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By G. S. Victorovich

Technical progress in primary smelting has changed the face of the copper industry in the years since the Second World War. Much of this change has resulted from a wide acceptance of flash smelting technology. In addition, research has been directed toward devising converting processes to replace conventional Peirce-Smith converting technology. One major thrust has involved a revival of the old " ", idea of oxygen flash converting of comminuted mattes. This paper reviews the 60-year history of flash converting. Particular attention is paid to Inco's investigations into the processing of white metal containing significant amounts of nickel and, in some cases, iron. Thermodynamic analysis and laboratory experimental results are presented which throw light on the behaviour of nickel and other salient features of flash converting. The possible role of oxygen flash converting in the copper pyrometallurgy of the future is briefly discussed vis-a-vis direct production of copper.

Jan 1, 1993

A relationship is predicted between oxidic nickel in slag, oxygen in matte and Ni/Fe ratio in matte after the examination of thirty sets of contiguous matte and slag samples taken from industrial nickel smelters. Oxidic nickel in slag is found to increase with increase in oxygen content of matte of constant Ni/Fe ratio, and it is proposed that the relationship may be used to predict nickel solubility in slag from a knowledge of matte composition alone.

Jan 1, 1979

Based on the examination of thirty sets of contiguous matte and slag samples taken from industrial nickel smelters a relationship is predicted between oxidic nickel in slag, oxygen in matte and the Ni/Fe ratio in the matte. Oxidic nickel in the slag is found to increase with an increase in oxygen content of a matte of constant Ni/Fe ratio, and it is proposed that the relationship may be used to predict nickel solubility in slag from a knowledge of matte composition alone.

Jan 1, 1980

By Velu Annamalai

In-situ uranium solution mining involves the injection of a lixiviant (leach solution) through appropriately placed wells into the underground ore zone. Upon contacting the uranium minerals, this solution will dissolve the uranium. The uranium containing solution is then pumped out of the wells into a processing plant where the uranium values are removed, typically in ion exchange columns, and the stripped liquor is recycled back into the field. The lixiviants may be acidic or basic. Where the ore zone mineralization contains appreciable carbonate, as in the South Texas fields, acid consumption would be excessive and the typical solution is ammonium carbonate bicarbonate at about 5-10 g/l and a pH of 7-9. Because the usual uranium minerals, uraninite or coffinite, contain uranium in the insoluble tetravalent state, it is necessary to add an oxidant to increase the valence to the hexavalent state where the uranium is soluble. Oxygen dissolved in the lixiviant has been shown to be quite effective for this purpose. It is also much more economical than other oxidants. Of concern is the possibility that (1) its solubility may or may not provide concentration levels adequate to give an economically attractive uranium level in the extracted liquor, and (2) the addition of oxygen in excess of the saturation level so as to increase the uranium grade in the lixiviant may cause gas blockage of the typical fine-pored ore formations.

Jan 1, 1981

By M P. Simpson

Forty one whole rock samples from the Gold Cross low-sulfidation epithermal Au-Ag deposit have d18O values that range from 4.4 to 9.3 per mil, with an average value of 7.0 per mil. Unaltered and weakly altered rocks have d18O values greater than eight per mil, and the orebody is surrounded by samples that are depleted in 18O. A strongly silicified sample adjacent to the Empire Vein System has a d18O value of 9.0 per mil, similar to previously reported analyses of vein quartz (7.0 to 11.7ë, average 9.4ë). This suggests that, in detail, Golden Cross may have a zone of 18O-enriched wall rocks in the core of the deposit, adjacent to the main underground veins. Although some workers have suggested that stable isotope geochemistry may provide useful information for epithermal mineral deposit exploration, at Golden Cross this is not the case. Alteration minerals, major elements and trace elements all define larger, less ambiguous halos than the zone of 18O-depleted wall rocks.

Jan 1, 2001

By G. G. Roy, R Shekhar

Pachuca tanks are extensively used for the cyanide leaching of gold and the carbonate leaching of uranium, processes in which oxygen mass transfer plays a very important role. Experiments were carried out to clarify the effect of design and operating parameters on oxygen mass transfer. Parameters such as the ratio of tank height to tank diameter, the ratio of draught-tube diameter to tank diameter and the tank design were found not to influence oxygen mass transfer. Results also showed that equal superficial gas velocities may be used as a criterion for scaling up oxygen mass transfer in both full-centre-column and free-air-lift Pachuca tanks with clear water. A volume-averaged, volumetric gas-liquid mass-transfer coefficient (k'av) was used to characterise oxygen mass transfer in full-centre-column tanks. The axial dispersion model was used to determine k'av. The resulting model used only tank geometry and air flow rate as inputs for the prediction of k'av in industrial-scale tanks. Predictions from the model show clearly that "local" mass-transfer coefficients, measured at one or two locations, may not adequately represent gas-liquid mass transfer in industrial tanks. It is therefore necessary to obtain an estimate of k'av

Jun 18, 1905

By Waladan M, Elliot B, Rankin W. J

A survey was undertaken on the Kalgoorlie Nickel Smelter in which samples of slag and matte were taken along the length of the integrated flash smelting furnace and analysed to determine the variation of nickel and iron concentration. At the same time the oxygen potential of the slag and matte was measured using disposable tip solid-state oxygen probes. The results show that the oxygen potential of the slag is higher than that of the matte and that both decrease from the reaction shaft end to the slag tap hole end of the furnace. The slag and matte are not at equilibrium except towards the tap hole end. Reduction of nickel and magnetite from the slag occurs before the slag enters the slag-cleaning appendage by reaction with iron in the matte. Thermodynamic modelling and laboratory experiments showed that the equilibrium nickel and magnetite contents of the slag in the absence of a carbonaceous reducing agent are about 0.4 per cent and 7.5 per cent, respectively. A carbonaceous reductant is required to obtain a lower nickel content in the slag.

Jan 1, 1991

By Canterford J. H, Sparrow G. J, Dyson N. F

Pressure leaching of a bulk flotation concentrate prepared from a complex Cu-Pb-Zn sulphide ore was carried out at 150 and 190¦C under 1050 kPa oxygen overpressure in 1 L and 4 L titanium autoclaves to extract zinc, and to obtain residues for smelting tests and leach liquors for purification and recovery of the zinc by electrowinning. Dissolution of 95% of the zinc was achieved at both temperatures. Copper and iron dissolution and the degree of oxidation of the sulphide sulphur to elemental sulphur or sulphate depended on the temperature of the leach. At 190¦C, a jarosite (a basic iron sulphate) was the major iron-containing material in a residue that contained 17% total sulphur. Its formation was associated with dissolution of 18% of the iron. At 150¦C, oxidation of the sulphide sulphur and dissolution of the iron were significantly less. Only 7% of the iron was dissolved and a residue containing 25% total sulphur, present as a lead jarosite, lead sulphate, and elemental sulphur, was obtained. The formation of small pellets of unreacted sulphides coated with elemental sulphur caused problems during the leaching at 150¦C, and also during scale-up from the 1 L to the 4 L autoclave at 190¦C. At 150¦C the concentrate required two stages of leaching to achieve dissolution of over 90% of the zinc. These problems are discussed.

Jan 1, 1989

By D. A. J. Swinkels

The problem of determining oxygen levels in liquid steel to aid in deoxidation control has received general attention for a number of years. Work in this direction started at the B.H.P. Central Research Laboratories early in 1967 with an evaluation of sampling techniques followed by vacuum fusion analysis to determine the oxygen content of the samples (1). It was found that these techniques had a number of drawbacks if they were to be used for deoxidation control. The method of analysis was rather too slow to allow effective control and measured total oxygen level rather than dissolved oxygen. Furthermore, the results were found to be very variable due to slag entrainment in the samples. Attention therefore turned to the galvanic cell method using a solid oxygen ion conductive electrolyte such as cubic stabilised zirconia. The ionic conductivity properties of electrolytes such as (ZrO2) 85 (CaO).15 had been studied by a number of investigators and had already been applied to the measurement of oxygen activity in gases, in lower melting metals such as copper, lead, tin, silver, alkali metals and indeed the first studies in steel had been made (2,3). Since then the results of a number of studies in the development of an expendable oxygen probe for steel have been reported (4-9).

Jan 1, 1972

By C. A. Pickles, J. M. Toguri

The refining of two molten Ag-Cu alloys, containing 7.5 and 11.2 mass% Cu, with a borosilicate slag was investigated using both air and pure O2 to determine the effects of the following variables: flow rate of oxidising gas; injection time; mass of sodium borosilicate flux; and injection of the oxidising gas into either the slag or the metal. The results demonstrate that more than 90% of the Cu can be removed with Ag losses of less than 5% and that refined metal with a Cu content of less than 0.5 mass% can be produced. Ag losses to the slag increased with the amount of Cu removed, and a mechanism is proposed to account for this

Dec 1, 1995

By R. E. Johnson

The No. 3 reverberatory furnace at Phelps Dodge. Corporation's Morenci, Arizona copper smelter first received oxygen from a new oxygen plant during October 1982 and began operation with oxygen-fuel and oxygen sprinkle smelting burners which burn concentrate with oxygen. The furnace was completely converted to roof-mounted oxygen-fuel firing in October 1982. All conventional air-fuel bridge wall burners were extinguished at that time. The novel arch-mounted oxygen sprinkle smelting system began continuous operation April 1983. Since startup, unit fuel requirements decreased and furnace throughput significantly increased. Furnace off gas SO2 strength increased from an average of 1.5% SO2 to an average of 20% using only oxy-fuel burners. Oxygen sprinkle burner operation also has given excellent results, with the furnace off gas strength increasing to 35%-60% S02. There has been a reduction in overall arch temperatures, an increase in matte and slag temperatures, and a lowering of furnace bottom buildup with oxygen smelting. Furnace off gas is blended with converter off gas and treated in a sulfuric acid plant.

Jan 1, 1983

By Ismar Antônio Sardinha

Usually outer straight steel tubes are used to blow supersonic oxygen into LD converters (BOF) to make liquid steel, although conical tubes are used too. Inner tube for oxygen blow and intermediary tube for water IN and water OUT are normally straight steel tubes. Present paper shows the influence of outer tube shape and metal used to in lance cooling and, consequently, a skull retention on lance surface. There are two parameters more important related to lance cooling: velocity of water out and the total lance cooling by addition of thermal conductivity of outer tube metal to it. For this comparison outer tubes are made of carbon steel or copper, and can be straight or conical. As related to velocity of water OUT, outer straight tubes have bigger efficiency than conical tubes. As related to total lance cooling, outer tube metal made of copper has much bigger efficiency than steel because of its thermal conductivity 7 to 12 times more depending on work temperature. The lance cooling has much bigger efficiency for the patented SKULLS3® technology with no skulls on the lance and no skulls into the mouth of LD converters (BOF).

Aug 17, 2017

By V. M. Paretsky

Oxygen-flame converting of a solid ground matte containing heavy non-ferrous metals in a wide range of concentrations is one of the perspective trends meeting the demands of modern non-ferrous metallurgy. As. a result, of semicommercial tests on oxygen-flame smelting of nickel matte containing 13,5-17,5% Ni; 0,45-0,65% Co under continuous autogenous conditions a converter matte containing 68 8-75,0% Ni and 0,48-1-,0% Co and ferrite -calcium slag containing 1,4-8,4 Ni and 0,16-0,56 Co were pro¬duced. Nickel recovery in a converter-matte was 76,2%, copper - 58,'2% and cobalt recovery in. a slag was 90%. Slag cleaning in an electric furnace allowed to after-recover nickel and cobalt in an alloy to produce a dumpy slag containing 0,03% Ni and 0,02% Co. The development of modern' ecologically pure energy-saving autogenous technologies of the treatment of sulphide raw materials containing heavy non-ferrous metals makes certain demands of the perfection of a process of converting rich sulphide-metallic intermediate products obtained at autogenous smelting. These-demands were connected first of all with the fact that converting process stages because of process periodicity are more unfavourable from the point of ecology, power intensity and unit stability. Besides, during rich matte treatment the problems connected with heat shortage when using air blast and heat excess-when using top oxygen blast to treat luquid matte a-rise and when enriching air blast by oxygen up to 26% fast erosion of the brickwork of a tuyere zone takes place. The technology of Outokumpu and Kennecott companies-on solid- copper matte converting in a flash smelting furnace using air blast is not universal as its possibilities are limited by certain composition of mattes. Besides, flash smelting to produce highly basic or combined slags requires larger enrichment-of blast by oxygen or extra fuel feed. Naturally a flowsheet with continuous converting of matte of various composition up to white matte production is simple,

Jan 1, 1993

By X. Shi, V. Vallyathan, N. S. Dalai

"Using. ESR spin trapping methodology, evidence was obtained that fresh quartz dust in a cell-free aqueous medium generated hydroxyl - and possibly superoxide radicals. The hydroxyl radical generation potential decreases on storing of fresh quartz dust in ambient air and on the addition of either catalase, superoxide dismutase, desferoxamine, or DMSO. The role of quartz related radicals in the biochemical mechanism of acute silicosis is suggested from these findings.IntroductionThis report summarizes our electron spin resonance (ESR) detection of oxygenated radical formation by freshly crushed quartz particles in a cell-free aqueous medium, and its inihibition by radical scavengers. This study was undertaken with to elucidate the primary biochemical mechanism involved in the development of silicosis (Farber, 1983; Reiser and Last, 1979; Silicosis and Silicate Disease Committee, 1988). In particular the mechanism by which the quartz particles exert their toxic action on cells and the process(es) by which these actions progress to fibrogenesis are still not well understood (Farber. 1983; Reiser and Last, 1979;). It is generally believed that the action of quartz particles on the cell membrane is the starting point of the silicotic process (Farber, 1983; Parazzi et al., 1968). Thus the surface characteristics of the quartz particles have been the subject of several recent studies (Bolls et al.. 1983; Dalai et al., 1986; Fubini et al., 1987). Recently, We reported that mechanical crushing of quartz under normal atmosphere generates free radicals which decay with time, and that these free radicals are associated with a higher cytotoxicity of fresh quartz dust as compared to aged dust from the same stock (Dalai et al., 1986; Vallyathan et al.. 1988). The formation of Si• and. SiO--type of radicals from quartz particles crushed under atmospheric conditions has also been reported by Fubini et al. (1987). In addition, Gulumian and van Wyk (1987) have reported that quartz particles react with hydrogen peroxide (H202) to generates hydroxyl radicals (•OH) and suggested that this process might contribute to quartz's pathogenicity. However, these authors did not report the effects of metal chelators, so it was not clear as to whether the detected -OH radicals simply resulted from the Fenton reaction involving exogenous metal ion contaminants. Earlier, Marasas and Harington (1960) reported that quartz particles could function as an oxidant in a number of in vitro oxidations, including the hydroxylation of proline and lysine. They postulated that silica dusts, on reacting with water, could release H2O2 which might have the potential to react with various biological constituents and thus cause tissue damage. In fact, Gabor and coworkers (Gabor and Anca, 1974; Gabor et al., 1975) suggested that the cytotoxicity of quartz particles might be associated with the generation of some 'factor or factors possessing the properties of a free radicals capable of promoting the peroxidative chain cleavage of polyunsaturated fatty acid moieties of the phospholipids in the cell membrane. More recently Weitzman and Graceffa (1984) reported that asbestos is able to catalyze the generation of • OH radicals from H2O2. Their later work indicated that lipid peroxidation may be one of the mechanism by which asbestos produces tissue injury (Weitzman and Weitberg, 1985). This is significant because • OH radicals are capable of causing peroxidation by abstracting hydrogen atoms from cell-membrane lipids and initiating lipid peroxidation in lysosomal membrane (Fong et al., 1973). In fact, the formation of oxygenated species in reactions involving quartz was suspected since Kolbanev et al. (1980) reported the detection of H2O2 in the reaction of fresh quartz particle with aqueous medium. The present work was thus undertaken to detect the anticipated formation of some oxygenated, radical species by reactions of quartz in a cell-free media and its inhibition by radical"

Jan 1, 1988

By D M. Verster, P L. Gillot, A Kone

Randgold ResourcesÆ MorilaÆs gold leach plant is subjected to uncommon æoxygen stressesÆ. Feed ores exhibit very high oxygen demands, primarily caused by iron sulfides. In addition, ore oxygen demand varies significantly over time, as well as between different feed ore sources. The inability of the Morila gold leach plantÆs oxygenation system to cope with these high and fluctuating oxygen stresses manifested itself in variable gold residue grades, and cyanide consumption rates.Management launched a Morila oxygen system review project during September 2009, with the objective of auditing the performance of the then current oxygenation system, against required performance parameters as calculated from oxygen demands of the various feed ore types and targeted dissolved oxygen levels in the leach train.This paper describes the systematic changes made since 2009 to the Morila oxygen system in four main areas: O2-supply plant, O2-volumes, O2-controls and oxygenation equipment. Data are provided on corresponding improvements in leach plant performance. Theoretical, as well as practical aspects of gold leach oxygenation systems are covered.CITATION:Verster, D M, Gillot, P L and Kone, A, 2013. Oxygenation system upgrades and leach plant performance improvements at Morila Gold Mine - 2009 to 2012, in Proceedings World Gold 2013 , pp 215-224 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By I. D. Reznik

On blowing nickel matte in a converter without quartz, first the oxidation of metallic iron and a part of FeS occurs without evolving sulfur dioxide, the formed FeO dissolves in a sulphide smelt and form a homogeneous oxysulphide smelt. On further increasing the FeO content, the oxysulphide separates into 2 layers. Based on the laboratory investigation of FeO-(FeS+Fe°) - (Ni3S2+Ni°) ternary phase diagram we have identified the separation region at 1250°C. The boundaries of the separation region have the form of an arc and the composition of the separated oxysulphide layers is defined by the canodes. In the nickel or copper-nickel matte - silicacalcium oxide slag system at 1250°C three layers, namely sulphide, oxysulphide, and slag may be formed. A high slag basicity due to the presence of CaO can serve to enhance the activity of FeO; a low nickel content in the matte corresponds to a high concentration of FeS therein; FeO from slag and FeS from the matte form a homogeneous FeO-FeS solution, i.e. an oxysulphide layer. The investigation on the "Camebaks" apparatus and by the nuclear gamma-ray resonance spectroscopy method of the phase composition in a slowly cooled oxysulphide layer has shown the presence of four phases: wustite, troilite, ferronickel grains, and calcium oxide-silica inclusions. Knowledge of regularities in the oxysulphides formation makes it possible to use them in pyrometallurgy of nickel and cobalt or preventing their formation.

Jan 1, 1997

By CHARLES R. KETES

I. INTRODUCTORY. INDUSTRIALLY, the most important service that geological science can now render to mining in the Upper Mississippi leadand zinc-fields is to devise some practical scheme whereby the productive ore-belts may be located with greater certainty than they have been in the past. Up to the present time there has been little service of this kind, and in spite of all that has been worked out concerning the geologic features of the region, and notwithstanding all that has been written about these ore-deposits, this particular phase of the subject has been, for some reason or other, the very one that has received the least consideration. The neglect by geologists in this respect has been all but complete. The following notes are suggestive of some practical solutions to the problems presented. As here suggested, the geologic relationships of the ore-bodies were surmised some years ago, though somewhat vaguely perhaps. No opportunity for securing critical data appeared until recent investigations of a private character were undertaken, which bad in view the extensive prospecting of undeveloped areas. Fresh from rather wide experiences of a decade in the principal mining-regions of four continents, and after a lenstrum's residence among the chief mining-camps of the West and of Mexico, under conditions which measured geologic hypotheses in meters and rigidly tested their values in, terms of dollars, the recent return to the Joplin field and a new survey of its ore-conditions were fraught with somewhat unexpected results. Aspects of the ore-deposition were presented of which previously there was no hint. Ten years' absence from the district had tended greatly to clarify former hazy impressions. It enabled many features, then only dimly outlined, to be considered more nearly in their true perspective and in their real relationships to their surroundings. It permitted a great mass of details collected a dozen years before in connection with the work of the Missouri Geological Survey to be viewed under new light and to

Feb 1, 1909

By C. R. Keyes

Discussion of the paper of C. R. Keyes, presented at the Chattanooga meeting, October, 190S, Bulletin No. 26, February, 1909, pp. 119 to 166. E. R. BUCKLEY, Flat River, Mo. (communication to the Secretary*) :-Some statements in the paper of Mr. Keyes relative to the nature and formation of the Ozark lead- and zinc-deposits seem to me erroneous and misleading, and I respectfully present the following criticisms, placing Mr. Keyes's original statements in quotations. Referring to the Ozark dome: (P. 127.) "It is a region that has been repeatedly upraised and planed off, until in the middle portion the oldest known' rocks only are exposed." Does he mean that the St. Francois mountains, which have always been considered as lying on the eastern flank of the Ozark dome, are the middle of the dome? Or does he mean that the Cambrian rocks of the generally-accepted middle are the oldest known rocks ? Certainly not the latter, and if the former, his idea of the middle of the dome is not in accord with that of others who are familiar with the region. (P. 138.) " . . . the ore-deposits are definitely associated with, or localized by, geologic structures of some kind that .produce in effect basins in which' the underground waters are impounded, or their flow retarded." This statement does not appear to be altogether consistent with the facts, since the ore- bodies of the Joplin district, as the rule, occur in those parts of the Mississippian formation which have a tendency to accel¬erate the flow of ground-water rather than retard it. I might name the open, breeciated ground near Joplin, Webb City, and Oronogo as especially noteworthy illustrations. The ore-bodies, everywhere, occur in positions where there must have been a free and copious circulation of dilute lead- and zinc-solutions in the presence of reducing constituents. The inequalities in the distribution of the ore-deposits are

Oct 1, 1909

By C. E. Gerity

Near Bunker, Mo., in the New Lead Belt, Ozark Lead Co. operates a 6000 tpd lead-zinc mine. Mined ore is transported to the surface in three mechanized and automated steps. The mine is developed by a rectangular-shaped sublevel haulage drift 15 ft high by 28 ft wide, driven on strike below the ore zones. Ore transfer raises were driven from the sublevel at locations near the shaft, 1500 ft distant, and on subsequent 1000 ft centers. These 6 x 5-ft raises are slashed to obtain maximum storage below dump points. These dump points are located on each mining level and are of steel and concrete construction. Spiral 12 X 24-ft inclines driven from the sub-level provide access to these levels for equipment and mine utilities.

Jan 11, 1972

By Farouk T. Awadalla

The presence of humic species in spent Bayer liquor causes many processing problems in the production of aluminum hydroxide. Ozonation of spent Bayer liquor was found to be an effective process to destroy the colored humic species. The kinetics of the decolorization in spent Bayer liquor was found to be slower than in the alkaline humic acid solution containing no alumina. However, the reaction kinetics ware enhanced by heating the solution during ozonation above room temperature. Copper ions which are used as catalyst to enhance the ozonation reaction were found to be ineffective due to the presence of large quantities of aluminum hydroxide in the liquor. Ozonation was a more favorable process than membrane separation as it achieved about 92% separation of color and produced lower amounts of organic material. The treated spent Bayer liquor can be recycled to the upstream process without causing any difficulties and the purity of aluminum hydroxide product would also be improved. A comparison of preliminary cost data indicated that ozonation compares very favorably with membrane separation in this application. Key words: ozonation, Bayer liquor, aluminum hydroxide, humic species, copper ions, membrane separation, purity and economic.

Jan 1, 1994