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By W. H. (Bill) Jay

The destruction of cyanide creates a significant impost on the financial returns of gold mines. These losses increase substantially when ores containing cyanide-soluble copper are treated. Failure to remove or destroy free or WAD cyanide before it is discharged into tailings dams has, on a number of occasions, led to significant fish, bird and animal deaths. Thus, the retention of cyanide within the leach circuit and the recovery or removal of stable metal cyanide complexes needs to become standard practice for all gold mining operations. Furthermore, reducing cyanide purchases will minimise the quantity of cyanide transported to the mine site thereby reducing the opportunity for spillage of this chemical. Many different physical and chemical methods have been investigated for the removal of cyanide from process solutions. All cyanide destruction methods create a financial impost on the economic viability of the gold mine. To reduce these costs, the recycle of cyanide and the economic recovery of the metals solubilised by cyanide is of prime importance. The alternative methods currently in use, or under consideration for the treatment of copper cyanide, entail high reagent costs, produce the recovered metal in a contaminated form and require the safe handling of hydrogen cyanide. These processes will be briefly discussed within this report Environmental and financial benefits are enhanced by recent laboratory and pilot plant studies conducted by Oretek Limited. The Oretek CPC process for the recovery of copper and the recycle of cyanide from copper cyanide-containing solutions does not require pH adjustment to the alkaline cyanide leach conditions. Copper ions are coordinated to a water-soluble and/or an organic soluble polychelating agent under alkaline conditions and the cyanide ions are displaced Membrane separation, or phase separation of the polychelated copper from the cyanide ions enables the cyanide ions to be recycled and the copper to be directly electrowon from the polychelating polymer. The polychelating polymer is then recycled. Ion exchange resins and solvent extraction systems which may be incorporated into the above process will also be discussed in detail.

Jan 1, 1998

Currently an Australian Standard for tunnel fire safety is being developed for road and rail tunnels. Other local guidance relating to tunnel fire safety that has recently become available includes publications by both the Roads and Traffic Authority and RailCorp of New South Wales. Internationally, the World Road Congress has completed its 2004 - 2007 cycle, which has resulted in a number of publications. International developments in rail guidance include a new European Standard regarding fire safety in railway tunnels that will come into effect in July 2008. In addition, the National Fire Protection Association committee NFPA 130 are in the process of revising their standard for fixed guideway transit and passenger rail systems, which is due for publication in late 2009. This paper outlines the status of these and other recently published relevant local and international fire safety guidelines and their implications for tunnel projects in Australia.

Jan 1, 2008

By Eduardo Montenegro

Apesar da relevância e interesse do tema de gerenciamento de alarmes na comunidade técnica industrial, observa-se que poucas empresas têm, de fato, implantado e conseguido extrair melhores resultados na eficiência e segurança operacional de suas plantas. O presente trabalho visa, a partir das experiências dos autores em implantação e acompanhamento de vários sistemas de gerenciamento de alarmes na indústria, discutir os principais motivos pelos quais estes sistemas falham em conseguir índices melhores em operação, monitoramento e gestão de alarmes. Além disso, propõe-se neste trabalho que estratégias, práticas e ferramentas sejam adotadas para que se consiga o máximo de benefício operacional ao se implantar e manter tais sistemas.

Aug 16, 2017

By Theodore Simons

Permission to present this paper at the February, 1915, meeting of the Montana Section of the American Institute of Mining Engineers was liberally granted by W. A. Clark, Jr., President-and General Manager of the Timber Butte Milling Co., and by the representative of the Minerals Separation Co. For the many courtesies shown the writer on his visits to the mill and for information supplied, he is indebted to all the officers of these companies, especially to W. N. Rossberg, W. D. Mangam, Hamilton Cooke, Jr., T. M. Owen, T. C. Wilson, R. McGillivary, L. L. Quigley, C. Bartzen and others. The writer takes this opportunity to herewith express to them his appreciation and sincere thanks. Location of Mine and Mill The concentrator of the Timber Butte Milling Co. was built to treat the ore mined at the Elm Orlu mine of the Elm Orlu Mining Co., which carries zinc and lead in sphalerite and galena; copper in bornite, chal-cocite, tennantite, and tetrahedrite; and gold and silver either free or chemically combined with the sulphides of the base metals. The gangue is chiefly quartz, barite, fluorite, rhodonite, and rhodocrosite. The iron in the ore occurs as irqn pyrites. The Elm Orlu mine is situated in Butte, Silver Bow County, Mont., near the northern border of what is locally known as the Butte sulphide-copper belt, about one mile north of the Anaconda mine, and adjoining the Black Rock zinc mine of the Butte & Superior Co. on the southwest. The mill is on the northern slope of Timber Butte, a prominent topographical landmark in the Butte district. This site permits to a large extent the gravity system of ore flow; it presents a convenient and extensive area for a tailings pond; and it is comparatively near to the source of water supply and to existing railroads.

Jan 1, 1916

By R. R. Wells, K. C. Vincent, A. O. Ipsen

"INTRODUCTION The Philipsburg Mining District, Granite County, Mont., has been the largest producing area for battery-grade manganese (70 percent MnO2) in the United States since the First World War. Two companies, the Trout Mining Division of the American. Machine & Meals Co., and the Moorlight Mining Co., have intermittently mined and milled 120 to 250 tons of 25-percent manganese ore per day for the production of concentrates of this grade.Investigation of the district by engineers of the Federal Geological Survey and Bureau of Mines indicated that further exploration and develop¬ment would make available additional oxide and carbonate manganese ores for milling and production of metallurgical-grade manganese. If the battery-grade producers converted their plants to the production of metallurgical-grade concentrates, their production also could be increased through greater recoveries.Until February 1, 1944, the Metals Reserve Company, through its agent, the Sunshine Mining Co., purchased milling-grade manganese oxide and carbonate are for stock-piling at Philipsburg. After that time, only carbonate ore was purchased. Based upon the assumption that the stock pile was a true cross-section sample of the producing area, metallurgical studies were made on representative samples from the Metals Reserve stock piles. Testing also was conducted on two other samples of Philipsburg oxide manganese ore obtained by engineers of the Bureau of Mines from the Little Dandy claim of the Donlan group and from the Marie mine. All ore samples tested were found to be amenable to concentration by ore-dressing methods for the production of concentrates that when sintered met Metals Reserve Company specifications for metallurgical-grade manganese."

Nov 1, 1947

Several short color films describing new technology developed through Bureau of Mines research are available on a loan basis. The films review results of Bureau research programs aimed at aiding the minerals industry by increasing mine productivity, ensuring worker health and safety, and enhancing minerals recovery, processing and recycling. Most of the films are available in a choice of for mats: 16mm film, ½" VHS cassette tape, or ¾" U-matic tape. The films are loaned by the Bureau of Mines free of charge; borrowers are requested to pay only the return postage and for any damage to the films. All titles are also available for purchase in 16mm or videotape formats. Interested persons wishing to borrow or purchase a film should specify its title and the preferred and alternate showing dates. All requests should be addressed to: Motion Picture Library Bureau of Mines Cochrans Mill Road P.O. Box 18070 Pittsburgh, PA 15236 A short description of each film follows: Safer Coal Mining Equipment Traces the development of modified conventional and continuous mining equipment, beginning with an investigation of the problems encountered with mining equipment and continuing through long-term testing of the modified equipment in two mines. "Human engineered" coal mining machines are shown in operation. These machines include features such as adjustable cabs, easy access controls, improved illumination, and other safety improvements. (19 min)

Jan 1, 1986

By W. B. Berwald, T. W. Johnson

"The United States Bureau of Mines, in cooperation with the Natural Gas Department of the American Gas Association, has been studying actively for the past several years the flow of natural as through high-pressure pipe lines. 4 This report deals with that part of the study involving the design of pipe-line systems consisting of lines laid parallel to each other. The lines are referred to as the original line and the parallel line. The paralleling lire may or may not extend the entire length &f the original line; however, the parallel line is connected at its two ends to the original line.As a result of the large expansion of the natural-gas industry almost all markets within economic distance, from the developed as fields have at least one pipe line supplying them with natural gas. Small increases in the consumers' demand for natural-gas can be met usually by increasing operating pressures, but any marked increase in demand necessitates paralleling sections of the existing systems. It is believed that to a large extent future expansion in the natural—gas industry will consist of paralleling the present lines. The several formulas given in this report have been developed to aid in the design of such systems. Curves and tables were prepared from these formulas to simplify the calculations materially and to facilitate determination of the sizes of pine to be used in paralleling various diameter lines to give the most economical design. The formulas are presented without detailed derivations, as a complete report on the flow of natural gas through pipe lines is being prepared which will contain the derivations of these formulas. Examples included here show the detail of application of the several formulas to problems of design of parallel lines."

Jun 1, 1934

By J Coward, S Bulatovic

There are currently two operators producing oil from the surface-mineable portions of AlbertaÆs oil sands (Syncrude Canada Ltd and Suncor Inc) and two other companies are proposing to enter the industry (Albian Sands Energy Inc in 2002 and True North Energy LP in 2004). Tailings from the two current oil sands plants contain approximately 220 000 tonnes per year of TiO2 and approximately 80 000 tonnes per year of zircon. This represents approximately six per cent of the worldÆs TiO2 consumption and approximately nine per cent of the worldÆs zircon production. With the commissioning of plants by Albian and True North, and the announced expansion of plants by Syncrude and Suncor, it is expected that these tonnages could quadruple in the next ten years. All of these operators have at least 50 years of reserves even at these expanded production rates. The occurrence of heavy minerals in AlbertaÆs oil sands has long been known and is well documented in the literature. There have been a number of attempts to produce market-grade products from this resource and the results of this work have been quite mixed. Typically, researchers have used the normal mineral dressing techniques of the industry and have found the mineral assemblage does not respond to these techniques all that well. This has led to the widely-held suspicion that there must be some difficult metallurgical problems associated with this resource. There are three main problem areas that have created difficulties for previous researchers:the bitumen coating on the sand grains; secondary mineralisation such as pyrite, siderite and calcite; and a high proportion of aluminosilicates (approximately 25 per cent) that have the same gravity, electrostatic and magnetic properties as other minerals in the heavy mineral suite. Recent work by Lakefield Research shows that these problems can be largely overcome with some novel approaches. The bitumen can be removed by washing with a solvent in the presence of a demulsifier; the pyrite can be removed by flotation; and the titanium and zircon minerals can be separated by selective flotation followed by conventional electrostatic and magnetic separation.

Jan 1, 2001

By E. O. T. Simpson

"IntroductionAS COMPARED with coal mines in the United States, and even with some of those in eastern Canada, the coal mines of western Canada, generally speaking, :have made little progress toward mechanization at the working faces. So far as Vancouver island is concerned, there are three main reasons for this : ( 1 ) in some areas, conditions• easy for hand-loading but unsuitable for mechanical loading make high outputs per man •possible by the former method; (2) faulting of the coal seams in ..some areas precludes long-term planning and the introduction and efficient use of expensive equipment; (3) thinness •and other characteristics of the seams in many areas favour hand-loading.No. 8 MINENo. 8 mine of Canadian Collieries (Dunsmuir), Limited, is located in the Cumberland sub-area of the Comox coalfield on Vancouver island about 90 miles west-northwest of Vancouver. The geological structure of this coalfield has been described by J. D. McKenzie. The seams occur in the Comox formation, a subdivision of the Upper Cretaceous Nanaimo Group. The formation is of near-shore origin and was laid down on an irregular surface of' older rocks. The irregular generally have a northeasterly dip, modified by gentile folds and by a •few large, and a number of smaller, faults.Four seams have been worked in the Cumberland area and all vary in thickness and in the amount and number of interstratified bone and rock •bands."

Jan 1, 1953

By John S. Ball

Aniline points have been used to some extent for more than 20 years. to indicate the types of structures in hydrocarbons and thus to analyze mixtures of hydrocarbons . This type of analysis has been applied - principally to the low -boiling hydrocarbons found in the gasoline range . Although there is some disagreement as to their merits , both aniline point and diesel index (aniline point in degrees Fahrenheit times A.P.I. gravity at 60 ° F. divided by 100) are used rather extensively for evaluating ignition qualities of diesel fuels . In recent years aniline points have been employed in the study of lubricating - oil fractions . They also have been used to predict : the tendency of different oils to cause swelling of synthetic rubbers.5/ Recent standardization of the aniline - point determination by the American Society for Testing Materials has encouraged wider use of this test . Considerable data concerning , aniline points and critical solution temperatures in aniline have been accumulated in the course of a study of related subjects . Thesc data , together with some original results , are presented here in the hope that they will prove useful to other worker's in this field ...

Oct 1, 1943

By W. L. Staker

The Bureau of Mines investigated methods for selectively eluting mercury, silver, and gold from strong-base anion-exchange resins, including Rohm and Haas resins lRA-430 and 900 and Dow Chemical resins 2lK, SMA-I, and SBR. Resins were typically loaded to 145 oz/st of each metal. Loaded resins were eluted with H2S04, NaCl-H Cl, NaOCl, and NaCl04 solutions. The resins tested had similar elution characteristics for mercury and precious metals. The best selective elution scheme was achieved by eluting in a column with 2N H2S04 to recover 99 to 100 pct Hg, with 200 giL NaCl in IN HCI to rec;ver 99 to 100 pct Ag, and with 2M NaCl04 to recover 79 to 89 pct Au.

Jan 1, 1987

There are a number of factors affecting the discovery and develop- ment of uranium in Australia which makes this mineral almost unique and quite different from other minerals. I. The role of the Australian Government, which initially encouraged the discovery by offering rewards to prospectors who discovered deposits that could become economic. 2. At a later stage, the Commonwealth and South Australian Govern- ments prevented the development and production of "new mines" by refusing to grant mining title and refusing to allow sales of uranium by not issuing export permits. 3. The unique property that uranium and its daughter products possessed, i.e. radioactivity, meant that any person who purchased a geiger coun- ter could go prospecting, even though they had no previous experience in prospecting and they had an equal opportunity of discovering a new deposit as a company or independent geologist. 4. Because the exploration/demand for uranium didn't occur until the 1940s very little background geological information or models were available and so the early discoveries tended to become the locus for exploration rather than moving into areas which might on geological concepts lead to exploration programmes based on geological models. Because of the lack of knowledge there was the exchange of geologists from the U.S. Geological Survey and the South Australia Geologist Survey.

Jan 1, 1988

By AIME AIME

The first Diesel-electric locomotives for the Mesabi iron range of the Lake Superior district were put into service last summer by the Oliver Iron Mining Co., U. S. Steel subsidiary. There were ten of these locomotives, rated 1000 hp. and weighing 125 tons each. They are designed for service from 16 to 24 hours per day to haul trains of loaded ore cars from open-pit mines, 200 to 400 ft. deep, on a two to eight-mile haul to the top of the pit. The locomotives push or pull the trains over switchbacks and up heavy grades with 5 per cent maximum against the load. High tractive effort, less smoke, and ability to negotiate sharp curves were among the reasons for the selection of Diesel-electric locomotives.

Jan 1, 1941

Discussion of the paper of DR. L. EDELEANU, presented at the Pittsburgh meeting, October, 1914, and printed in Bulletin No. 93, September, 1914, pp. 2313 to 2332. F. W. BUSHONG,* Pittsburgh, Pa.-This process of extraction is particularly advantageous in the case of Roumanian oil, on account of its high aromatic content. I have prepared a paper, which will appear probably next month in the Journal of Industrial and Engineering Chemistry, describing a series of two-degree fractions of oil from the Nowata field in Oklahoma. I have made extractions with liquid sulphur dioxide in accordance with Dr. Edeleanu's method, and found that the Oklahoma oils, for instance the kerosene fractions, are purified in this way, although the quantity taken out does not at all compare with that taken out of the Roumanian oil. I have made careful analyses of separate fractions, before and after extraction, and they show a very distinct fractional separation-. I like the distinction, brought out by Dr. Day in previous discussions, in regard to oils, rather than oil, and his beautiful illustration of fractionation. Just as fuller's earth, and other clays, will enable us to obtain lower-boiling fractional portions of the oils, and eventually retain a residuum which is hard to get rid of, or to remove, so there is an advantage to be gained by the use of a reagent which begins at the other end by taking out these last constituents first, namely, ozone. I have also analyzed the ozonides and they are derivatives of hydrocarbons very much poorer. in hydrogen than we have heretofore supposed. Similar results have been obtained with Roumanian, Russian, and Italian petroleums. Furthermore, I have prepared ozonides from a fraction of Oklahoma oils, both before and after ex-' traction with liquid sulphur dioxide, and found that the ozonide obtained from the extract is the same as that precipitated out of the original oils. In other words, the residual substance, which the fuller's earth retains, is the one first thrown down by the use of ozone, but it may also be extracted by liquid sulphur dioxide- and be thus separated in apparently unaltered condition. The analysis of this extract corresponds to the formula C15H20, which is surprising, since it is lower in hydrogen content than we have been in the habit of considering among the constituents of our oils. The extract was probably contaminated with other hydro-carbons, but I think it is unquestionable that we must look for hydro-carbons in petroleum which correspond to a formula at least -as low in hydrogen as C15H2o, and possibly even as low as C15H16.

Jan 4, 1915

By Tassos Grammatikopoulos, Mike Johnson, Niels Verbaan

Seabed polymetallic nodules, which contain significant quantities of metals key to electrification such as nickel (Ni), cobalt (Co), copper (Cu) and manganese (Mn) can be processed using several different metallurgical processing options, including direct smelting and subsequent hydrometallurgical refining of the copper/nickel matte; ammoniacal leaching (gas reduction or Cuprion); and acid leaching (often reductive). Many of these approaches suffer from reduced cobalt extraction, difficult physical performance, or overall circuit complexity in general, leading to increased risk to the overall project. SGS has considered the pressure acid leaching of nodules for further investigation, as publicly shared data on this processing route stem from the 1970s and 1980s, and are not always easily accessible. This article details the series of tests conducted and provides updated results obtained — high Ni/Co/Cu recovery with limited manganese/iron (Mn/Fe) — as well as comments on the potential treatment options on the product solution and residue.

Sep 1, 2025

By B. Hines

Grinding efficiency in a vertical stirred mill is affected by a wide range of process and mill configuration variables. Of these, the media fill, size, and intrinsic density have a significant effect on power draw and grinding performance. Media-related factors that influence grinding performance include, e.g.,a higher media filling providing additional particle breakage sites, or a lower bead density decreasing the running torque at a given media filling. It has been estimated that the grinding media can cause up to a 30% change in the specific energy required to grind. FLSmidth has generally recommended that the intrinsic density (specific gravity) of the grinding media be more than triple the slurry density. This density difference helps to ensure that sufficient stress intensity is generated in the mill to provide particle breakage. It also reduces the chance of media ?float? if there is a spike in either slurry density or slurry flow rate. The VXPmills have historically operated at slurry density values between 1.2 and 1.5 kg/L, which translates to nominal bead intrinsic density range between 3.6 and 4.5 kg/L. The current trend towards regrinding bulk flotation concentrates to even finer sizes, to improve recoveries of fine grained minerals, has provided motivation to consider closed-circuit operation of stirred media mills. The slurry density in this application is typically higher than in open-circuit operation due to the higher percent solids in cyclone underflows. An additional effect is that closed-circuit operation increases the potential for media float due to higher flow rates as slurry is recycled to the mill. The normal progression in extending the operating range of existing equipment is to carry out laboratory testing before pilot-scale and plant-scale trials. The results presented in this paper examine the media density to slurry density ratio and its effect on grinding performance.

Feb 23, 2014

It has been fairly firmly established (Fisher, N. H., 1945) that the fineness of the gold in any ore deposit varies with the depth from the surface at which the deposit was formed, and, as a corollary to this, that it is dependent upon the temperature and pressure at the time of deposition. This relationship is such that, under certain conditions, the gold fineness, taken into consideration with other recognised criteria, furnishes a very sensitive and reliable guide to the relative temperature of ore formation, at least within the epithermal and the upper part of the mesothermal range.Definition of Fineness.The fineness of gold is calculated in parts per thousand and refers to the proportion of gold present in the naturally occurring metal in the lode, which is actually a gold-silver alloy, containing usually about 10 parts per thousand of base metal and up to 500 parts perthousand of silver. A clear distinction should be made between fineness and gold-silver ratio. The latter refers to the total gold and silver in the lode as determined by assay and is usually expressed as the ratio Au:Ag. Only in deposits where other silver-bearingminerals are entirely absent, which occurs comparatively rarely, can the gold-silver ratio be used as a measure of gold fineness and, in many cases, the two have no relationship. For instance, in the Edie Creek area in New Guinea, the lodes formed under shallow epithermal conditions all carry gold 500 to 550 fine, although the gold-silver ratio ranges from 1:100 to 1:1, in places in adjacent lodes.Determination of Gold Fineness.The fineness of lode gold can be determined only after it has been separated from all other minerals. Amalgamation recovers gold fairly cleanly - unless native silver is present - and the fineness of amalgam bullion is generally a reliable indication of the correct fineness of the gold. If the use of plates is involved, the bullion may be adulterated, but the effect of any copper, or other metal, that may have been introduced can be cancelled by assuming that the gold and silver shouJrl add up to about 990 fine, or by ignoring the base metal content altogether, which varies little in naturally-occurring gold, and in calculating for comparison purposes all fineness figures to the basis Au + Ag = 1,000.The composition of bullion obtained from cyanidation is generally intermediate between the true gold fineness and the total gold-silver proportion as determined by assay of mine or mill-head samples of Cyanide solution dissolves other silver-bearing minerals and the fineness of the resulting bullion is thereby lowered. Consequently, the fineness of cyanide bullion rarely corresponds to the true gold fineness and is useless for diagnostic purposes, although it is a common fallacy to refer to the fineness of cyanide bullion as the fineness of the gold.

Jan 1, 1950

By C. Isaac Garcia, Sihai Jiao, Anthony J. DeArdo

"A practical model based on the Hill analysis has been developed to calculate the Lankford value of interstitial free (IF) steels and its distribution in different rolling directions, by considering only a few selected texture components. The Texture Intensity Ratio (TIR), i.e. (111 ) /(100), was used in the model to describe texture. By using the new TIR parameter, the texture-based prediction models can be used more easily to predict the Lankford value in a rather straightforward way.IntroductionThe deep drawing capacity of sheet steels is generally indicated by the Lankford value, which is mainly determined by the texture in steels1. Traditionally, various models derived from the Taylor model are employed to calculate the Lankford value from the texture2-4. In such models, the plastic deformation of steel is assumed to be the result of the slip of dislocations in certain slip systems, i.e., by either pencil glide or restraint glide. The slip direction is the <111> direction. In the case of pencil glide, the slip is thought to be possible in all crystal planes with the <111> crystal direction. Assuming the material is elongated in the X1-direction by d n and compressed in the X2 and x3-direction by qd n and (l-q)d n, respectively, corresponding to a deformation tensor"

Jan 1, 2001

By Z. Jin, D. DePaoli, P. Zhang

"Phosphorite, or phosphate rock, is the most significant secondary rare-earth resource. It contains high amounts of phosphate-bearing minerals along with low contents of rare earth elements (REEs). In Florida, about 19 Mt of phosphate rock are mined annually and most are used to manufacture fertilizers using a wet process, in which sulfuric acid reacts with phosphates to produce phosphoric acid and phosphogypsum. In the wet process, REEs are also leached out into solution and eventually get lost in the leaching residue and phosphate fertilizer. Recovering REEs from Florida phosphate rock in the wet process will be beneficial to broadening rare-earth availability, improving the quality of phosphoric acid product and protecting the environment.This study focuses on the influences of wet-process operating conditions on REE leaching efficiency. The results indicate that REE leaching efficiency increases with phosphoric acid addition in the initial pulp. At a temperature of 75 °C, a stoichiometric ratio of sulfuric acid (H2 SO4 ) to calcium oxide (CaO) of 1.05 and a weight ratio of liquid to solid of 3.5, REE leaching efficiency reached a relatively high value of 52.82 percent. The trends of REE leaching efficiency were similar to those for phosphoric acid (P2O5 ). Extensive tests on the leaching residue showed that during leaching, about 90 percent of the REEs were released from the phosphate rock but only 52.82 percent ended up in the leaching solution. This phenomenon can be attributed to two factors: (1) the effect of phosphate ions (PO4 3-) in the solution, which caused REE ions to form REE phosphates and be precipitated into the leaching residue, and (2) the influence of large amounts of anions such as sulfate (SO4 2-), dihydrogen phosphate (H2 PO4 -) and hydrogen phosphate (HPO4 2-) anions as well as the polar molecule H3 PO4 , which surrounded the REE cations and formed an ion atmosphere that prevented the PO4 3- from contacting and combining with REE cations. Interaction of these two opposite effects determined the REE distribution between leaching solution and residue."

Jan 1, 2017

By Peter Hayes, Evgueni Jak, Taufiq Hidayat, Gary O’Connell, Denis Shishin, Jeff Chen, Francis Letarte

"Knowledge of slag properties is required for the optimisation of smelting operations. The phase equilibria and viscosities of the Al2O3-CaO-FeO-Fe2O3-MgO-MnO-NiO-Cr2O3-SiO2 slags at conditions of interest to Koniambo Ni-laterite smelting operations have been investigated. High-temperature re-equilibration phase equilibrium experiments of industrial slags followed by rapid quenching and direct measurement of phase compositions using electron probe X-ray microanalysis (EPMA) have been undertaken in the olivine and pyroxene primary phase fields at temperatures between 1475 and 1600°C and SiO2/MgO weight ratios between 1.57 and 2.09. Phase equilibria predictions were performed using FactSage thermodynamic software. A slag viscosity model available in the FactSage thermodynamic package has been used to calculate the viscosities of the liquid slags. The Einstein-Roscoe equation combined with the predicted phase equilibria data have been used to estimate the viscosities of the slag slurries (slag + solids). The information provided can be used to assist in the evaluation of the furnace performance, to assess further optimisation of slag composition and to explore possibilities of targeted feed changes.INTRODUCTION One of the key steps in the production of ferronickel from nickel laterite ore at Koniambo Nickel SAS involves reduction and smelting of pre-dried nickel-bearing saprolitic ore (high Mg and Si) in an electric furnace at temperatures up to 1650°C. The characterisation of the slag properties as functions of key operational parameters, such as, temperature and composition, including liquidus, the proportions of solids and viscosity, is essential for improving control and optimisation of the operations. The slag produced in the smelting process is a complex oxide system with the major chemical components including Al2O3, CaO, Cr2O3, “FeO”, MgO, “MnO”, “NiO” and SiO2. Characterisation of these multi-component systems using a solely experimental approach becomes increasingly complex as the number of components is increased."

Jan 1, 2017