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By M. S. Alam, Jae-Chun Lee, M. Tanaka, K. Koyama

Extensive research work is being carried out at AIST for developing energy saving green technology for base and precious metals recovery. In the present work, a new flowsheet is developed for copper recycling from waste electronic circuit board where copper was recovered by leaching followed by solution purification and direct electrowinning of Cu(I) from ammoniacal alkaline solution. In this new technology, power consumption in EW circuit was greatly reduced. This paper describes the overall process with an emphasis on different aspects of solution purification where impurities were selectively removed by cementation and solvent extraction techniques under nitrogen atmosphere.

Jan 1, 2004

By M. Moats

World copper refining tankhouse practices have been surveyed. This survey is a supplement to previous surveys that have been carried out in the 1987, 1991, 1995, 1999, 2001 and 2003. On a world basis, process technology trends include the further installation of automated electrode handling systems including permanent cathode systems, automatic anode preparation and cathode handling machines, section switches, fully automatic cranes and polymer concrete cells. General plant process control has increased with more automation of material handling in the copper refining tankhouse. The general trend for most greenfield copper refining projects remains in eastern Asia.

Jan 1, 2007

By Z. -G. Ren, J. -S. Qian, Y. -G. Yang

The waste slags from chemical and metallurgical plants contain approximately wt 1% water soluble Cr6+. This hexavalent chromium is very harmful to human health, and the treatment of the slags has concerned metallurgists for many years. A sintering method was developed to treat the waste slag. In this process, sinter was made from a mixture of the waste slag containing hexavalent chromium, iron concentrate and coke breezes. During sintering, hexavalent chromium was reduced to trivalent chromium. The latter is known as a non-harmful material and can be used as chromium resource for the production of ferrochromium or chromium-containing cast iron. After sintering the hexavalent chromium in the sinter could be reduced to less than 0.0008%. It was found that the waste slag with fine particles was favourable to the Cr6+ removal. An increase of carbon content in the sintering mixture could increase the rate of Cr6+ removal and the strength of the sinter produced. The rate of Cr6+ removal increased with increasing basicity of the sintering materials with basicity less than B=1.8, above which it decreased with increasing basicity. Blast furnace was found to operate smoothly when using the sinter made from the waste slag containing chromium. However the productivity of sintering machine was slightly low compared to the sintering operation using ordinary raw materials.

Jan 1, 2004

By W. Baranek

The paper describes activities undertaken for intensification of copper cathodes production in electro-refining plants of the Polish copper smelters: 'Legnica', `Glogów I' and `Glogów II'. In the 'Legnica' smelter, Outokumpu?Wenmec machine was used for preparation of copper anodes. Intensive studies were conducted in order to optimise copper electro-refining conditions. As the result of them, spacing between the electrodes was reduced to 99 mm, which enabled placing forty-one cathodes in each tank and increasing amperage from 10.8 to 13.0 kA. This modification resulted in the increase of electro-refining capacity to 103,000 tons/y. Intensification of the copper production at `Glogów II' by 18,000 tons/y became possible after development of new electro-refining procedures, including application of a regime of changes in electrolyte level during the cathode cycle, implementation of the changes in location of starting sheets relative to anodes, and in dimensions of the sheets, and modification in the shape of the anodes. Similar works have been performed at `Glogów I', which were concentrated mainly on defining of a new method of anodes preparation, modification of their geometry, determination of optimum current density, composition of a set of inhibitors and of a method of their introducing. The implemented solutions resulted in the increase in electro-refining capacity at `Glogów I' from 207,000 to 240,000 tons/y.

Jan 1, 2007

By I. Bakry

Uncertainty is an inherent characteristic of construction projects. Neglecting uncertainties associated with different input parameters in the planning stage could well lead to misleading and/or unachievable project schedules. The objective of this paper is to present a new approach towards scheduling repetitive construction projects while accounting for uncertainty. The paper presents an algorithm that quantifies anticipated delays resulting from different sources of uncertainty in the form of fuzzy time buffers. Through inserting the time buffers in strategic places in a time schedule, the algorithm provides protection against those main anticipated delays. The presented algorithm comprises two integrated components, a scheduling component responsible for producing a basic Linear Scheduling Method (LSM) schedule with deterministic activity durations, and a buffer component that handles fuzzy buffers sizing and insertion. The presented algorithm offers four different buffer insertion techniques covering different cases of interrelations between successive activities. The algorithm is implemented in a spreadsheet application, which automates calculations, yet allows users to fine tune the algorithm to fit the project at hand. With a focuses on highway construction projects as an example of repetitive construction projects, this paper accounts for sources of uncertainty such as weather, site conditions, change orders and equipment related delays. A hypothetical case is studied and explained to further demonstrate how the proposed algorithm works.

Aug 1, 2013

By R. Maxwell

"At Opemiska Copper Mines we have, over the past four years, operated 300 cu. ft. and 700 cu. ft. flotation cells as roughers, scavengers and cleaners and found them competitive with conventional flotation cells on a cu. ft. basis on all phases of flotation.The economics are very much in favour of the large cells for the following reasons:Power consumption is 35 to 40%, of conventional machinesMaintenance cost is about 20 to 25% of conventional machinesSpace required is about 30 to 35% of conventional machinesInstallect cost is about 40%, of conventional machinesTo put the above in more concrete terms below is what we are doing at Opemiska:1. Increasing mill capacity from 2000 to 3000 T.P.D. and will use only 5Cff, of the flotation space for 3000 tons that we used for 2000 T.P.D. with conventional flotation machines.2. Will require only 10 flotation cells for 3000 tons against 85 conventional cells for 2000 tons.3. Cells will be, one 2000 cu. ft. rougher, six 700 cu. ft. scavengers (2 banks of 3 each) and one cleaning circuit using three 300 cu. ft. cells.You will note that in this 3000 ton per day plant, we are going to have only ten cells. Had we put in conventional cells for this tonnage, we would have needed 120 cells."

Jan 1, 1970

By J. Scalise

The paper covers a wide range of topics relative to filtration for continuous cast copper and aluminum. Subjects include system concepts, filtration concepts, system components, filter types, filter media selection, caster water filtration, coolant disposal, and recommended materials of construction.

Jan 1, 2007

By E. P. Cadwell

"Throughout the years Cyanamid has been a supplier of cyanide and a supplier of information to the mining industry. In general, the knowledge of mineralogy is greatly overlooked. Mineral deposits in the Western hemisphere have been exceedingly rich in the past but now they are becoming poorer. In other words, we will have to use our talents to the utmost to extract the precious metals and base metals from these ores. Modifications of some of the mineralogical equipment displayed here belong in the mill.Cyanidation of copper has been one of the main projects in our labs in recent years. De-rimming or de-filming of copper in order to upgrade copper concentrate was the main aspect investigated. A study was made as to how wide spread was the filming of secondary copper on pyrite, and to what extent it affected the copper industry. It was very wide.Often there is no conception as to what the minerals are. One open pit copper producer with a chalcopyrite ore was producing a copper concentrate with a 5% copper value whereas chalcopyrite contains 35% copper. They used primary and secondary grinding and a regrinding section. The ore contained about 8 parts chalcopyrite to one part of other copper minerals. In tests, a 3 1/ 2% copper rougher concentrate, cleaned without regrinding but conditioned with cyanide for a low contact time of 30 seconds produced a 30% copper concentrate with 90% recovery by removal of the film. It was of utmost importance that some quantitative mineralogical analysis be made before flow sheet changes were made. Every man should be trained to do his own microscopic examination in order to get quick answers. The fundamental thing in all mineral dressing is to first of all know the minerals and the mineral associations."

Jan 1, 1964

By D. C. Van Aken, O. J. Rajtora

A research effort sponsored by the Department of Energy (DOE) and several steel producers, is investigating the benefits of coating steelcasting nozzles with various materials. Coatings were applied to casting simulation nozzles made from industrial tundish nozzles (primarily of magnesia) and industrial submerged entry nozzles (SEN's) (primarily of alumina-graphite) in order to extend casting time prior to nozzle clogging. Nozzles were coated by air plasma spray (APS) using a 9M series APS system from Sulzer-Metco. The ability of these coatings to provide protection from clogging was evaluated using a steel casting simulation. Substrate-coating compatibility was characterized using optical and SEM microscopy.

Jan 1, 2004

By Juan Pablo Vielma

In this work we study how to incorporate risk control to the generation of ultimate pits when orebodies are modeled through a finite number of conditional simulations. To control risk we consider a chance constraint on the value of the ultimate pit. We incorporate this measure into the generation of ultimate pits by solving a stochastic programming version of the ultimate pit problem. We compare this stochastic programming problem to previous approaches such as generating the ultimate pit for each simulation and the hybrid pit approach introduced by Whittle and Bozorgebrahimi. We also study the effect of using different number of simulations in the generation and evaluation of ultimate pits.

Oct 1, 2009

By I. Takahashi

Recently, electronic devices have become smaller for some kinds of electronic devices, thermal dissipation and electrical conductivity of conventional Fe based alloy becomes insufficient. We selected the Cu-Fe based alloy CDA19400 and optimized the wire manufacturing process. Precipitates during aging treatment were observed by TEM. The size and distribution of the precipitates varied according to solution treatment temperature. With solution treatment at 950°C, the precipitates of y-Fe as fine as 10 nm were distributed dense in the copper matrix with coherency. For the solution treatment at 750°C, y-Fe of approximately 200 nm was observed. Comparing heat resistance of drawn wires, the material at 950°C treatment was superior. Electrical conductivity decreased from 63% IACS upon aging to 29% IACS by drawing. It is considered as particular phenomena for wires where materials are drawn with high reduction ratio. By the optimized manufacturing process, we successfully developed a new wire that has superior in strength, thermal conductivity, electrical conductivity, heat resistance and repeated bendability.

Jan 1, 2007

By K. Morikawa, K. Asano, J. Yoshitomi

The quality requirements for ladle shrouds have become stricter year by year to the pursuit of higher productivity and improved quality in the continuous casting of steel. The ladle shrouds must be sufficiently durable under severe conditions, such as operation without preheating and during several sequential castings. The consideration is that ceramic fibres, which have been applied in shrouds for thermal insulation during casting, could pose a risk to the worker's health. We realized materials for the ladle shrouds which show high strength and low elasticity. At the same time pursuing effective insulation, a coating which contains no fibres (Foaming Coat) has been developed, replacing the conventional one containing fibres. These materials are durable under conditions of repetitive use and consequently satisfy the customer's demands. The ladle shrouds which were improved in this way have achieved an excellent durable life in hot service of three times that of conventional ones. This paper reports the recent technological developments in ladle shrouds as well as their performance under hot operating conditions.

Jan 1, 2004

By P. V. Barr, Y. -H. Li, A. P. Watkinson

Subsequent to a campaign of pilot-kiln trials of firing bio-oil and natural gas, scale-up to commercial lime kilns was made using an in-house mathematical kiln model. Both dry limestone and lime mud kilns of 3.5 m OD. by 100 m length were used for bio¬oil firing simulations. Comparisons were made against natural gas firing on the basis of specific firing rate, off-gas volume, energy consumption and overall lime quality. Model simulation results indicate that conversion from natural gas to bio-oil with no productivity loss will increase energy comsumption by about 7.5% and total off-gas volume by about 8%. Alternatively, a 6% decrease in productivity would be expected if off-gas volume is maintained constant. The calculations are sensitive to deviations in the lower heating value (LHV) used in the simulations. A 5% increase in the LHV of the bio-oil, which could result from a 3% decrease in the moisture content, reduces the energy penalty to 2% coupled with a slight reduction in off-gas volume.

Jan 1, 2004

By C. Sorel

The solvent extraction systems devoted to uranium purification from crude ore to spent fuel involve concentrated solutions in which deviation from ideality can not be neglected. The Simple Solution Concept based on the behaviour of isopiestic solutions has been applied to quantify activity coefficients of metals and acids in the aqueous phase in equilibrium with the solvent. This approach has been validated on various solvent extraction systems such as trialkylphosphates, malonamides or acidic extracting agents both on batch experiments and counter-current flowsheets. Moreover, this concept has been successfully used to estimate the aqueous density which is useful to quantify the variation of volume and to assess criticality parameters such as number density of nuclides.

Aug 1, 2010

By M. Matsuda

The Hitachi refinery of Nikko Smelting & Refining Co. Ltd. began its electrolytic copper refining operations in 1911. In December 2002, the refinery changed its operation scheme by introducing the ISA permanent cathode technology for the first time in Japan. The change resulted in higher productivity, better cathode quality, and lower operational costs. The operation has been continuously improved to reach a 20% higher production capacity than the original one. For the electrolyte purification process, the Hitachi refinery has developed a new process for removing impurities. The process involves As, Sb and Bi adsorption from the electrolyte by means of chelating and ion exchange resin. The new resin process will achieve higher efficiency in removing impurity.

Jan 1, 2007

By Aalbert Zwijnenburg

One of problems connected with the use of gold/titania-based catalyst systems is the low yield in propene oxide (up to 2 wt %). It is shown that the low propene oxide yield is due to product inhibition. New options for propene epoxidation with hydrogen and oxygen are discussed. INTRODUCTION The direct gas-phase synthesis of propene oxide (PO), by the use of molecular oxygen, is still aimed for. Agbased catalysis is in principle possible, but selectivity at present is not promising. Highly dispersed gold on titanium containing catalysts show an extraordinary selectivity in the oxidation of propene to the corresponding epoxide (> 99 %), using a combination of H2 and O2 as oxidation mixture [1]. Additional studies of the epoxidation reaction have indicated several drawbacks of the Au/TiO2 catalyst. Firstly, the low conversion (1- 2 %) obtained under typical reaction conditions (atmospheric pressure, 323 - 423 K) cannot be increased by increasing the reaction temperature, because this leads to extensive by-product formation. Secondly, the low efficiency of hydrogen (relatively large amounts of water are formed) is hard to prevent. Finally, significant deactivation of Au/TiO2 catalysts within several hours on stream has been observed. Deactivation can be almost completely prevented by using dispersed TiO2 supports, such as TiO2/SiO2 and Titanium-Silicalite-1 (TS-1) [2]. In recent literature [2,3] a hydroperoxide-like intermediate has been proposed to be responsible for the selective epoxidation. This oxidising species is said to be formed over gold and subsequently used for epoxidation over the Ti-containing support. The support is responsible for the slow desorption of PO. One of the problems for future industrial application might be the low yield in propene oxide. Furthermore, the presence of minor amounts of by-products, not detected on lab-scale catalyst testing, might complicate the separation unit in an industrial process. The reason for the low PO yield over Au/TiO2-based catalysts will be discussed in this paper. Temperature Programmed Desorption (TPD) and micro-flow experiments have been carried out to study PO desorption and catalyst performance, respectively. A catalytic cycle is proposed together with its consequences for the maximum yield in PO. Finally, several process and catalyst options are discussed in view of potential future industrial application.

Oct 1, 2003

By T. Melfi, M. James

Attaining required mechanical properties in welds made using the double submerged arc welding (DSAW) process is difficult, and it is becoming more difficult as the strength level of the base materials continues to increase. Producing weld metal with adequate mechanical properties involves factors that are often overlooked and not taken into consideration. Not least amongst these problems is simply finding information to use in selecting the appropriate flux/wire combination. Most of the available data on flux/wire combinations provided by consumables manufacturers is generated using the multiple pass welding procedures required for classification per specifications such as AWS A5.17 and A5.23. This data really gives no insight into the properties that can be expected in a DSAW application. Also, base plate composition plays a very significant role because of the fact that base plate dilution can be as high as 70% in DSAW welds. This means that if any elements are present in the base metal that are deleterious to mechanical properties, they will also be present in significant quantities in the weld deposit. Some of these elements can decrease toughness and increase hardness (increased hardness is a concern if the pipe is intended for sour service). Some of these problems can be mitigated by proper selection of welding consumables. Selection of proper welding consumables means selecting an electrode that provides the appropriate alloying elements to obtain the desired level of impact toughness while also keeping the hardness within any specified limits. In order to attain the necessary impact toughness, selection of a flux with an appropriate composition (in terms of its basicity and its ability to control the nitrogen content of the weld deposit) is required. As with all welding processes, the mechanical properties of DSAW welds are also highly dependent on the welding procedures. This work clarifies how to select appropriate consumables to meet a given set of requirements, and also how to achieve the optimum mechanical properties from those consumables.

Jan 1, 2005

By A. L. Irwin

THE disposal of tailing or waste material, which is generally a very large proportion of the ore treated, is a major problem in the location and operation of any concentrating enterprise and especially so where the life of the operation is expected to continue for many years. Many factors need to be taken into consideration in the selection of a tailing site, chief among which are economical handling of the material, subsequent re-treatment of the tailing, and precaution against stream pollution by waste water. The final location of many mill sites bas been governed largely by the selection of a sui table area for tailing storage. The Sullivan concentrator of the Consolidated Mining and Smelting Company is situated about three miles from the Sullivan mine at Kimberley, B.C., and one of the deciding factors in its location at this distance from the mine was the availability of a suitable area in which tailing could be deposited. In view of the indicated long life of the property, a far-sighted policy bad to be adopted in the matter of tailing storage, for not only would it be necessary to accumulate a huge tonnage of finely ground material, but also reclamation for iron recovery at some future date bad to be considered. Some idea of the extent of the problem may be grasped when it is noted that, by the end of 1938, over 18,000,000 tons of tailing bad been impounded in an area of some 200 acres.

Jan 1, 1939

By J. H. Hodgson

"Those of us who have been concerned with the problem of geophysical exploration in southwestern Ontario have followed the development of the Poulter method with much interest. I have much appreciated the opportunity of reading an advance copy of Dr. Poulter's clear exposition and of preparing the following brief remarks on the probable applicability of the method to the Palaeozoic area of southwestern Ontario.During the years 1944 to 1946, the Ontario Department of Mines, in co-operation with the Union Gas Company and the Dominion Natural Gas Company, operated an experimental party in the hope of establishing a seismic technique appropriate to the •area. The results were completely negative. During two summers' field work, no reflections whatever were obtained except in one area near Windsor. It is the •purpose of these remarks to inquire whether Dr. Poulter's techniques might yield favourable results.It was the conclusion of the report on our work that two principal causes contributed to the failure of the method. In the first place, the geological column possesses few elastic discontinuities and those that exist appear to have low reflection coefficients. In the second place, the area is drift-covered in general. This drift complicates the situation by absorbing seismic energy and by giving rise to groups of complicating refracted phases which obscure the entire interesting section of the record. The situation is further complicated by the high reflection velocities and the relative shortness of the Palaeozoic section, these factors combining to bring in a reflection from the basement in about half a second."

Jan 1, 1950

"In mills, metallurgical efficiency is important in every step of the operation through to the tails. Different problems which hinder metallurgical efficiency exist in different mills. One such problem occurred in the Bralorne mill at the tailings end of the circuit, where the washing efficiency of the filters was so low that serious losses in dissolved gold occurred.The new cyanide plant at Bralorne went on stream in August 1961. Test work done showed that: a flowsheet of grinding in water, jigging, thickening, agitating, followed by double filtration, gave satisfactory results and was more economical than a counter current plant. Two filters, 141 x 161, with approximately 700 square feet of filtering surface on each, were purchased and installed in series. Test work showed that this was ample filtering area for 500 tons per day.When the plant started up a density of 45% solids was maintained in the agitators, and a 20 ounce cotton dl1ck was used on the filters. Vacuum was between 23 - 25 inches. Under these conditions the filters would not work and only picked up a very slight skim of pulp. Various speeds were experimented with, 4 minutes per revolution being the most efficient. At this speed the thickness of the pulp on the filters increased to about 1/8”• It was therefore quite apparent that, under these conditions, the filters would not handle very much tonnage and the mill tonnage would have to be reduced drastically until the problem was solved."

Jan 1, 1967