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By J Samosir, L Snyman

Northparkes was the first mine in Australia to use block cave mining method which relies on gravity and natural rock stresses to fragment and recover the ore. It was also the first hard rock mine to use hydraulic fracturing, in conjunction with CSIRO, to promote caving of E26 Lift 1. The technique was later used on E26 Lift 2 wedge and E48 prior to undercutting.Northparkes production is currently sourced from the E48 Lift 1 block cave mine and E26SLC. The E48 block cave contains economic ore to the north and south of the current cave footprint. To recover this ore the footprint has been extended on the north and south with two extraction drives and one extraction drive, respectively. Modelling of cavability above the additional drives indicated that the cave would not readily propagate to a sufficient height of draw to mobilise the ore and tended to arch over into the existing cave. To address the modelling results and to reduce the risk of the project, rock mass preconditioning was adopted.This fracturing campaign was performed from surface drill holes adjacent the subsidence zone angled to intersect the higher grade and higher elevation ore zones.Optical televiewer surveys, run prior to fracturing, picked intervals and fault zones to be avoided. Holes were resurveyed post-fracturing to detect newly created fractures and as a measure of success of the program.During fracturing operations water and gel fractures were run at varying depths and pumping pressure was logged for each fracture. The mine seismic system monitored significant events and dye in the fluids utilised for tracking water inflow locations during underground inspections.Towards the end of the project, guar fibres from gel were detected within the mill circuit and required treatment to resume optimum processing.CITATION:Webster, S, Snyman, L and Samosir, J, 2016. Preconditioning E48 cave extension adjacent to an active cave, in Proceedings Seventh International Conference and Exhibition on Mass Mining (MassMin 2016), pp 471–478 (The Australasian Institute of Mining and Metallurgy: Melbourne).

May 9, 2016

By James W. Hendrix

A survey of endomycorrhizal fungi occurring on orphan coalmine lands in Western and Eastern Kentucky revealed a great diversity of species present. Thus a large number of fungi are available for isolation and evalution for enhancing revegetation of mined land. Endomycorrhizal fungi isolated from orphan mines stimulated growth of sweetgum seedlings on mine soil at low fertilisation but inhibited growth at high fertilization; this growth inhibition at high fertilization did not occur with plants growing on peat-perlite. Banding of endomycorrbizal inoculum was not advantageous, compared with incorporation of inoculum throughout the growth medium, for production of mycorrhizal sweetgum seedlings. Newly reclaimed mine spoils were nearly nonmycorrhizal, compared with land reclaimed four or eight years earlier. A procedure for isolation of single-spore cultures of endomycorrhizal fungi was developed; this procedure is necessary for studies of ecotypic variability. A practical procedure using container-grown Pisolithus tinctorius-infected shortleaf pine seedlings for production of large numbers of bareroot pine seedlings infected with P. tinctorius for mined land reclamation was demonstrated.

Jan 1, 1982

By D. van der Veen

Mining companies and contractors are looking at Wirtgen Surface Miners to provide flexibility at their operations. Wirtgen Surface Miners have been used in the surface mining industry for over fifteen years. The principle behind the Wirtgen Miner is a rotating drum equipped with tungsten carbide tipped cutting tools that excavates and sizes the material. The drum helix augurs the mined material to the center of the drum where it is loaded onto the primary conveyor belt. From there the material is conveyed to the discharge belt and into a truck bed. The cutting drum is located in the center of the machine, near the center of gravity. This permits the machine to cut hard materials as the entire machine weight is converted into cutting forces. Conventional mining practices are process, equipment, and labor intensive. Furthermore, strict environmental requirements pertaining to noise levels, dust pollution, and blasting, near buildings or urban areas, limit the application of conventional methods. Mining/ Construction contractors are using Wirtgen Miners in various limestone excavation projects, such as highway expansion projects, and new roads in housing developments. Mining companies in the industrial minerals and coal industry are using Wirtgen Miners to load directly onto trucks, eliminating the rehandling process and ultimately, primary crushers.

Jan 1, 2002

By Alexander J. Verstraeten

The design and construction of foundations for power transmission line towers present some special problems. This paper describes a system of design and construction for these foundations that was developed in Europe and has attained general use there because of its reliability and cost effectiveness. Transmission line foundations distinguish themselves by having to deal not only with compressive and lateral loads, but with uplift loads and, because of the wind (in some regions earthquakes), with dynamic loading. The construction of transmission line foundations distinguishes itself mainly in the great number of inaccesible locations involved, resulting in extensive geotechnical investigation and logistical problems in moving men, materials and equipment.

Jan 1, 1987

By M. C. Roberts

As nations advance through various stages of economic development, the patterns of demand for minerals change. For example, as a nation develops from a subsistence economy through industrialization and into a service based economy, the use of minerals is at first low, then grows rapidly, and finally stabilizes. The past trends in the use of agricultural minerals by the currently advanced nations provide a pattern that the world as a whole may follow as it progresses through the stages of economic development. Future needs for agricultural minerals are estimated using this approach.

Jan 1, 2001

By Takashi Furuyama, Sukeyuki Mori, Ltd. Kyushu Metal Industry Co., Abel Bissombolo, Yoshitsugu Koga, Masamichi Hata

"Actually, the recovery of valuable metals such as iron, aluminium and copper is a nowadays practice in factories dealing with the processing of scrapped automobiles (Harder (WERG); Koga et al., 1997). This process has reach a recycling rate of about 75%, and generates a huge volume of waste (including cottons, sponge, plastics, rubber, etc…), locally known as “shredder dust”, which is commonly dumped on landfills; its recycling is either unsatisfactorily or not yet performed (Keller and Schebdat, 2000).The saturation and depletion of valuable disposal sites in the not-so-distant future, as well as the social and environmental problems related to the accumulation of these residues disposals are a major challenge for the automobile shredding industry.To promote an alternative way for the management of these disposals, the authors have initiated and developed a system for their processing, on the basis that more than 90% of these residues are combustible materials that could be used as refuses derived fuel. The developed processing system points out the mechanical/physical separation of a calibrated (–80+5mm) shredded automobiles residues into two streams by means of an ascending airflow passing through a vertical zigzag separator and, the compaction of the light-weight materials (that is about 60% of auto shredder residue recovered as float products and mainly composed of cotton, sponges and light plastics) to form a refuse derived fuel (RDF), the density, calorific value and ignition loss of which are 1.19 g/cm3, 4470 kcal/kg and 60.7%, respectively. A sedimentation tank is used to recover the light-weight materials deported in the heavy fraction stream."

Jan 1, 2003

By F. Matanzo

[Nine wire rope terminations were pull tested and fatigue tested to destruction to measure the termination efficiency and relative fatigue life. The terminations were selected on the basis off mine site visits and the specimen were assembled in a manner similar to industrial slings. To measure a termination's sensitivity to poor workmanship, both standard and modified assembly specimen were tested. Lang and Regular construction of the 6x19 and 6x37 class wire ropes were used in diameters of 13 mm (1/2 in.), 19 mm (3/4 in.), 25 mm (1 in.), 38 mm (1 1/2 in.), and 51 mm (2 in.). In static pull tests rope class, construction, and diameter interacted with the termination to influence the efficiency of the termination. In axial fatigue tests using only the 6x19 class rope, the effect of rope construction was negligible since failure was primarily dependent on the termination type. The Swaged Socket, a termination requiring a high capacity hydraulic press, gave the best overall performance in terms of efficiency and fatigue life. The short body length of the Zinc Poured Socket (RR-S-550) was attributed with the short fatigue life of this termination. The use of thermosetting resins as a replacement for zinc was demonstrated successfully for some socket designs. The fatigue life of the termination, expressed as a percentage of the fatigue life of the wire rope, was shown to be a guide for the retirement of the wire in these applications where the wiry' rope is primarily in axial loading.]

Jan 1, 1978

By Dan Alexander, Ivan Crnkovic, Sarah Schwarz

"Several plant studies have been conducted at the Zinifex Century Mine over the past 5 years. For each of the plant studies, surveys of the zinc primary circuit were conducted, characterisation measurements for each operating cell taken, and the floatability components of the ore mapped to develop a model of the circuit. The floatability components and machine parameters were then used to simulate changes in circuit configuration and operating conditions, enabling further potential improvements in circuit performance to be identified.This paper reviews the current flotation practice at the mine, as well as various circuit changes and developments implemented by site. The application of the methodology and the evolution of the standard procedure are also discussed.INTRODUCTIONBase metals were first discovered in the Lawn Hill region of Queensland’s North West in 1869 and the first mining lease in this area was pegged in 1887 over what is now known as the Silver King vein deposit. The area encompassing these veins, which includes the Century deposit, was proclaimed the Burketown Mining Field in 1899. Exploration titles were granted to CRA in 1987, precisely 100 years after the initial discovery at Silver King, hence the name ‘Century’.Century was commissioned by Pasminco in late 1999, with the mine becoming fully operational on 1 March 2000 and the official opening taking place in April. Pasminco had bought the Century and Dugald River deposits from CRA in 1997 for A$345 million, and invested some A$710 million in bringing Century into production. Today, Century is the world’s second-largest zinc mine in terms of its output, having reached full capacity in 2003.The Zinifex Century Limited (“ZCL”) lead-zinc-silver deposit is located approximately 250 kms north-north west of Mt Isa in north-western Queensland. The deposit is a large flat-lying ore body covering an area of some 1.2 by 1.4 km, the 45 m-thick stratabound sulphide orebody is hosted within an 850 m-thick sequence of Proterozoic siltstone, shales and sandstone, amenable to open-cut mining methods. The mine has ramped up to full production delivering five and a half million tonnes of ore per annum, yielding approximately 900,000 tonnes of zinc concentrate and 90,000 tonnes of lead concentrate. Mine life is expected to be about 8 years"

Jan 1, 2008

By Ziyad Abunada, David O’Connor, Abir Al-Tabbaa

"Abstract Contaminated land remediation using soil mix technology (SMT) is a relatively recent development which has been shown to be a cost effective and versatile system with numerous environmental advantages over other remediation techniques. The added complexities and variability associated with contaminated sites has escalated the need for field trials, field monitoring and specific QC measures to be undertaken for this setting and was the rationale behind project SMiRT (Soil Mix Remediation Technology). The main aim of project SMiRT was field validation, testing and assessment to provide stakeholder confidence in SMT and increase its uptake for land remediation in the UK. The field trials involved the treatment of 800 m3 of soil, through applying six different remediation techniques with four different SMT systems and introducing over thirty binders and binder compositions with a range of installation methodologies. Various issues were faced during the installation process and which were addressed on site. This paper presents some aspects of early age field observations, field monitoring, in-situ testing, coring and laboratory testing of cored samples and highlights some lessons learnt, providing valuable information on the issues that need to be addressed for this application of SMT.IntroductionAlthough soil mix technology (SMT) was developed in the 1960s in Japan and Sweden for geotechnical applications, its potential in geo-environmental applications became evident more recently the 1980s in the US and in the 1990s in Europe, having since increased to provide a range of remediation systems (Al-Tabbaa and Evans, 2003; Al-Tabbaa et al., 2011). The most common applications to date have been (a) the construction of low permeability containment walls or cut-off walls to contain a contaminated site; (b) stabilisation/solidification (S/S) treatment, with cementitious binders, for physical and chemical encapsulation of contaminants in soils and (c) the installation of permeable reactive barriers (RPBs), which are permeable walls that intercept the groundwater flow and remove contaminants from it, by mixing special additives with the native soil. Contaminated land remediation using SMT is a cost effective and versatile approach with numerous technical and environmental advantages over other remediation techniques. These advantages include the use of simple and well established techniques and equipment, speedy implementation, applicability to sites of any size and to multiple contaminants, elimination of off-site disposal, low risk and low emissions. There is a lack of competing alternative technologies that offer the same level of versatility and economic, environmental and social benefits, under current environmental legislation constraints. In addition, most currently available contaminated land remediation techniques are only partially effective, and are relatively contaminant-specific. This makes SMT a promising and timely contender to lead the market place in offering a cost-effective, efficient and low risk solution to contaminated soil and groundwater remediation and has resulted in a range of recent innovations."

Jan 1, 2014

In 1992, the United States economy grew at a rate of 2%. The Gross Domestic Product rose to $5,946 billion. With 257 million people - 635,000 in mining including petroleum - the United States has more than 100 million dwelling units and more than 190 million licensed motor vehicles. New private housing starts rose I 1 % to 1.2 million units. New car production rose 4% to 5.7 million units. Truck and bus production rose 20% to 4 million units. The rate of inflation was 3.5% and the prime rate of interest was 6.25%. The Producer Price Index (1982 =100) was relatively unchanged from 1991 as follows: fuels and related products and power 80, metals and metal products 119, chemicals and allied products 126 and nonmetallic mineral products 117. Energy Imports of crude and refined petroleum, costing $50 billion, rose 3% to 455 Mm3 (2.9 billion bbl). Domestic petroleum production fell 1 % to 582 Mm3 (3.5 billion bbl). Petroleum supplied about 41 % of US energy, natural gas 24% and coal 23%. Coal production, 60% from surface operations, rose 1 % to 914 Mt (1 billion st). About 78% was used to generate electricity and 3% was coked. Exports valued at $4 billion included 57 Mt (63 million st) of metallurgical coal and 39 Mt (43 million st) of steam coal. Ura¬nium mining, including recovery from phosphates, fell 18% to 3 kt (3300 st) U308.

Jan 1, 1993

By R. Karl Zipf, David Newman

The objective of this is paper is to review the current state of knowledge and practice in highwall mining (HWM). HWM has become a widely-applied method in surface mining, commonly used alone or in conjunction with contour or slot mining. It provides 800-feet to 1,200-feet of additional recovery when the economic stripping ratio is reached in contour mining or in slot mining when surface access to a reserve is limited. A significant attribute of the highwall miner is its versatility. HWM has been used successfully to mine abandoned pre-reclamation law highwalls, points or ridges uneconomic to mine by underground or other surface methods, outcrop barriers left adjacent to underground mines, separate benches of the same seam where the parting thickness or quality differences between benches render complete extraction uneconomic, previously augered areas containing otherwise inaccessible additional reserves and close or widely spaced multiple seams. The theory and design methods to assess roof, pillar, and floor stability are presented followed by three case histories. Simple design charts for sizing HWM web and barrier pillars are also presented. A recommended web pillar width may be obtained from the design charts given the overburden depth, the HWM cut width, and the mining height. Given the depth and panel width for a set of HWM cuts, another set of charts gives a suggested barrier pillar width. The case histories, from Northern and Southern Appalachia are used to illustrate the application of rock mechanics to quantify the stability of the highwall, roof, web pillars, and floor. The case histories involve 1) mining through a previously augered highwall, 2) mining under back-stacked spoil and 3) selective mining of closely spaced benches of the same seam. Because each site is unique, the appropriate pre-mining geotechnical analyses range from the calculation of roof, web pillar, and floor bearing capacity stability factors to detailed numerical modeling of the auger and underground mine workings. When operating in the vicinity of existing underground mine or auger workings, the determination of ground deformation and strains resulting from highwall mining is a necessary facet of a ground control investigation.

By H. Maleki, G. Tetreault

This study was initiated by the Bureau of Land Management (BLM) to develop guidelines for determining the maximum economic recovery of resources in coal mines. The work was in response to a requirement in the Mineral Leasing Act of 1920 and Federal regulations. The intent was to address the economic rainability of small, irregular reserves in existing longwall mines. In particular, there was a need to determine if room-and-pillar mining using a continuous miner (CM method) was economically sound, or whether unconventional (short or odd-shaped) longwalls could be used to recover small coal reserves economically. Small reserves, called "widgets" are left in longwall mines on one side of the mains, near outcrops and adverse geological conditions, or near any other location where reserve geometry does not lend itself to mining with a rectangular longwall panel. The work included (1) analysis of the geologic, geo-technical, and economic factors that influence the recovery of small coal reserves, (2) analysis of historic changes in supply, demand, and coal prices, (3) development of typical cost models for room-and-pillar and longwall mines, and (4) development of a practical methodology for determining maximum economic recovery. The methodology included an evaluation of the ratio of coal mined during longwall mining to that mined for development (LDR) as well as costs of maintaining coal quality depending on market conditions. The LDR is a good indicator of mine efficiency and overall coal recovery in modem longwall mines and thus is used to evaluate the

Jan 1, 2001

By Virginia T. McLemore

The Gallinas Mountains are in northern Lincoln County and southern Torrance County, New Mexico, USA where a series of alkaline igneous bodies, including porphyritic latite, trachyte/syenite, andesite, and rhyolite laccoliths, flows, dikes, and plugs, have intruded Permian sedimentary rocks belonging to the Permian Abo, Yeso, and Glorieta Formations. A small amount of bastnaesite, a REE mineral, was recovered during processing for fluorite from the Gallinas Mountains. Four types of deposits are found in the Gallinas Mountains: epithermal REE-F veins, Cu-REE-F veins, REE-F breccia pipes and iron skarn deposits; all are associated with Tertiary alkaline to alkalic-calcic igneous rocks. Alteration includes brecciation, silicification, chloritization, and fenitization. District zonation is defined by Cu-REE-F (±Pb, Zn, Ag) veins that form center of the district, surrounded by REE-F veins. Carbonatites are inferred at depth by the presence of fenitization, carbonatization of the breccias, presence of REE and similarity of the intrusive rocks and mineralization to areas with known carbonatites.

May 1, 2011

By J. Griesel, P. H. F. Bouwer, K. Bisaka

Transalloys produces 160 000 tons of SiMn per annum from five AC submerged-arc furnaces. The lime-ore melt from two AC open-arc furnaces is contacted with SiMn to produce 50 000 tons of medium carbon FeMn per annum. Metallics in the slag are reclaimed in a jigging plant, which has been in operation since 1999. The flow of materials between the jigging plant and furnaces has been optimised. The amount of recycle slag in the feed of the SiMn furnaces has been decreased by more than 30% which still provides satisfactory stability of the furnace operation. The jigging plant has absorbed all the additional slag generated, to recover SiMn metal. A review of the raw materials used and operating parameters for SiMn production was also undertaken. Slag to metal ratios were decreased by more than 30% by reducing the slag recycle, removing magnesite from the recipe and introducing high-grade ore. Electrode penetration was improved by reducing coke levels and by utilising more reactive coal. The pitch circle diameter (PCD) was reduced to get a better operating stability on furnace no 5 using the MINSTRAL Control System. Energy consumption on the furnaces improved by more than 15% while SiMn production increased as a result by more than 18%.

Jan 1, 2004

By S. Belair, V. Weigel

As a growing mining company, ERAMET is looking for new positions on the strategic metals market. In this context, the Gabonese Maboumine pyrochlore deposit is currently being studied for the recovery of niobium, tantalum, rare earth elements (REE), and uranium. This ore shows mineralogical and chemical characteristics that make it challenging to process by already known practices, from both technical and economic points of view. In this context, ERAMET has developed since 2008 an innovative hydrometallurgical process which has been successfully operated at a pilot plant scale. While the upstream part of the process aims to dissolve the valuable elements in sulphuric acid, the downstream part of the process aims to recover them separately in a marketable form. The focus here will be on the recovery of the REE. The ore deposit contains approximately 1.4% of REE including 87% of light REE and 13% of medium-heavy REE. The challenge in this process lies in the fact that the major elements in the matrix are iron and aluminum. An innovative process has been developed in order to recover all of the REE in these unfavourable conditions, described in this paper.

Jan 1, 2014

By S. L. Aaroe

"TYRETHANE PRODUCTSTyrethane® is the family brand name which has been adopted by The W. S. Tyler Company of Canada, Limited to identify its polyurethane products. Since we have been manufacturing Woven Wire Cloth for over one hundred years and have been the innovator for most of the product improvements and developments of that industry, it is only natural that our first and primary efforts involve the use of Tyrethane® as a screening medium. The product is ideal for application in the mining industry and other operations where the rate of wear on existing media is exceptionally high.In the event that you have already had some experience with polyurethane it should be poirted cut that there are many grades of the material. The polyurethane used in Tyrethane® Products will be compounded in a variety of chemistries and different heat treatments will be used to develop best mechanical properties to handle specific applications. However Tyrethane® will not be a ""cure all"" but when it is properly applied as a screening medium it will assist by lowering the unit cost for screened materials.Prior to an explanation of the advantages of Tyrethane® let's review the conventional screening media whose applications may be considered as good candidates for replacement by Tyrethane®.1.,Woven Wire Cloth.2.,Perforated metal screens.3.,Rubber faced perforated metal screens.4.,Perforated rubber screens.5.,Cast steel screen segments and weldiments.6.,Profile wire.In most cases a Tyrethane® section is designed for a one for one replacement of the material now being used. It is rarely necessary to modify the screening equipment to enable you to install the Tyrethane® Product although it may be desirable to take some steps to improve the service life of hold down components such as Clamping Strips or Tension Members. Those parts can be encapsulated in polyurethane if necessary.To fabricate the Tyrethane® section we have three basic building blocks. They are: (1) Small molded segments having square or slotted openings, (2) Reinforcing material and (3) the raw liquid polyurethane."

Jan 1, 1976

By Richard Weinstein, Richard Snoby

There are many advantages to upgrading coal with dry jigging technology. The most obvious is the lack of process water, which eliminates the need for fines dewatering and slurry confinement. Dry jigging eliminates the clean coal moisture penalty associated with wet processing. Particulate emissions are virtually nonexistent due to inclusions of fabric dust collectors on all modern dry jig plants. Because of the environmentally friendly nature of dry jig plants, installation permits are often measured in days, not months. There has also been a fundamental advance in dry jigging efficiency. All of these advantages have renewed the coal industry’s interest in dry jigging. But air jigging is not right for every application. There are limitations due to particle size, particle shape, moisture and near gravity content. This article explores the evolution of dry jigging. It reviews parameters important for determining the suitability of dry jigging. It also compares historical performance data as measured by imperfection, against results from modern dry jigging technology. The article also presents data from modern dry jig installations.

Jan 1, 2007

By D. Vogt

South African underground hard rock mines are typically managed using measurements made daily, weekly or even monthly of key parameters such as face advance, readiness to blast, blast success, temperature or dust levels. Health, safety and productivity can all be greatly improved if a real-time measurement system can inform decision making. To enable this vision of widespread sensing, communication and decision support, CSIR has developed an open standard architecture for communication of sensor data, and a reference implementation using that standard. The standard, called AziSA, meaning ?to inform? in isiZulu, will allow any device that complies with it to join any network that supports it. The standard is designed for South African gold and platinum mines. To be practical in a typical Bushveld platinum mine, a real-time sensor system needs to be robust, reliable and cheap: ?Sensors are equipped with power sources that will last as long as the sensor is required. In effect, sensors need to be disposable: cheap enough not to warrant repair if they break. ?Communication in the stope is wireless, to avoid there liability problems associated with wire connections. For example, wires to sensors in the face area are unlikely to survive blasting. ?To get information out of the stope, the power line to the scraper winch is used as a communications link. Unlike a separate communications link, the power line will be repaired if damaged, because of its importance to production. ?Outside the stope, communications are transferred onto the mine communication infrastructure. To succeed as a management system, the next key element is the use of software decision support tools that will analyse masses of real-time data to extract key parameters and trends for decision makers. A range of sensors has been developed, including commercial sensors that have had wireless adapters added to make them AziSA compliant, and bespoke sensors that provide low cost sensing of typical mining parameters. An important parameter in any sensor network is the location of the sensor. This has to be easy and cheap to establish, so a tool has been developed to locate sensors in the confines of a stope, using ultrasonic and radio techniques. Once sensors are installed and located, they associate their location to all data that they produce. All the data from the system are captured at surface in a flexible database that can be queried by any application that requires data of any kind. It is simple to program alerts, and for actions to be associated with alerts. The use of wireless in stope also allows for communication from surface to the stope, or from stope to stope. The first implementation of an AziSA compliant system is being installed as part of the Mine Health and Safety Council funded rockfall elimination project. The design is discussed, and a future application for a platinum mine is considered.

Jan 1, 2009

By Michel Aubertin

Les digues de retenue de résidus miniers devraient être conçues de façon à supporter les charges les plus défavorables qui puissent être anticipées. Les nombreux incidents survenus au cours des dernières années à travers le monde montrent toutefois que la stabilité de ces ouvrages reste encore problématique. Les cas de rupture les plus courants sont reliés aux glissements le long des pentes, à la liquéfaction des rejets, au débordement des bassins, ainsi qu?à l'érosion régressive et de surface. Après avoir rappelé la nature et l?importance des certains incidents récents, l?origine de ces problèmes est brièvement présentée. On aborde ensuite le lien entre les critères à adopter pour la conception des ouvrages et les risques associés à leur rupture. De nouvelles avenues pour aider à contrôler certains problèmes sont enfin discutées, en mettant l?emphase sur la codisposition des roches stériles dans le parc à résidus miniers.

Nov 1, 2002

By P. Taskinen, D. Lindberg, H. Viitala

The formation of copper chlorides in flue dust or deposits in heat recovery boiler of copper smelters or waste-fired boilers may lead to formation of corrosive partially molten deposits on walls and heat exchangers of the boilers. These deposits can contain various other metals, such as alkalis, Fe, Zn, Pb together with oxides and sulfates. In the present study, a thermodynamic model for copper-containing binary and ternary metal chloride systems within multicomponent CuCl-CuCl2-FeCl2-FeCl3- PbCl2-ZnCl2 system has been assessed and optimized based on own experimental phase equilibrium data, as well as literature data. The thermodynamic properties of the liquid phase was modelled using the quasichemical quadruplet model and a thermodynamic database was optimized to predict all available experimental data within the experimental error limits. The thermodynamic database allows for more accurate predictions of potential corrosion-related issues in various heat recovery boilers and waste-fired boilers due to formation of copper chlorides. INTRODUCTION In the copper flash smelting, flue dust can cause severe problems in the gas train, used for separating dust from the SO2-rich off gas, by forming corroding accretions on the walls of the heat recovery boiler. Formation of dust build-ups in the boiler need to be cleaned regularly and potential corrosion damage checked, requiring costly and unscheduled shutdowns of the flash smelting process. Compounds of copper and zinc among other elements having high vapour pressures may volatilize during the smelting of the copper concentrate, forming dust when the process gas cools down. Also, particles of solid or liquid iron oxides originating from the ore get transported with process gas to the heat recovery boiler as a result of entrainment in the flue gas (Miettinen, 2008) The dust deposit build-ups on the boiler walls are formed partly by direct impact of particles and partly by vapour condensation on the boiler walls. The initial deposition takes place by the condensation of vapours that contain zinc, lead, arsenic and other metals having high vapour pressures. Also, low melting point eutectic components of alkali salts such as chlorides and sulphates can act as sticky cohesive particles attaching to the boiler walls. The fine particles landing on the surface of the porous dust deposit layer react in the SO2-rich atmosphere of the boiler to sulphates. The process gas within the boiler contains SO2, O2, SO3, H2O and N2 that diffuse into the porous accretions to form a stagnant gas layer within the dust deposit structure. The composition of this gas layer may differ greatly from the composition of the process gas that is flowing on the surface of the accretion layer. Locally HCl and H2SO4 are formed and even a reducing atmosphere may exist within the dust deposit layer, allowing new reactions to take place. The local micro-atmosphere may enable metal sulphates to be reduced to secondary sulphides and even metallic components. Within the accretion layer, components may be formed that would not be stable in the gas atmosphere inside the boiler (Miettinen, 2008). This may be the mechanism by which for instance chlorides of Cu, Fe and Zn are formed within the deposit layer.

Jan 1, 2019