1, 1984

There are two mechanisms in the flo- tation process by which particles are transported from the pulp to the con- centrate: bubble-mineral aggregation and entrainment. It is the chemical processes which occur in the pulp which are critical to the success of flotation since they control the floatability of different min- erals and the selectivity which can be obtained. However, these chemical pro- cesses are so complex that metallurgists are still limited in their ability to predict the floatability of particles in industrial circuits by consideration of the minerals present and the chemical environment. The alternative approach to understand- ing flotation is to examine the behaviour of minerals in industrial flotation pro- cesses, to recognise similarities and differences, and to define the "laws" which appear to apply. Using this ap- proach it has been found that minerals float at a rate which is proportional to their concentration in the pulp, and that the rate of flotation of different min- erals is influenced by variables which' affect the pulp or the froth phase. The ultimate application of this approach is the use of models for circuit simulation purposes. It is this alternative approach which is the theme of this paper. One of the most important problems in understanding the technology of flotation has been in defining the characteristics of the particles being floated. Particles entering flotation vary widely in size and mineral composition, and different par- ticle types float at different rates. These rates do not change uniformly as operating variables change. It has been conventional practice to assess flotation performance in terms of the metal contents of total streams because no better method has been available, and this procedure has obscured important effects which occur in

Jan 1, 1984

A 36-year-old A-S-H pump, manufactured to designs dating back to 1936, was recently presented to the Gold Mine Museum by Envirotech. The pump, a B-frame three-piece rubber-lined Hydroseal unit, was supplied by Envirotech's predecessor company, Denver Machinery, and was installed by South Roodepoort Main Reef Areas Limited on 22nd March, 1948. Metals, materials, manufacturing The 37th Annual Conference of the Australasian Institute of Metals will be held in Ballarat (Australia) from 13th to 17th May, 1985. 1985is the Sesquicentennial year of Victoria, and for the first time the historic City of Ballarat has been chosen as the venue for an Australasian Institute of Metals congress. Steel rolling Conferences on steel rolling, sponsored by The Iron and Steel Institute of Japan (ISH), and supported by iron and steel institutes in many countries of the world, have been held since 1980. The first conference was held in Tokyo in 1980, sponsored by The Iron and Steel Institute of Japan.

Jan 1, 1984

By E. B. Thorn

The production of portland cement requires that four basic elements -- calcium, silica, alumina and iron -- be ground to a fine powder, homogenized, and fed to the pyroprocessing unit, where it is burned to a cement clinker. The raw material must either be ground wet in a slurry form or dried and ground to a dry powder, with a fineness of approximately 85% passing the 200 M screen. According to the Portland Association's Plant Information Summary, approximately 38% of the U.S. capacity is ground wet and 62% ground dry. The following data is taken from the Portland Cement Association's 1981 Energy Survey: [Million BTU/Ton kW h/Ton Wet Process Plants 5.86 138 Long Dry Process Plants 4.97 123 Dry Preheater Plants 4.03 157 ]

Jan 1, 1984

By K. R. Weller

The Ardlethan Tin Ltd. concentrator typically recovers 55% of the tin in a gravity concentrate at 51% grade from fresh ore assaying 0.5% Sn. Coarse gravity concentration is performed in a complex circuit involving Reichert cones, spirals, shaking tables and two regrind mills. The paper describes how flow and size-by-size sample data from a steady-state survey were used to construct a computer model of the plant involving 46 process streams. The data reduction involved a computer- aided mass balancing technique, recovery-size modelling of gravity concentrators and the use of a mineral dressing flowsheet simulator. The model was used to simulate possible rearrangements of the available equipment. Early simulations indicated that improved performance could be obtained by using spirals to-treat cone middlings or tailings rather than cone concentrates. A test spiral rig was used at Ardlethan to determine typical performances for all cone product streams and the results were incorporated in new simulations. A revised circuit was recommended and implemented by Ardlethan Tin as far as physical restraints within the plant would allow. Production figures show that a substantial increase in tin recovery and 10-15% increase in milling rate were achieved following the circuit changes, and these improvements were sustained over a six month period.

Jan 1, 1984

By James A. Everts

Calcined bauxites are classified by their major end uses - abrasives and refractories. Target properties are dictated by application and processing requirements. The chemical and physical properties of premium grade calcined bauxites are far more stringent than metallurgical bauxite and this limits the sources and availability. Premium grade calcined bauxites are considered to be strategically critical to the industrialized countries of the world. Subject to disruptions in the key source countries, adequate supplies of premium grade calcined bauxites are anticipated in the foreseeable future.

Jan 1, 1984

By Paul R. Kruesi

A patent-applied-for process has been developed in which zinc chloride is extracted by tributyl phosphate in kerosine, and stripped with ethylene glycol or ammoniated ethylene glycol. The anhydrous zinc chloride is precipitated from the glycol as the ammine and zinc chloride is prepared by thermal decomposition with recycle of ammonia. The process permits the production of high grade zinc from scraps and drosses. Its applicability to the recycling of zinc will be illustrated.

Jan 1, 1984