United States
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Cincinnati OH 45268
Research and Development
c/EPA
Annual Summary of
Technical Awareness
in the Nonferrous
Metals Industry
.
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4, Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7 Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the ENVIRONMENTAL PROTECTION TECH-
NOLOGY series. This series describes research performed to develop and dem-
onstrate instrumentation, equipment, and methodology to repair or prevent en-
vironmental degradation from point and non-point sources of pollution. This work
provides the new or improved technology required for the control and treatment
of pollution-sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-79-092
April 1979
ANNUAL SUMMARY OF TECHNICAL AWARENESS
IN THE NONFERROUS METALS INDUSTRY
by
E. S. Bartlett and B. 6. Koehl
BatteHe Columbus Laboratories
Columbus, Ohio 43201
Grant No. R805095-01
Project Officer
A. B. Craig, Jr.
Metals and Inorganic Chemicals Branch
Industrial Environmental Research Laboratory
Cincinnati, Ohio 45268
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
-------
DISCLAIMER
This report has been reviewed by the Industrial Environmental Research
Laboratory, U.S. Environmental Protection Agency, and approved for publica-
tion. Approval does not signify that the contents necessarily reflect the
views and policies of the U.S. Environmental Protection Agency, nor does
mention of trade names or commercial products constitute endorsement or
recommendation for use.
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FOREWORD
When energy and material resources are extracted, processed, converted,
and used, the related pollutional impacts on our environment and even on our
health often require that new and increasingly efficient pollution control
methods be used. The Industrial Environmental Research Laboratory-Cincinnati
(lERL-Ci) assists in developing and demonstrating new and improved methodolo-
gies that will meet these needs both efficiently and economically.
To perform this task, lERL-Ci must not only keep abreast of current and
emerging industrial technology, but also of various aspects of commerce
important to industrial segments under its purview. Maintaining such an
awareness of the technological and business aspects of industry is no menial
task. This summary report describes efforts designed to facilitate awareness
of the nonferrous metals industry. The result has been the preparation of
periodic awareness bulletins, examples of which are appended. The descrip-
tion of methodology contained in this report will be useful to agencies and
persons involved in or contemplating formal means of assessing industrial
status for other than the nonferrous metals industry. Further information on
this subject may be obtained from the Industrial Pollution Control Division,
Metals and Inorganic Chemicals Branch, of lERL-Ci.
David G. Stephan
Director
Industrial Environmental Research Laboratory
Cincinnati
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ABSTRACT
The goal of this project was to pilot and refine methods and procedures
for maintaining current awareness of technology and commercial trends in the
U.S. nonferrous metal mining and manufacturing industry. The principal effort
resulted in the publication of six bimonthly technical awareness bulletins
during the first year. Items culled from the technical and trade literature
were presented as news notes, brief patent and foreign technology abstracts,
and, where the article content warranted, brief analytical summaries of per-
tinent technology. Examples of the product are appended.
This report was submitted in fulfillment of Grant No. R805095-01 by
Battelle's Columbus Laboratories under the sponsorship of the U.S. Environ-
mental Protection Agency, The report covers the period from May 1, 1977, to
April 30, 1978.
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CONTENTS
Foreword iii
Abstract iv
Tables vi
1. Introduction > 1
2. Conclusions and Recommendations 2
3. Methods 3
4. Results and Discussion 9
5. Usefulness to EPA 13
Appendix
Compilation of Technical Awareness Bulletins 15
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TABLES
Number Page
1 Indexing Strategy and Terms for Technology and Trends Summary . 4
2 Summary of Open Literature Findings, May 1977 to April 1978 . . 5
3 Summary of SSIE Catalogue of Research Programs Related to
Metal Ore Extraction and Refining (April 1978) 10
4 Sources of Funds and Types of Performing Agencies for
SSIE-Posted Projects 11
5 Returns of Data Base Searches for Chemical Abstracts and
Engineering Week 11
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SECTION 1
INTRODUCTION
The intent of this project was to provide a means whereby the Metals and
Inorganic Chemicals Branch of the Industrial Environmental Research Laboratory-
Cincinnati (lERL-Ci) could maintain a timely cognizance of new and developing
technology and operations in the nonferrous metals industry. The operational
basis at the outset was a methodology recommended in Report No. EPA-600/2-76-
303, Methodology for Assessing Environmental Implications and Technologies:
Nonferrous Metals Industries.
The primary objective of this program was to prepare an analytical com-
mentary on technology within the nonferrous metals industry that might affect
the impact of^that industry on the environment. Chief goals during the first
year of this program were (a) the piloting of methodology, (b) the develop-
ment of a suitable information bulletin format, and (c) the submission of six
bimonthly awareness bulletins to the U.S. Environmental Protection Agency
(EPA), (see Appendix).
Information and data were to be obtained primarily through a timely
review of the current open literature. A recommended list of 44 publications
ranging from daily to quarterly periodicals, and involving about 230 individ-
ual issues for each 2-month period, were to be searched. Supplementing
periodicals as the primary sources of information was attendance at selected
conferences, review and purchase of pertinent conference preprints and special
publications, abstract searching, and personal contacts.
Although selected foreign language journals were included in the recom-
mended list, only titles and abstracts (where available) printed in English
were perused. Translation was not included within the scope of this program.
Some changes in methodology and strategy were indicated and instituted
during the course of this project. The report describes the methods and pro-
cedures found to be most effective in providing a medium for monitoring
awareness.
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SECTION 2
CONCLUSIONS AND RECOMMENDATIONS
In general, the effectiveness of technology coverage during the first
year of this project was judged to be fair. Coverage of English language
literature was generally very good. Areas of weakness were the foreign
literature and conference proceedings. Steps have already been taken to cor-
rect the weak coverage of the foreign literature. By using the methods
described here along with some minor changes in technique, coverage of truly
pertinent technology (excluding foreign patents) should be effective enough
to include 80 to 90 percent of the pertinent items in the abstract data bases
studied.
News items are not normally covered by the technical abstract services,
so there is no convenient way of assessing the coverage effectiveness; but
for news clips of major import, several publications often report the same
item, indicating that coverage is probably good.
In conclusion, the methodology adapted for this task of maintaining
awareness of technology and events in the nonferrous metals industry is
believed to provide the intended coverage. A few weak coverage areas are
recognized and will be corrected in continuing activities. Coverage of for-
eign literature and conference proceedings will receive more emphasis. We
recommend that this activity be continued.
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SECTION 3
METHODS
To facilitate collection of data for each bimonthly bulletin, incoming
journals and periodicals were set aside by the libraries at Battelle for a
few hours after receipt each day. These were searched daily by the project
staff. Selections were made by scanning the tables of contents of technical
journals and appropriate scanning of popular journals and news periodicals.
Items and articles of possible interest were noted and clipped or reproduced
for more detailed review, culling, sorting, and analysis. On the average,
about 200 publications (roughly 1,000 issues in a 2-month period) were
scanned in this way.
The publications screened in this manner included most of the recommended
list from EAP-60Q/2-76-303. In addition, many other publications were
retrieved from publications not on the recommended list.
In the preparation of each bulletin, the collected material was reviewed
in detail. Items judged to describe new technology or news pertinent to the
nonferrous metals industry, and particularly items that related to possible
local or generic changes in environmental quality, were set aside for analysis
and summary. Items that lacked novelty, were out-of-date, or could not be
conceived to have significant environmental implications were rejected at this
point.
News items were grouped according to topic, summarized, and referenced
for reporting. Technical articles were reviewed in detail and abstracted,
with comments on probable environmental implications where this was appro-
priate, in the Technology and Trends Section. Each selected article sum-
marized as a Technology and Trends item was indexed according to a three-tier
system defining the material, process, and area of potential environmental
impact, insofar as these were applicable. Table 1 lists the index terms and
describes the index order. This index may be used for the ready retrieval of
information according to the index classification.
Patent abstracts were reviewed to extract technical information, which
was then briefly summarized in technical rather than legal language.
Abstracts of foreign language articles were reviewed and often rephrased for
more appropriate syntax. The manuscripts were assembled, typed, edited,
collated, and submitted to the EPA/IERL project officer. The draft bulletins
were reviewed by the project officer and preprinted by IERL for distribution
to selected government offices and industrial concerns with known interest in
the subject matter. Upon conclusion of the year's activity, the bulletins
-------
were formally reviewed and assembled as a single annual" review document. This
is included as the Appendix to this report.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
TABLE 1.
Metals
Cu (and As,
Pb, Zn (Sb,
Al (Ga)
Ti (Zr, Hf)
Mo (Re, Sn)
Rare Earths
Be
Hg
Ag, Au, Pt,
W
V, Cr
Cb, Ta
Ml (Co, Mn)
Mg
Multiple
Unspecified
INDEXING STRATEGY AND TERMS FOR
TECHNOLOGY AND TRENDS SUMMARIES
Process
Se, Te)* .1 Mining (P)f
Cd, Tl) .2 Beneficiation (P)
.3 Smelting/Extraction (P)
.4 Refining (P and S)
.5 Ingot Melting (P and S)
and Y .6 Preparation (S)
.7 Smelting/Extraction (S)
.8 General Recycling (S)
Pd .9 Multiple (P and S)
Environmental Concern
.1 Air (Human)
.2 Air (Ecology)
.3 Water (Human)
.4 Water (Ecology)
.5 Solid (Human)
.6 Solid (Ecology)
.7 Noise
.8 Multiple
.9 Not Determined
Example: 5.3.4
This article deals with the extraction of molybdenum
(or rhenium or tin) values as it may impact ecologi-
cal effects of aqueous effluents.
* ( ) = common byproducts
t ( ) = primary or secondary
A summary of returns from technical and commercial literature perusal is
given in Table 2 for those publications that yielded items of potential
interest. Of 740 items separated for further study, about two-thirds were
actually used in preparing the awareness bulletins. The rest were discarded
when review indicated the item or technology was not new, not pertinent to
the nonferrous metals industry, or not significant to environmental considera-
tions. About three-fourths of the collected items came from about one-fourth
of the most productive publications.
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TABLE 2. SUMMARY OF OPEN LITERATURE FINDINGS, MAY 1977 TO APRIL 1978
Publication title
J. Air Pollution Control Association
American Metal Market
American Scientist
Proc. Australasian Inst. Mining and
Metallurgy
Australian Mining
Canadian Chemical Processing
Canadian Inst. of Metals Bulletin
Canadian Mining Engineer
Canadian Mining Journal
Chemical and Engineering News
Chemical Engineering
Chemical Processing
Chemical Week
Chemistry in Australia
Chemistry in Canada
Chemistry and Industry
Chemtech
Electronic Progress
Engineering and Mining Journal
Environmental Science and Technology
Environmental News
Erzmetall (German)
Foundry Management and Technology
Hitachi Review
Hydrometallurgy
Indian and Eastern Engineer
Industrial Heating
Number of
Publication articles of
frequency interest
Monthly
Daily
Bimonthly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Weekly
Bimonthly
Monthly
Weekly
Monthly
Monthly
Biweekly
Monthly
Quarterly
Monthly
Monthly
Monthly
Monthly
Monthly
Bimonthly
Monthly
Monthly
(Continued)
1
108
1
3
1
3
5
1
1
7
12
3
12
1
1
1
1
1
34
6
1
26
1
1
2
1
1
Number of items
News
i terns
_.
52
-
-
_
-
_
1
_
2
4
2
4
-
-
-
-
-
18
1
1
-
-
-
-
-
-
Technology
summary
1
9
1
2
1
3
3
_
1
1
4
1
-
1
-
1
-
:
6
1
_
-
-
-
1
1
-
used
Abstracts
_
-
-
-
_
-
_
_
_
_
_
_
_
_
_
-
_
_
_
-
_
21
_
_
-
_
-
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TABLE 2. (Continued!
Publication title
Trans. Inst. of Mining and Metallurgy
Iron Age - Metal working International
J. Water Pollution Control Federation
Journal of Metals
J. Occupational Medicine
Light Metal Age
Metal Bulletin
Metallurgical Transactions B
Metal Progress
Metal 1 (German)
Metals Week
Metals and Materials
Metalurgia Italiana (Italian)
Mineral Industry Survey
Minerals and Materials
Mining Congress Journal
Mining Engineering
Mining Journal
Mining Magazine
Mining Record
Modern Application News
Modern Metals
Neue Hutte (E. German)
Northern Miner
Pay Dirt - Arizona
Pay Dirt - New Mexico
Plating and Surface Finishing
Pravda Ukrainy (Russian)
Number of
Publication articles of
frequency interest
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Semi weekly
'Quarterly
Monthly
Monthly
Weekly
Monthly
Monthly
Monthly
Monthly
Monthly
Monthly
Weekly
Monthly
Weekly
Bimonthly
Monthly
Monthly
Weekly'
Monthly
Monthly
Monthly
Weekly
(Continued)
2
1
1
11
2
4
9
1
1
1
2
2
1
13
48
26
17
15
12
53
1
4
1
2
48
24
1
1
Number of items
News Technology
items summary
_
-
-
2
-
2
3
-
-
-
1
-
-
3
29
11
4
4
-
39
-
1
-
-
26
17
-
-
2
-
1
4
2
-
-
1
-
-
1
2
-
-
-
3
4
1
4
1
-
-
-
2
1
-
«««
-
used
Abstracts
-
-
-
-
-
-
-
-
-
1
-
-
1
-
-
-
-
-
-
-
-
-
-
-
-
-
-
1
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TABLE 2. (Continued)
Publication title
Precision Metals
Rudi I Metale (Polish)
Skill ings' Mining Review
Soviet News in Science and Technology
Sulfur
Technische Mitteilungen Krupp (German)
Thirty Three
Transactions of the National Institute
for Metals
Tsvetnye Metal ly (Russian)
U.S. Patent Gazette
Wall Street Journal
Water, Air, and Soil Pollution
Wire Technology
World Mining
Total for 69 Publications
Publication
frequency
Monthly
Monthly
Weekly
Monthly
Bimonthly
Monthly
Monthly
Monthly
Monthly
Weekly
Daily
Monthly
Bimonthly
Monthly
-
Number of
articles of
interest
1
12
30
2
2
1
4
1
1
118
12
1
1
14
740
Number of items
News
i terns
«.
-
18
1
-
-
1
_
-
-
5
-
-
6
258
Technology
summary
_
-
6
-
1
-
1
1
-
-
-
-
-
3
79
used
Abstracts
_
9
-
-
-
1
-
_
1
84
-
-
-
-
119
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Collections made during the first 2-month period showed that detailed
reports of technology were fewer in number than had been expected and that
newsworthy items relating to business and regulatory concerns of the non-
ferrous metals industry were dominant in the collections. Accordingly, the
awareness bulletin format was revised to include sections on news, patents,
and technology of potential interest and utility to EPA. Also, because of
the abbreviated nature of English abstracts in foreign language journals, a
foreign technology section was later added.
In addition to the above primary functions, the following activities
were pursued:
1. Abstracts of the Canadian Institute of Metals (CIM) August 1977
symposium in Vancouver, B.C., were reviewed, marked, and sent
to the EPA project officer. (Preprints of selected papers were
sought from CIM but were not available.)
2. A number of special publications were purchased for use in this
program:
Arizona Pay Dirt (monthly)
New Mexico Paydirt (monthly)
Mining Record (weekly)
Lead and Zinc Update, 1978 (book)
Light Metals, 1978 (two-volume book).
3. The Annual Meeting of the American Institute of Mining, Metal-
lurgical, and Petroleum Engineers in Denver, 1978, was attended
by the principal investigator, and a report was sent to the EPA
project officer. Several preprints were ordered, received, and
reviewed.
4. Selected personal contacts were made to clarify some points of
written papers or to check news items. The results were incor-
porated into the awareness bulletin comments and analyses.
5. Searches were made of the following data bases:
• SSIE (Smithsonian Scientific Information Exchange),
Topic HS45-08 - Metal Ore Extraction and Refining,
April 1978
• CHEMCON (Chemical Abstracts), April 1978
• COMPENDEX (Engineering Index), April 1978.
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SECTION 4
RESULTS AND DISCUSSION
Effectiveness of the technology coverage achieved by this study was
judged by comparisons with the three data bases searched—SSIE, Chemical
Abstracts, and Engineering Index. The usefulness of these abstract data
bases was limited, however, because entries were generally not current.
The lag in abstract service postings is such that most are not listed
until 8 to 13 months after publication in the case of the Engineering Index,
and 10 to 16 months for Chemical Abstracts. Of the research projects listed
in the SSIE data base (Metal and Ore Extraction and Refining Catalogue), 93
of 169 were pertinent to nonferrous metal and ore processing, but only four
were current (April 1978). The rest had either been terminated recently or
as many as 2 years ago. Some listed programs were obviously continuations
of earlier studies, which were also listed. Several of these programs have
already been reported in the open literature, and some have been the subject
of awareness bulletins.
Results of the data base searches are nonetheless useful, despite their
limitations. A categorical summary of SSIE-posted research pertinent to the
nonferrous metals industry is useful for indicating areas in which this type
of research is typically conducted (Table 3). The SSIE data base heavily
emphasizes Federally funded programs performed by government agencies and
universities (Table 4). A similar search of the COMAT (an interagency
government committee on materials) data base on file at Battelle's Columbus
Laboratories for the Federal fiscal year 1976 yielded half again as many pro-
grams as the SSIE data base. The COMAT programs have more emphasis on the
environment because they include more U.S. Department of Health, Education,
and Welfare programs pertinent to the nonferrous metals industry.
Searches of the Chemical Abstracts and Engineering Index data bases were
conducted for nonferrous metallurgical processes with environmental implica-
tions. The searches were made on data base entries from January 1, 1977, to
April 17, 1978 (the date the search was made). Returns of the searches are
presented in Table 5.
Fifty-six percent of the possibly pertinent items from Chemical Abstracts
was from periodicals covered in this grant; 26 percent was from foreign patent
literature and foreign journals not covered by current searching; 7 percent
was from conference proceedings not published in regular periodicals; another
7 percent was in one periodical available to the grant activity but not
included in the searching (it will be in the future); and 4 percent was in
the report literature. This result indicates that greater attention should
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TABLE 3. SUMMARY OF SSIE CATALOGUE OF RESEARCH PROGRAMS
RELATED TO METAL ORE EXTRACTION AND REFINING
(APRIL 1978)
Material
Aluminum
Copper
Lead
Zinc
Precious Metals
Ni/Co
Chromium
Toxic material
Other and unspecified
Total number of projects
Development of
domestic resource
5
0
0
0
5
5
6
0
3
25
Improvement of
energy efficiency
1
0
1
2
0
0
0
0
1
5
Amelioration of
environmental
problems
2
5
3
2
1
0
0
6
5
24
Improved
process
economy
1
6
0
3
0
0
0
0
3
13
Material recovery,
recycle, and
conservation
1
3
0
1
0
0
0
0
2
7
Education and
basic research
0
2
0
0
0
0
0
0
17
19
Total
number
of
projects
10
16
4
8
6
6
6
6
31
93
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TABLE 4. SOURCES OF FUNDS AND TYPES OF PERFORMING AGENCIES
FOR SSIE-POSTED PROJECTS
Item
Funding Source:
Federal Government
Department of Interior
National Science Foundation
EPA
Department of Defense
National Oceanographic
and Atmospheric
Administration
Industry
Local Government
Foreign
Number
88
56
24
6
1
1
3
1
1
Item
Performing Agency:
Federal Government
United States Bureau
of Mines
Army Materials and
Mechanics Research
Center
Oak Ridge National
Laboratorys
Universities
Industry
Foreign
Other
Number
57
55
1
1
27
4
1
4
TABLE 5. RETURNS OF DATA BASE SEARCHES FOR
CHEMICAL ABSTRACTS AND
ENGINEERING INDEX
Item
Chemical Abstracts
Engineering Index
Number of items
Weighted age of items,
April 17, 1978
Number of items dated after
138
15.5 months
103
11.7 months
May 1 , 1 977*
Number of applicable items
Number of items dated after
January 1 , 1977
42
27
0
52
30
1
* Date on which the grant began.
t Title scan of items dated May 1, 1977, or later indicated that this was
the number of items pertinent to the scope of this grant.
11
-------
be paid to worldwide conferences, and attempts should be made to obtain pro-
ceedings from such conferences where they or the abstracts are available in
English. The purview of foreign journals during the first year was less than
desired, and steps have been taken to remedy this situation. However, con-
siderable input to Chemical Abstracts derives from foreign patent literature.
The expense of monitoring and assessing the foreign patent literature would
be out of proportion with the value accrued. On the basis of this evalua-
tion, the target coverage for this project relative to the eventual Chemical
Abstracts postings should be about 70 percent.
The Engineering Index appears to concentrate more heavily on the index-
ing of technical periodicals than does Chemical Abstracts. About 80 percent
of the possibly pertinent items returned by the search of this data base
were derived from publications covered by this grant. Thirteen percent of
the Engineering Index yield was from foreign journals (or translations
therefrom) not covered by this study. The remainder was from special con-
ference proceedings and the report literature.
12
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SECTION 5
USEFULNESS TO EPA
The Environmental Protection Agency has comprehensive legislative and
judicial mandates for regulating all pollution resulting from the production
and use of industrial chemicals and products. Emphasis is being placed on
toxic and hazardous pollutants. To aid EPA's Office of Research and Develop-
ment (ORD) focus its future control technology research and development
efforts on those pollution problems which have the greatest health and eco-
logical impacts, an approach has been developed for simultaneously assessing
the total environmental impact of industrial pollution discharge to the air,
water, land, and to municipal treatment systems. This multimedia approach
necessarily involves the active cooperation and participation of the appro-
priate industrial and EPA components to define the industry, identify the most
pressing environmental problems, and structure development programs on promis-
ing existing or emerging technologies. Pertinent research projects in the
private and public sector (both foreign and domestic) continue to advance the
state of the art of control and abatement technologies. Results of these
efforts are often reported in trade journals, magazines and conference pro-
ceedings. Without some attempt to centralize this flow of information, dup-
lication of effort or reinvention of existing information would likely exist.
From ORD's perspective, an immediate need to maintain cognizance of the
development of control technology by industry exists. This is apparent when
technology application studies are initiated to address either a specific or
a generic pollution problem. Promising new or novel approaches are important
and welcome. The best current solution, rather than just a possible solution,
can then be resolved. This necessitates maintaining an up-to-date data base
that evolves from public and private inputs and the technical literature to
create a more complete picture. This need is addressed by the bulletin in
that the information in the public domain is screened for relevance to a par-
ticular program for technical soundness and directed to the appropriate
individuals. Specifically, the Metals and Inorganic Chemicals Branch is
developing a data resource center that will use the bulletins' findings for
review, analysis, and development of current and proposed nonferrous metals
program directions.
There are ancillary benefits accruing to the nonferrous research and
development program as well. Technical personnel often read many publications
to remain abreast of current technological developments. To approach a com-
plete review would be time consuming if each individual in an operational
group were to perform a comprehensive review. In addition, attendance at
relevant conferences is not always possible. The bulletin, therefore, becomes
a time-saving device providing a complete and timely summary of the technical
13
-------
literature at a comparatively modest price. The EPA's nonferrous research and
development program also gains visibility through the bulletin by informing
its user group of current projects and products. Constructive criticism and
suggestions often result which aids in program direction, provides new initia-
tives, and encourages industry participation.
14
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APPENDIX
COMPILATION OF TECHNICAL AWARENESS BULLETINS
July 1977«May 1978
TECHNICAL AWARENESS BULLETIN--NONFERROUS METALS
This is a regular publication of the USEPA's Metals and Inorganic
Chemicals Branch, Office of Research and Development, designed to spotlight
selected events and concerns of the nonferrous metals industry.
HIGHLIGHTS
* Woea continue In the. coppeA industry as tow pAi.ces, iwpoAts,
and laAge. inve.ntoAi.es oveAhang the. domestic, supply situation.
?Aopose,d stockpile, changes may pAovi.de. A owe. tempo AaAy Aeli,e.{,,
but the. pAoje.cte.d cAippli.ng e.fi£e.cts o& e.nviAonme.ntal. Ae.quiAe.-
me.nts indicate, that conditions \aiUi continue, to dzteAi-OAate,.
(Item S, 11)
• Domestic, zinc. pfiadu.c.eju> OAJL at&o kaM kit. by depte^ed con-
ditions, and additional cloAusieA and cutback* OA.Q. announced.
AuthoJvUti&A qu.esti.on wheJJneA the. domestic zinc i.nduAtA.y can
sux.vi.ve.. A 5-yejOA. suA.vi.val. ptan has been p>ie-6en£ed to the.
InteAnational. TAo.de. Commission (Itm& 26, 27)
9 The. State, oft AAJ,zona and its coppeA smelting -industry aAe.
agi£ate.d by the. Ae.ce.nt USEPA annou.ncwe.nt ofi The. Arizona
flan, the. pAe.paAati.on ofa which appe.aAs to have.
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NON-FERROUS METALS INDUSTRIES
IN THE NEWS (SB
tu
Aluminum
(1) Construction has begun on a 91,000 tpy potline expansion at the
Eastalco primary aluminum smelter of Alumax Inc. at Frederick, Maryland.
This will expand the Frederick smelter capacity to 267,000 tpy. The new
potline addition will be owned jointly by Alumax and Mitsui and Co. Ltd.
Construction is scheduled for completion in 1980. Howmet Aluminum Corp.
has the option of becoming a part of the joint venture in 1982.
Copper
(2) The addition of a new dumping pocket with a 350-ton capacity,
and an 8 x 40-foot pan feeder will provide an improved and controlled
2000 tph flow of ore to the crusher at Kennecott's Ray Mines Division
in Arizona.
(3) Occidental Minerals Corp. has suspended indefinitely work on its
copper project near Cerillos, New Mexico, citing the depressed copper market
and the high cost of meeting state environmental requirements as factors.
Another contributing factor may have been a petition by environmentalists
who were expressing concern that the in situ leaching operation might be a
threat to the local water table and its purity.
(4) Hanna Mining Co. has raised the estimated reserve by 40 percent to
350 million tons of 1 percent copper ore at the recent discovery near Casa
Grande, Arizona. Drilling will continue through 1978, along with intensive
geological, metallurgical, and environmental studies, to determine the
feasibility of a large-scale operation by the joint venture of Hanna and
Getty Oil.
(5) The Magma^Copper Co. is converting the furnaces of its San Manuel
smelter to coal firing. The first furnace conversion is slated for comple-
tion by July 1, 1978, but must await installation of electrostatic precipi-
tators before its use, probably in mid-1979. Natural gas shortages and the
increasing cost of fuel oil is given as the reason for several other copper
producers contemplating a similar change to coal.
(6) Effective May 1, 1978, the Anaconda Co. will shut down its Anaconda.
Montana smelter for 2 months for repair of an electric furnace. Sufficient
anode copper is stockpiled to meet deliveries.
16
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Kennecott has closed its Nevada Mines Division for at least 3 months
and the Baltimore copper refinery for 3 months effective May 1. Oversupply
in the copper market resulting in depressed prices was the stated reason for
these closures.
(7) Approximately 5 million tons of copper contained in ore assaying
0.2 to 0.4 percent copper has been defined in exploration north of Safford,
Arizona, by the Kennecott Corp. Efforts for the past 7 years have been
devoted to in situ piloting of this deposit. The pilot mining study is not
now economically feasible. No additional details are available.
(Note: Through personal contact, it has been learned that Kennecott is
cancelling its in situ mining program.)
(8) A recent study by Arthur D. Little. Inc. for the U.S. EPA concludes
that the copper industry will be crippled by environmental requirements. The
Clean Air Act and Water Pollution Control Act will cost the domestic copper
industry 21,000 to 28,000 jobs, force prices up 30 to 39 percent, reduce pro-
duction 25 to 33 percent, raise copper imports by 18 to 21 percent, and
reduce total domestic consumption by 8 to 11 percent by 1987.
(9) Kennecott, Phelps Dodge, Anaconda, Asarco. Magma, Inspiration,
Duval, Cities^Service, Copper Range. Cyprus, Hecla, and Ranchers recently
filed a petition with the International Trade Commission stating that tem-
porary import relief is necessary to remedy the injury to the copper indus-
try caused by increased copper imports. The Commission must now prove that
the producers have been injured and qualify for protection under the law.
(10) A decision was made to establish a "standing intergovernmental
copper body" by the Third Preparatory Meeting on Copper which met in Geneva
on January 30-February 3, 1978. This group will continue to examine the
copper situation and search for solutions to identified problems.
(11) In a move to diminish the domestic glut of copper, a bill intro-
duced in the House of Representatives by Rep. Udall and concurrently in the
Senate by Sen. De Concini calls for the disposal of up to 45,000 long tons
of tin from the national stockpile. Proceeds from up to 26,000 tons are to
be used to finance purchase of up to 225,000 short tons of copper, the
remaining tin receipts to be used to finance other strategic materials pur-
chases. No funds for the purchase of the copper are included in the supple-
mental 1978 or,fiscal 1979 budget requests; thus, the only method of acquir-
ing the copper is by the sale of tin or tungsten, or through direct barter.
It is believed that barter or the swaping of tin and/or tungsten for copper
would expedite the acquisition of the copper without incurring the delays of
the appropriations procedure.
The Carter administration has given its full and unqualified endorse-
ment to the Udall-De Concini legislation.
17
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Lead
(12) Amax has no specific plans to expand lead and zinc production,
although the demand for lead has been excellent with a 2 percent growth
expected by 1979. A recent report that the ambient air standard of 1 .5
micrograms per cubic meter would close down about 80 percent of the domestic
lead smelting and refining capacity is thought to be an accurate assessment.
The Buick. Missouri, lead facility of Amax cannot meet this standard as the
technology for compliance with the standard apparently doesn't exist.
(13) Construction has begun on a $3 million lead strip fabricating
plant by the St. Joe Lead Co. near its lead smelter in Herculaneum, Missouri
The facility is slated to go into production in late 1979,
capacity of 30,000 tons per year to serve the growing
battery market.
with an initial
maintenance-free
Molybdenum
of
(14) Further geological exploration has increased
molybdenite mineralization to 165 million tons at Amax
near crested Butte, Colorado. An estimate of 130 million tons was reported
in "In the News" for September/October, 1977.
the estimate
s Mt. Emmons project
(15) In order to coordinate all activities in reviewing and issuing
permits and drafting environmental impact statements at Climax's Mt. Emmons
molybdenum project near Crested Butte, Colorado, the State of Colorado has
proposed "The Colorado Venture". This pioneering process would identify all
Federal, State, and local agencies that should be involved in the planning
and conceptual process of the mine development.
Nickel
(16) The Port Nickel Refinery of Amax, Inc., near New Orleans,
Louisiana, has saved 35,000,000 kilowatt hours of electricity per year by
bypassing a $1.8 million electric arc furnace used to melt crushed copper-
nickel matte.
Precjious Metals
(17) One and a half million dollars has been invested to revive the
Blazing Star Gold Mine in California's Mother Lode country. Apparently,
the previous owners had only mined down to the oxidized (free gold) level.
A 13.5-foot-wide vein at a depth of 1600 feet has assayed 17 ounces of gold
per ton of ore, in contrast to the 7 ounces per ton of the former mining
operation.
(18) The Homestake Mining Company's gold mine in Lead, South Dakota,
has recently completed and placed into operation a $14 million project for
tailings disposal and environmental enhancement. This brings to an end the
18
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practice of discharging mine tailings and wastewater pollutants into the
rivers and streams of the Black Hills.
(19) The high market price of gold continues to induce many companies
to prospect for.gold as well as silver with increasing intensity. The
Bueno Coeur d'Alene Company has drilled 2200 feet, near Mullan, Idaho, into
a vein assaying 15.2 ounces per ton of silver, while its exploration near
Boulder, Colorado, has an excellent potential for reserves of telluride gold.
Placer mining for gold will begin in 60 days by the Boardman Gold Mining Co.
near the Columbia River at Boardman. Oregon. Ladd Enterprises, Inc. will
begin placer mining its claims in Mineral County, Nevada, at the rate of
3000 tons per week. An estimated 100 million tons of placer material
averages 0.06 ounce per ton of gold and 0.3 ounce per ton of silver. Gold
Placers, Inc. intends to return its Liberty gold placer property to produc-
tion this year because of the discovery last year of a number of gold nug-
gets in the old channel of Liberty Creek near Ellensburg. Washington.
(20) Approximately 30 million tons of sulfide ore mineralization is
indicated by exploratory drilling in Aroostook County, Maine, by the joint
venture of the Superior Oil Co. and the Louisiana Land and Exploration Co.
At a depth of 108 feet, a deposit averaging 350 feet in thickness assays
3.38 percent Zn, 0.11 percent Cu, 0.861 ounce Ag and 0.0206 ounce Au per ton
for one ore type, and 1.64 percent Cu, 0.219 percent Zn, 0.2415 ounce Ag,
and 0.0074 ounce Au per ton for a second type of ore.
Sea Nodules
(21) The SS Glomar Explorer will be used later this year to explore
ways of mining manganese nodules on the ocean floor southeast of Hawaii.
The government-owned ship (formerly owned by Howard Hughes) is under a 3-year
lease by Global Marine Development, Inc., and later will be used by a con-
sortium headed by Lockheed.
(22) What to do with a possible 10,000 tons per day waste from sea
nodule processing has been given considerable thought in the Puna district
on the island of Hawaii. This is the most likely location for a processing
plant of sea nodules. The possibility exists that the residue could be used
to cover lava flows as a substitute top soil for agriculture use.
Zinc
(23) Low prices, tight markets, imports, and outmoded plants continue
to plague the domestic zinc industry. Additional facility closures and pro-
duction cutbacks are the result. For example, the Bunker Hill Company
closed its Pioche. Nevada, mine and mill on March 31, 1978. for an indefinite
period. The declining price of zinc was given for the closure. The Pan
American Mine and Case!ton concentrator was currently producing about 400
tons of zinc metal monthly.
19
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(24) During the last week of April, 1978, the production at the Corpus
Christi, Texas, zinc refinery of Asarco, Inc. was curtailed to 50 percent of
capacity for an indefinite period. Other zinc plants which have closed or
"are operating at reduced capacity are Amax, Inc.'s Sauget. Illinois, electro-
lytic refinery, closed down; the Bear Hole mine of Eagle-Pitcher, near
Shullsburg, Wisconsin, closed down; St. Joe Zinc Co.'s Monaca, Pennsylvania,
verticle retort plant, operating at 65 percent capacity; New Jersey Zinc
Co.'s Palmerton, Pennsylvania, vertical retort plant, operating at 72 percent
capacity; and Bunker Hill Co.|s Kellogg. Idaho, electrolytic refinery,
operating at 70 percent capacity.
(25) Operation of the zinc fuming plant of the Bunker Hill Co.'s lead
smelter in Kellogg, Idaho, was resumed in early March after a 39-day closure
due to poor market conditions. Jersey Mini ere Zinc Co. will bring its
Clarksville, Tennessee electrolyte refinery with a capacity of 90,000 tons
of zinc per year on stream this fall, rather than in August, as had been
planned.
(26) The zinc industry appears to be at a crossroads with the survival
of the industry at stake, according to some producers. Two major problems
face the producers:(TJ outmoded facilities and (2) declining zinc consump-
tion. The outmoded plants have caused a decline of 50 percent in zinc pro-
duction since 1970, with the gap filled by imports. A 50 percent cutback in
the use of zinc in the 1978 model cars has compounded the problem of
inefficient plants.
(27) In an attempt to curb imports, the zinc producers have presented
to the International Trade Commission a 5-year plan. The plan recommends a
quota of 350,000 tons the first year (beginning September, 1978), beyond
which a $0.07 tariff on each pound of slab zinc would be imposed. Each year
the quota would be raised, until it reached 525,000 tons in 1982. The
quotas are based on a domestic consumption of 1,140,000 short tons during
ithe first year, and a 2.5 percent annual growth rate through 1982.
Miscellaneous
(28) American Metallurgical Products Co. will produce 3 to 5 million
pounds of mischmetal and other rare earth metals at its new $1 million
plant, which began production in March, 1978. at Sprindale, Pennsylvania.
(29) The entire issue of the Journal of Metals for April, 1978. is
devoted to a review of extractive and process metallurgy, including over
500 references. The details will be reported in a future Awareness Bulletin.
(30) Residential and commercial heat as a byproduct of the metals
industry? Heat wasted at Intalco's Ferndale, Washington, aluminum reduction
plant could heat as many as 6,500 homes within a 20-mile radius, according
to a study by Intalco, Rocket Research, and Bonneville Power. An estimated
2000 megawatts of potentially marketable heat are wasted by domestic alu-
minum plants alone. Federal funds will be requested to pilot a heat collec-
tion and distribution system.
20
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(31) The Arizona Plan of the U.S. EPA to regulate smelter emissions
became effective on February 3, 1978. Many legal suits and battles are
anticipated as it is impossible for any copper smelter in Arizona, except
the Phelps Dodge Ajo plant, to meet the air quality standards, now or in
the foreseeable future. The state-adapted plan under which the smelters
are now operating was submitted to the EPA in January, 1977, for review
and comment, but was never acknowledged. This plan improved the air
quality 75 to 80 percent in the past 2 years.
A Nonferrous Smelter Order passed as an amendment to the Clean Air Act
last year allows a 10-year postponement of expensive new pollution controls
for those companies who show the EPA they cannot afford the maximum emission
controls.
(32) A hearing chaired by Rep. tidal! of Arizona and Rep. Johnson of
Colorado was held in Grand Junction. Colorado, on February 18, 1978, to
consider repeal or reform of the General Mining Law. Attended by 200 per-
sons, statements were made by 82 witnesses, two-thirds of whom urged leaving
the present law intact or using an amended version of HR 5831 (the Ruppe
bill backed by Rep. Udall and the American Mining Congress), if Congress was
determined to pass some kind of a mine reform bill this session.
21
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REFERENCES
(1) U.S. Bureau of Mines, Minerals and Materials, 1 (April, 1978).
(2) Arizona Paydirt, (464), 37 (February, 1978).
(3) New Mexico Paydirt, (10), 41 (March, 1978).
(4) Skillings1 Mining Review, 67_ (14), 17 (April 8, 1978).
(5) Engineering Mining Journal, 179 (3), 236 (March, 1978).
(6) American Metal Market, 86 (75), 10 (April 18, 1978).
(7) Arizona Paydirt, (464), 50, 51 (February, 1978).
(8) Arizona Paydirt,(465), 10, 11 (March, 1978).
(9) U.S. Bureau of Mines, Minerals and Materials, 2 (March, 1978).
(10) U.S. Bureau of Mines, Minerals and Materials, 10 (February, 1978),
(11) Arizona Paydirt, (465), 12 (March, 1978).
American Metal Market, 86 (58), 1, 7 (March 24, 1978).
(12) American Metal Market, 86_ (68), 8 (April 7, 1978).
(13) The Wall Street Journal, LVIII (98), 11 (March 6, 1978).
(14) The Mining Record, 89 (12), 3 (March 22, 1978).
(15) U.S. Bureau of Mines, Minerals and Materials, 47 (March, 1978).
(16) World Mining, *L (3), 122 (March, 1978).
(17) The Mining Record, 89 (16), 1 (April 19, 1978).
(18) U.S. Bureau of Mines, Minerals and Materials, 59 (February, 1978),
(19) The Mining Record, 89 (9), 1 (March 1, 1978).
The Mining Record, 89_ (8), 1 (February 22, 1978)
The Mining Record, 89 (12), 1 (March 22, 1978).
Engineering Mining Journal, 179 (3), 240 (March, 1978).
(20) Skillings1 Mining Review, S7_ (14), 19 (April 8, 1978).
(21) Arizona Paydirt, (464), 12 (February, 1978).
(22) U.S. Bureau of Mines, Minerals and Materials, 53 (February, 1978)
-------
(23) The Mining Record, 89 (12), 1 (March 22, 1978).
American Metal Market, 86_ (50), 20 (March 14, 1978).
(24) The Mining Record, 89 (14), 1 (April 5, 1978).
American Metal Market, 86. (65), 2 (April 4, 1978).
Engineering and Mining Journal, 179 (4), 153 (March, 1978)
(25) Arizona Paydirt, (465), 35 (March, 1978).
American Metal Market, 86 (56), 8 (March 22, 1978).
(26) American Metal Market Lead and Zinc Supplement, 86 (66), 4A, 15A
(April 5, 1978).
(27) American Metal Market, 86 (57), 1, 8 (March 23, 1978).
(28) U.S. Bureau of Mines, Minerals and Materials, 7 (March, 1978).
(29) Journal of Metals, 30 (4), 10-47 (April, 1978).
(30) Chemical Week, J22.(13), 10 (March 29, 1978).
(31) Arizona Paydirt, (464), 1, 4, 5 (February, 1978).
(32) The Mining Record, 89 (8), 1 (February 22, 1978).
23
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RECENT PATENTS
4,073,641
SELECTIVE REDUCTION OF NICKEL ORE WITH A LOW NICKEL CONTENT
Jean Montanteme, Andre Greffe, and Francois Grandjacques, assignors to
Societe Francaise d'Electrometallurique, Paris, France
(A method for selective reduction of nickel from ore or slag, the novel fea-
ture of which appears to be blending the reducing agent with an inert car-
rier, with the resulting volume being no less than one-fourth of the finally
blended ore plus reducing mass charge. This appears to be a scheme to
obtain superior dispersal of a solid reductant in a smelting charge to allow
electric-furnace smelting.)
4,073,646
PROCESS OF SMELTING SULPHIDIC COPPER ORE CONCENTRATES
Walter Fritsch and Gerhard Melcher, assignors to Klockner-Humboldt-Deutz
Aktiengese.ilschaft, Germany
(A method for coupling roasting and reverberatory smelting of sulfide copper
ore wherein roaster offgas with its sensible heat is oxygen enriched and
mixed with the reverberatory fuel and roasted concentrate is continuously
introduced through the reverb flame to effect some degree of flash smelting.
The S02~ enriched reverb offgas would presumably be amenable to acid
manufacture.)
4,076,605
DICHROMATE LEACH OF COPPER ANODE SLIMES
Edward A. Bilson, assignor to Inspiration Consolidated Copper Company,
Morristown, New Jersey
(Copper anode slimes are leached with acid dichromate to recover copper
values in solution. Selenium is precipitated with cement copper, and dis-
solved copper is recovered by electrowinning.)
4,078,917
EXTRACTION OF ANTIMONY TRIOXIDE FROM ANTIMONY SULFIDE ORE
Rollan Swanson, Santa Monica, California
(A hydrometallurgical process using alkanol solutions of sodium or potassium
hydroxide to extract antimony from sulfide ores in the absence of air. On
standing, the filtered pregnant liquor dissociates to yield Sb203 which is
further purified.)
4,078,918
METHOD FOR PRECIOUS METAL RECOVERY
Craig A. Perman, Waterloo, Iowa
(Ammoniacal leaching of a source containing silver, mercury, or palladium
returns a solution containing the metals as amine complexes. Treatment of
the solution with ascorbic acid or a salt thereof precipitates the metals in
elemental forms that are readily filtered.)
24
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4,078,993
PROCESSES FOR FLOTATION OF MINERAL SUBSTANCES
Robert M. Griffith, Christopher Parkinson, and Ronald A. Palmer, assignors
to Allied Colloids Limited, Bradford, England
(The use of an aldehyde with a compound containing two to six groups of
amine or amides in flotation is claimed to selectively depress pyrite,
pyrrhotite, and sphalerite from metalliferous sulfides or oxidized sulfide
ores. Perhaps useful in treating lead-zinc ores?)
4,080,420
LEACHING OF TUNGSTEN VALUES FROM TRI (ALKALINE EARTH METAL) TUNGSTATE
Hans Peter Kasserra, Denis Bertram Kelly, and Isaac Obadia, assignors to
Du Pont of Canada Ltd., Montreal, Canada
(An extraction process for tungsten wherein the scheelite or wolframite con-
centrate is calcined with an excess of limestone, e.g., to form water-
soluble tricalcium tungstate, then extracting with a warm salt solution,
e.g., sodium carbonate, etc., to yield soluble sodium tungstate and insoluble
calcium carbonate, e.g., and separating soluble from insoluble matter.)
4,080,418
EXTRACTION OF COBALT, COPPER AND NICKEL VALUES FROM AMMONIACAL SOLUTIONS
WITH CHELATING EXCHANGE RESINS OF RESTORED CAPACITY
John R. Carlberg, assignor to Amax Inc., Greenwich, Connecticut
(Extraction of amine complexes of nickel, copper, and/or cobalt with a che-
late exchange resin, polymeric ar-vinylbenzylamino dicarboxylic acid, strip-
ping with a mineral acid, and regenerating the resin as necessary with an
aqueous alkaline solution of a halo salt of water-soluble carboxylic-acid.)
4,081,506
METHOD FOR RECOVERING NON-FERROUS METALS FROM HYDRO-THERMAL SLIME
Peter Proplesch and Erich Zimmer, assignors to Kernforschungsanlage Julich
Gesellschaft mit beschrankter Haftung, Julich, Germany
(A method for recovering metal values such as Fe, Zn, Cu, and Ag from hydro-
thermal slimes comprising mixing the debrined slimes with 5 to 15% sulfur,
sulfate-roasting part at 400-450 C and extracting soluble sulfates with
water, oxide-roasting the rest at 350-400 C and extracting the metal values
with H2S04 produced from the roaster offgas from both stages.)
4,082,542
COPPER PRECIPITATE AGGLOMERIZATION PROCESS
David B. George, assignor to Kennecott Copper Corporation, New York,
New York
(A method for prerefining impure copper precipitates containing up to 15 per-
cent copper and 2 percent sulfur. The precipitate is moistened with water,
pelletized, and fed to a reduction kiln operating at 700 C or greater where
25
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oxygen and sulfur contents are reduced to 1 percent or less, and the pellets
are upgraded sufficiently for treatment in a final refining furnace.)
4,082,629
HYDROMETALLURGICAL PROCESS FOR TREATING METAL SULFIDES CONTAINING LEAD
SULFIDE
Edward F. G. Milner, Ernest G. Parker, and Godefridus M. Swinkels, assignors
to Cominco Ltd., Vancouver, Canada
(An elaboration of a ferric chloride leach process for separating lead and
other metal values from complex lead sulfide concentrates. Lead is con-
verted to solid chloride, extracted with brine in multiple stages, crystal-
lized, mixed with NaCl, fused, and electrolyzed to metal. By-product
streams depicted by a flowsheet include ZnS, ZnS04/FeS04, and two sulfide
mixtures, gold-free and gold-containing Ag/As/Bi/Cu/Sb sulfides.)
4,082,832
TREATMENT OF RAW MATERIALS CONTAINING TITANIUM
Morio Watanabe and Sanji Nishimura, assignors to Solex Research Corporation,
Osaka, Japan
(A hydrometallurgical method for separating and extracting titanium and
other metal values from titaniferous material which may also contain V, Mn,
Cr, and Nb. The material is first dissolved in sulfuric acid. Hydrated
ferrous sulfate is precipitated, and the solution is progressively and selec-
tively purged of the various metal ions by liquid-liquid extraction with a
series of LIX agents.)
4,083,920
TREATMENT OF TRI(ALKALINE EARTH METAL) TUNGSTATES WITH ACIDS
Stephen Peter Beaton and Hans Peter Kasserra, assignors to Du Pont of Canada
Limited, Montreal, Canada
(Similar to 4,080,420. Wolframite is calcined to form, e.g., tri-calcium
tungstate, but scheelite is reduction roasted to form a mixture of, e.g.,
tri-calcium tungstate and tungsten powder. Products are leached in HC1,
HN03, or mixtures of these to dissolve impurities, retaining the tungsten
values in the solid residue. Sheelite-derived values are treated with NH/^OH
to return soluble ammonium tungstate.)
4,083,921
PURIFYING MOLYBDENUM FLOTATION CONCENTRATES
Rolf Jurgen Wesely, assignor to Kennecott Copper Corporation, New York,
New York
(Treatment of molybdenum flotation concentrates to remove copper, iron, and
lead impurities. Claims cover a low-temperature chloride roast followed by
an oxidizing chloride leach at temperatures no less than 70 C, and separat-
ing the solution containing metallic impurities from the molybdenum-rich
residue.)
26
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4,083,927
CONTROLLED CARBO-CHLORINATION OF KAOLINITIC ORES
Ronald Wyndham, assignor to Toth Aluminum Corporation, New Orleans,
Louisiana
(Preferential carbo-chlorination of alumina contained in kaolin is achieved
by roasting the kaolin to drive off water of hydration, then carbo-
chlorinating in the presence of boron chloride, which suppresses the chlori-
nation of silica.)
27
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FOREIGN TECHNOLOGY
(The articles listed are from foreign-language journals, with titles and
abstracts printed in English.)
A. Kuivala, J. Poijarvi: "Removal of Mercury and Selenium From Roaster
Gases"
Erzmetall, Vol. 30 (1977), No. 12, 555-558 (German)
The recovery of mercury and selenium, and the production of 40 to 50 percent
sulfuric acid from roaster gases of the Kokkola zinc plant of Outokumpu Oy is
described.
N. Eresen, R. Kammel: "Investigations About the Extraction of Nickel From
Limonitic Type Laterite Ores With Aqueous Solutions of Polyamines"
Erzmetall, Vol. 30 (1977), No. 12, 561-566 Part I (German)
Erzmetall, Vol. 31 (1978), No. 2, 75-81 Part II (German)
The extraction of nickel from lateritic ores, both limonitic (high iron) or
garnierite (high magnesia and silica), by pressure leaching with an alkaline
solution of polyamines is described. Phase transformation of goethite into
hematite govern the leaching kinetics and mechanism.
B. Heide: "Purification of Zinc Concentrates by Reversing Flotation"
Erzmetall, Vol. 31 (1978), No. 1, 33-38 (German)
The Meggen flotation pi ant-of Sachtleben Bergbau GmbH has improved selec-
tivity between zinc blende and pyrite by the addition of sulfur dioxide at a
pulp temperature of 80 C. With the pyrite retaining its flotability and the
zinc blende almost completely suppressed, the zinc middling product is
improved from 35 to 50 percent zinc. The testing of various xanthates is
described.
L. Sivila, W. Wuth: "Volatilization of Tin by Top Blowing"
Erzmetall, Vol. 31 (1978), No. 2, 57-61 (German)
The results obtained by the use of the "Top Blowing" technique for recovery
of tin from natural and artificial slags are described. Slag conditioning
was obtained by the use of oxygen, propane, sulfur dioxide, and pyrite.
(The following articles of potential interest from a German journal contained
no English abstracts.)
R. Kullmann, E. Pfeil: "Processing of Intermediate Products of Smelting
Works in a Rotary Converter by Using the Oxygen Process"
Metal!, Vol. 32 (March 1978), No. 3, 257-260
D. Liesegang: "Advanced Waste Gas Cleaning Process for Copper Refining
Furnaces"
Metal 1, Vol. 32 (March 1978), No. 3, 272-273
28
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G. Pommerening, A. Gerberding, H. Stodieck, and U. Harms: "Possibilities for
the Processing of Selected Nonferrous Ores in Developing Countries - Part I"
Metal 1, Vol. 32 (March 1978), No. 3, 278-281
29
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TECHNICAL AWARENESS BULLETIN - NONFERROUS METALS
^-^^-H^^^~^~^«^^^^^^^~*«M»^^H^^^^^^^^M^^_VM.^»_^^_.^.MW«.^^_^_^^^HBW__^^_^^V»W^^^^^^^^H
This is a bimonthly publication of the USEPA's Metals and Inorganic
Chemicals Branch, Office of Research and Development, designed to spotlight
selected events and concerns of the nonferrous metals industry.
HIGHLIGHTS
Power restoration permit* resumption ofa aluminum production
Jin the. Pacific Northwest. (Itm 1}
?o*tmining restoration can leave the land -in better condi-
tion than it was before the. mining op&iation. (Item 8)
Improved proces* control* and automation are gaining
increased importance, in primary copper. operations. Co*t-
*aving proces* e.^icie.nciu and impSLOv&d envitonme.nta£ con-
trol OML the. neAutt. (Item S and TBT ab&tsuictA 1.3.2)
• The. con&lict* between domestic mineAat de.ve.topme.nt and pro
duction and e.nvisionme.ntal constraint* will. be. among the.
iAAueA addAeA&e.d by a cabinet- le.ve.1 commiA&ion to investi-
gate. and analyze. non^ueJt mineral policies. {Item 9)
* Nicke.1 has joine.d coppeA and zinc as a commodity w-Lth a
de.prest>e.d market /price, structure.; two domestic opeAatoxs
have. curtaile.d production in the. ^ace o£ re.cord-high pro-
ducer inventories. (Item 16}
• Tfoe promise ofa continued increase in gold price* is spark-
ing renewed activity in exploration and reopening o£ old
mines where yellow metal operation* may be profitable.
(Item 17)
Individually contributed news items may be submitted to Mr. Fred Craig,
Metals and Inorganic Chemicals Branch, Industrial Environmental Research
Laboratory, USEPA, 5555 Ridge Avenue, Cincinnati, Ohio 45268, 513-684-4491.
Prepared by Battelle's Columbus Laboratories under EPA Grant R805Q95.
30
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NON-FERROUS METALS INDUSTRIES
IN THE NEWS
Aluminum
(1) Aluminum potlines in the Pacific Northwest, idle for almost a year
because of power curtailment resulting from the drought in the area, are
being brought back on stream. The companies affected and the location of
the potlines where the Bonneville Power Administration is restoring power
are: Reynolds, in Troutdale, Oregon, and Longview, Washington; Kaiser, in
Mead, Washington; Alcoa, in Vancouver, and Wenatchee, Washington; Intalco,
in Ferndale, Washington; Anaconda, in Columbia Falls, Montana; and Martin
Marietta in The Dalles and Goldendale, Oregon.
With relief from the drought assured and aluminum production resuming,
the cost of electric power will rise. The Pacific Northwest Power Supply
and Conservation Act (HR 9020), supported by the industry as being the most
equitable way to meet future energy needs, will triple the industry's power
costs.
While the Northwest resumes aluminum production, Alcoa's two potlines
at the Point Comfort, Texas, plant will be shutdown for an indefinite period.
About 50,000 tons of aluminum output per year will be lost after April first
because of the high costs of natural gas used to generate the plant's elec-
tricity. The alumina refinery at Point Comfort will continue to operate as
wi11 A1coa's largest aluminum plant at Rockdale, Texas, which is powered by
lignite-fueled generators.
In Sheffield, Alabama. Reynolds Metals Company will expand its secondary
smelter to 100,000 tons per year.
Arsenic
(2) With completion of tests by the EPA in February, 1978, on the
health effects of arsenic, cooperation of three other federal agencies, OSHA,
FDA, and CPSC will be sought for scrutiny of potential health hazards and
risk assessment of toxic substances, including arsenic. The EPA will propose
reduction of arsenic emissions, while OSHA will order controls and respi-
rators for exposure.
Copper
(3) Negotiations with interested companies by the Colvilie Confederated
Tribes will begin immediately concerning the development of a large, open-pit
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copper mine which would become the second largest operation of its kind in
the U.S. This massive copper-molybdenum open-pit mine will be located near
the town of Keller, Washington.
(4) The State Hearing Examiner of Wisconsin has dismissed a request
of the Flambeau Mining Company (a Kennecott subsidiary) for permits to mine
copper deposits in Grant (Rush County), Wisconsin. Too long a delay in
making requested changes in the permit applications was given as the reason
for denial. Kennecott must reapply if it wishes to pursue this operation
further.
(5) Asarco's Tacoma.Washington, copper smelter can continue to operate
at variance with air pollution standards in the state, as the Pierce County
Supreme Court has ruled against the Washington State Pollution Control
Hearings Board. The Washington Air Quality Coalition, an environmental
group, plans an appeal.
Kennecott has also won a round in smelter emission rulings in New
Mexico. The Environmental Improvement Board refused to classify the area
surrounding Kennecott's smelter at Hurley, New Mexico as a nonattainment
area (an area failing to meet standards emissions) because of work done in
1977 to control sulfur dioxide emissions. The board was told that there
was no better control technology available to Kennecott than that which it
already has in use.
The Environment Improvement Agency has prepared a map of Arizona showing
nonattainment areas for particulate matter as Phoenix, Tucson, Hayden,
Douglas, Ajo, and Globe and'for sulfur dioxide as Ajo, Douglas, San Manuel,
Hayden, Globe, and Morenci.
(6) Mining, concentration, and leaching operations, by Inspiration
Consolidated Copper Company in Arizona, will be resumed by mid-January. The
company had not reopened after the July-August strike of last year because
of the depressed market. The Christmas mine and dump leaching at
Inspiration,and mining operations at the Ox Hide mine will remain closed.
Outside consultants, together with executives of the Heel a Mining
Company, are searching for a solution to the huge deficit acquired in the
operation of the Lakeshore Mine near Casa Grande, Arizona. Maintenance
expense was running $600,000 per month with total operational losses of
$30 million in about 20 months, when it was closed in August, 1977. The
mine has estimated reserves of 500 million to 1 billion tons.
(7) Anaconda was reported to have curtailed operations at its copper
mine near Yerington, Nevada, by 40 percent on December 31, 1977, with the
discontinuance of processing sulfide ores. The oxide ores will be depleted
by mid-1978 at which time the mine will close unless there is a market
upturn.
Anaconda also continues to have regulatory problems with its smelter at
Anaconda, Montana, and will pay a fine to avoid litigation even though they
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deny any air standards violation. They also have agreed to fund a study of
the upper air in the vicinity of the smelter.
Anaconda is studying the economic feasibility of operating its under-
ground mines at Butte, Montana, based on a new engineering procedure. The
answer is expected by spring.
(8) The annual meeting of the Arizona conference of the A.I.M.E. was
held in December, 1977. Several highlights of the papers given at this meet-
ing follow:
The environmental effects of mining can be beneficial, as several mining
companies have reclaimed areas that are more useful now than prior to mining.
The expansion program of Cyprus Bagdad's open-pit mine at Bagdad,
Arizona, completed in 1977, resulted in employment increase of 50 percent,
although ore production jumped 700 percent. The increased productivity
resulted from the use of new and larger equipment.
The results of a study by the Morencl branch of Phelps Dodge, on the
Concentrator Process Control System, indicate economic benefits from process
control of a 9-ton per day increase in total copper production, a 10-ton per
day increase in tonnage milled per man shift, and a 0.01 pound per ton
decrease in froth reagent consumption. Another benefit is stabilization of
the process which will probably decrease the likelihood of upsets.
The Magma Copper Company of Arizona has recently converted to the use of
None! Primadets for blast initiation in its Superior mine. Significant
improvements are fewer holes required, improved fragmentation, faster load-
ing, and elimination of lost production from unfired holes. The Nonel system
has proved to be more efficient and economical desoite higher unit cost.
Sherritt-Cominco has developed a hydrometallurgical process to refine
copper from sulfide concentrate which is applicable to a wide range of con-
centrate and recovers sulfur in the elemental form. Thermal activation with
hydrogen decomposes chalcopyrites and pyrites into simpler sulfides, which,
after iron removal, are leached under oxygen pressure to produce copper sul-
fate solution and elemental sulfur. The copper is recovered by
electrowinning.
(9) President Carter has appointed a cabinet-level committee to study
America's nonfuel mineral policies. Interior Secretary Andrus and
Frank Press, Director of the Office of Science and Technology Policies, are
to develop the framework of a top-level minerals study. Environment concerns
will be a major part of the study, especially where a conflict exists between
mineral development and land, water, or air pollution. Existing laws and
regulations governing the nonfuel minerals will also be considered as part
of this 15-month study.
The President has indicated his agreement of the concept of stockpiling
copper, and it was predicted by Arizona Congressman Udall that a copper
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stockpiling bj'il would be Introduced in Congress in January or February to
alleviate pressures on the copper industry.
The debate continues on the Administration-sponsored Bill HR 9292 vs.
the Ruppe Bill HR 5831 supported by the mines. The first field hearings
were held in Phoenix in December, with the second scheduled for Grand
Junction, Colorado, in February. Amendments to the Ruppe bill, which retains
the most important features of the 1872 laws, will provide additional envi-
ronmental protection as well as protection for individuals who own the sur-
face but not the minerals on their land.
Other government actions (state and federal) that seek to alleviate
the problems of the copper industry are (1) an increase in the current tariff
for copper imports from eight-tenths to $0.07 a pound for the countries with
Most Favored Nation status; (2) an equilization tariff of $0.10 a pound to
assure that foreign competitors do not secure unfair competitive advantage
over U.S. concerns by ignoring environmental considerations that domestic
enterprises are required to observe; (3) relief from subsidized imports by
an ad valorem tariff; and (4) state relief from the sales tax which taxes
every pound of copper, and only copper, which is shipped from the State of
Arizona.
(10) A recent newsitem of interest reported that the combined
San Manuel and Superior, Arizona, operations of Newmont's Magma Copper
Company in 1976 produced 363 thousand tons of sulfuric acid. Also produced
were 186 thousand tons of refined copper, 2,000 tons of molybdenum concen-
trate, and significant amounts of gold, silver, selenium, and rhenium. The
total direct contributions to the economy in terms of payroll and benefits,
local purchases, and state and federal taxes was about $172 million. I_n
1977, the 300 millionth ton of ore was hoisted from the San Manuel mine, a
new record for underground copper mines. About two-thirds of this orebody
remains for future production. The San Manuel operation alone employs about
4,000 persons.
Lead
(11) The zinc fuming plant of the Bunker Hill Company's Kellogg. Idaho,
lead smelter is temporarily suspending operations. The EPA has recently
filed a suit in the amount of $25,000 a day against Bunker Hill for excessive
particulate emissions. However, the company denies this to be the reason for
the closing, stating depressed domestic markets due to excessive imports as
the cause.
The EPA's proposed new standard for lead, a monthly average of 1.5
micrograms per cubic meter of ambient air by 1982, is causing much alarm and
discussion among those affected. The situation may not be as bleak for cop-
per and primary lead smelters as for the battery makers. — Samples taken
at Asarco's lead smelters at East Helena, Montana, and El Paso. Texas, never
exceeded 1.8 micrograms, while those taken at Bunker Hill in Kellogg, Idaho.
averaged 12.5 micrograms. Lead emissions from Anaconda's copper smelter at
Anaconda, Montana, never exceeded 0.6 microgram. -- The main problem in
34
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battery manufacture or lead recovery is not stack emissions but fugitive
emissions—dust from plant operations that require hoods, ducts, and fans to
remove the dust through a filter system. Also, these plants are usually
located in urban areas where pollution is difficult to control, compared to
the primary smelters which are located in sparsely settled regions. An
investment of 32 percent of the secondary smelters' annual income could be
required to meet the standards advocated by the EPA, a hypothetical case
points out.
A very thorough study of heavy metal body burdens of persons residing
near nonferrous smelters in Ajo, Arizona, is being carried out by the Arizona
Department of Health and the Research Triangle Institute. Three hundred
twenty persons, ages 1 through 60 plus, are involved in blood, hair, and
urine sampling. Drinking water, dust, and soil samples are also being col-
lected. Although specific results have not been announced, no significant
health problems have been identified in the physical examinations and lab
studies, to date.
Magnesium
(12) The Utah magnesium plant of NL Industries, Inc., has recently
undergone modification and its capacity of 24,000 tons per year was expected
to be reached by the end of 1977.
Molybdenum
(13) With the acquisition of Molycorp by Union Oil, an agreement has
been reached with Kennecott whereby Kennecott has terminated its joint-
venture interest with Molycorp in the development of a molybdenum property
for a new underground mine near Molycorp's Questa, New Mexico, operations.
The Union Oil/Molycorp plans for the new operation are in early stages, and
no sizing decisions have yet been made.
(14) Phelps Dodge Corporation has announced discovery of a deposit of
porphyry-type molybdenum mineralization with minor tungsten values near
Mil ford. Utah, in Beaver County. In four drill holes, mineralization was
located 3000 to 5000 feet beneath the surface and was 200 to 950 or more feet
thick and assayed 0.29 to 0.38 percent molybdenum disulfide. An extensive
drilling program and economic feasibility studies, taking several years, must
be undertaken before mining can begin.
(15) At Quartz Hill, 45 miles east of Ketchikan, Alaska, the U.S. Borax
and Chemical Corporation has found a potential molybdenum orebody in excess
of 250 million tons at or near the surface which can be mined by the open-pit
method. The ore assays 0.18 to 0.25 percent molybdenum disulfide,_with 50
million tons of 0.25 percent ore outcropping at the surface. Permission to
construct an access road is being delayed because of an appeal by environ-
mental groups with theT.S. Forest Service. Development of the project will
depend on successful resolution of the access road issue.
35
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jNickel
/ /
(16) The Port Nickel refinery of Amax Nickel. Inc.. will not Increase
. nickel, production to capacity but will operate at 75 percent capacity during
the first half of 1978 because of excessive nickel inventories. This will
amount to about 50 million pounds of nickel and 750,000 pounds of cobalt.
To adjust its nickel inventories, Hanna Mining Company's Riddle, Oregon.
mine and smelter operations were suspended for 6 weeks during January and
February. (
Precious Metals
(17) Predictions that gold may be selling at $190 to $200 per ounce by
the end of 1978 have resulted in an increase in exploration and development
activities. The following are some of the latest to be announced:
A placer mill has been constructed by the A. J. Madden Company near
Quartzsite, Arizona, to extract gold from gravel originating in the nearby
Plomosa Mining District. Production will reach 1000 yards per 16-hour day
in a few months.
Mining is to be reinstituted this spring at the Mary Nevin mine near
Cripple Creek, Colorado. A significant orebody was found at 300 feet in the
old mine, first staked in 1895 and last operated during World War II.
The Duval Mining Corporation has plans to invest $4.5 million to convert
its Battle Mountain, Nevada, cooper operation to gold mining. The work is
to begin in March and be completed late this year.
The Jarbidge Wilderness area of Nevada is the subject of a USGS mineral
resources report recently published. More than $10 million worth of gold
and silver production was recorded between 1910 and 1949 from the Jarbidge
Mining District in this area.
(18) The San Juan Milling Company has spent nearly a million dollars on
exploratory drilling on the Henrietta mine at Silver-ton. Colorado. Appre-
ciable quantities of silver, copper, lead, and zinc have been found. Assays
as high as 15 ounces of silver per ton, 10 percent lead, 15 percent zinc, and
0.5 percent copper have been obtained.
Tungsten
(19) Teledyne Wah Chang's Strawberry mine near Yosemite National Park
in California recently has begun production and will produce about 800,000
pounds of tungsten in 1978, making it the fourth largest tungsten mine in the
U.S.
36
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Vanadium
(20) Union Carbide will suspend operation at its mine and mill near
Hot Springs. Arkansas, early this year. This complex accounts for the
largest domestic output of vanadium oxide in the U.S. and should be able to
resume operations in 6 to 12 months after market conditions have improved and
inventories have become lower.
Zinc
i
(21) Closure of the Eagle, Colorado, zinc mine has been announced by
the New Jersey Zinc Company because of high costs, low prices, and depleted
reserves.
(22) Eagle-Picher Company's Shullsburg and Bear Hole operations in
southwestern Wisconsin may be forced to close in 2 years or less because of
excessive zinc discharge from minewaters into ground water. Conformance to
the EPA's standard of 0.75 mg per liter to be invoked on January 1, 1980, is
not economically feasible. The current allowable of 3.5 mg per liter can be
met.
(23) Operations were planned to be suspended by February 15, 1978, ajb
the Ontario mine near Park City. Utah. A joint venture of Anaconda and
Asarco (Park City Ventures), Park City, conducted lead, zinc, and silver
mining and milling operations. Operating problems relating to rock condi-
tions and ground water resulted in high costs, making the operation
unprofitable.
(24) In the lone bright spot concerning the future of domestic zinc,
production of the Elmwood, Tennessee, mine of the Jersey Mini ere Zinc Company
has recently been increased to 3000 tons per day and in August of this year,
another mine at Gordonsville. Tennessee, (3 miles from the Elmwood mine) will
begin production at 9000 tons per day. Another mine site is being explored
for zinc,25 miles from these two mines.
Miscellaneous
(25) Superior Oil of Houston and Louisiana Land and Exploration have
reported significant deposits of zinc and copper and small amounts of silver
and gold in northern Maine. These exploratory drill holes show 9 percent
zinc, 4 percent copper, 2.57 ounces of silver, and 0.04 ounces of gold per
ton.
Sea Nodules
(26) A study of the environmental, social, and economic effects of the
sea nodule processing facilities in the Hawaiian Islands is tied to a com-
panion NOAA' study of the effects in the ocean proper (see Technology and
37
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Trends 15-1.4, page 1). Federal and state funding from DPED and NOAA totals
$200,000 to date.
/
AIME Meeting /
(27) The Annual Meeting of the American Institute of Mining,
Metallurgical, and Petroleum Engineers held in Denver, February 26-March 2,
1978, featured more than 200 split-day sessions, at which more than 1000
papers, talks, panel discussions, and seminars were presented. Of particular
interest were several All-Institute sessions to consider and discuss general
societal, environmental, economic, and regulatory issues impacting the min-
erals industry. At these sessions, considerable concern was expressed over
future availability and economics of energy, although some participants
expressed confidence in man's ability to adapt to whatever the future might
bring. A common lament by attendees from industry was the terrific and ever-
increasing burden placed on industry by various government regulations.
Selected papers dealing with technology in the nonferrous metals industry
will be reviewed in the next issue of the USEPA Awareness Bulletin.
38
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REFERENCES
/
(1) American Metal Market, 86> (9), 1, 14 (January 13, 1978).
Chemical and Engineering News, 56_ (4), 8 (January 23, 1978).
American Metal Market, 86. (21), 2 (January 31, 1978).
U.S. Bureau of Mines, Mineral Industry Surveys, 1 (February 1, 1978).
American Metal Market, 86. (4), 1, 9 (January 6, 1978).
(2) Chemical Week, 122 (2), 18 (January 11, 1978).
(3) The Mining Record, 89_ (3), 1 (January 18, 1978).
(4) U.S. Bureau of Mines, Minerals and Materials, 49 (January, 1978).
(5) Mining Journal, 290 (7433), 87 (February 3, 1978).
New Mexico Paydirt, (9), 28 (February, 1978). \
Arizona Paydirt, (463), 13 (January, 1978).
(6) Engineering Mining Journal, 179 (1), 133 (January, 1978).
(7) Mining Engineering, 30 (1), 17 (January, 1978).
Arizona Paydirt, (462J, 59 (December, 1977).
The Mining Record, 8jM6), 3 (February 8, 1978).
(8) Skill ing's Mining Review, 67_ (2), 1, 6, 7, 14-19 (January 14, 1978).
(9) Arizona Paydirt, (463), 20, 22 (January, 1978).
Arizona Paydirt, (462), 14, 16 (December, 1977).
New Mexico Paydirt, (8), 8, 10, 12 (January, 1978).
New Mexico Paydirt, (9), 20, 23, 24 (February, 1978).
(10) New Mexico Paydirt, (8), 3 (January, 1978).
(11) Mining Journal, 290 (7433), 87 (February 3, 1978).
Skilling's Mining Review, 67. (5), 27 (February 4, 1978).
Environmental News, U.S. £PA, R-289, 1-4 (December 12, 1977).
Chemical Week, 122 (4), 45 (January 25, 1978).
Arizona Paydirt7T462), 54 (December, 1977).
(12) U.S. Bureau of Mines, Minerals and Materials, 9 (December, 1977).
(13) New Mexico Paydirt, (8), 6 (January, 1978).
(14) The Mining Record, 89 (2), 1 (January 11, 1978).
Arizona Paydirt, (463), 16 (January, 1978).
(15) American Metal Market, 86 (27), 12 (February 8, 1978).
The Mining Record, 89_ (IT, 1 (January 18, 1978).
(16) Mining Congress Journal, 63. (12), 7 (December, 1977).
U.S. Bureau of Mines, Minerals and Materials, 4, 5, 9 (December, 1977).
39
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(17) The Mining Record, 89 (6), 1, 10, 23 (February 8, 1978).
(18) The Mining Record, 89 (6), 4 (February 8, 1978).
(19) American Metal Market, Tungsten Section, 86 (3), 8-9 (January 5, 1978)
(20) U.S. Bureau of Mines, Minerals and Materials, 47 (December, 1977).
(21) U.S. Bureau of Mines, Minerals and Materials, 5 (January, 1978).
(22) Engineering Mining Journal, 179 (1), 137 (January, 1978).
(23) Skilling's Mining Review, 67 (4), 4 (January 28, 1978).
(24) U.S. Bureau of Mines, Minerals and Materials, 52 (December, 1977).
(25) U.S. Bureau of Mines, Minerals and Materials, 49 (December, 1977).
(26) U.S. Bureau of Mines, Minerals and Materials, 48 (December, 1977).
(27) Annual Meeting of AIME, Denver, Colorado, January 26-March 2, 1978.
40
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RECENT PATENTS
4,065,110
METHOD AND APPARATUS FOR PURIFYING BLISTER FURNACE EFFLUENT
Ralph A. Koenig, assignor to John Zink Company, Tulsa, Oklahoma
(A mechanical arrangement for treating gaseous discharge from blister copper
refining furnaces is claimed. Stages include particulate settling, precool-
ing, oxidation, and cooling and waste-heat recovery before passing to bag-
house and stack.)
4,065,300
METHOD FOR EXTRACTION OF COPPER PRODUCTS FROM COPPER BEARING MATERIAL
Archie L. Poarch, Mesa, Arizona
(Claims a hydrometallurgical process for purification of cement copper
involving nitric acid dissolution, NH3 complexing and reduction, conversion
to cuprous oxide, redissolution in nitric acid, and disproportionate to
pure copper and cupric nitrate (recirculated). Impurities are rejected dur-
ing first-stage ammonia neutralization. Ammonium nitrate is a by-product.)
4,066,445
PROCESS FOR PRODUCING MAGNESIUM UTILIZING ALUMINUM METAL REDUCTANT
James D. Johnston, Robert N. Sanders, and James M. Wood, Jr., assignors to
Ethyl Corporation, Richmond, Virginia
(An aluminothermic method for magnesium production from MgO is claimed. Tem-
peratures of about 1600 C are required.)
4,066,520
SLURRY ELECTROWINNING PROCESS
Robert C. Emmett, Jr., James K. Dicksa, Bruce C. Wojcik, and Frank A. Baczek,
assignors to Envirotech Corporation, Menlo Park, California
(Calcium sulfite treatment of pregnant copper leach liquors precipitates pure
copper values for subsequent electrowinning.)
4,066,733
METAL EXTRACTION FROM SEA NODULES
Michael Dubeck and Gordon G. Knapp, assignors to Ethyl Corporation, Richmond,
Virginia
(Ammoniacal leaching of nickel, copper, and cobalt from sea nodules is
improved by preroasting at 400 C maximum in gases from alcohols and alde-
hydes. Improved cobalt solubilization is claimed by sulfite additions to the
leachant.)
4,067,952
LEACHING OF COPPER-NICKEL CONCENTRATES
Willem H. Pittie and Kingsley F. Doig, assignors to Anglo-Transvaal
Consolidated Investment Company Limited, Johannesburg, South Africa
(Claims a multistage, combined hydrometallurgical and roasting process for
separating nickel and copper values from a nickel-copper sulfide matte.
41
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Part of the nickel is recovered in a first leach with HC1 . Residue is
sul fate-roasted, water leached, treated with H£$ to precipitate CuS. Remain-
ing nickel is hydrometallurgically purified, converted back to the chloride,
and electrowon.)
4,069,119
COPPER RECOVERY BY LEACHING AND ION EXCHANGE
Soon Y. Wong, assignor to Continental Oil Company, Ponca City, Oklahoma
(Claims a two-stage solid ion exchange-elutriation process combined with
electrowinning for the hydrometallurgical recovery of copper from ore.)
4,069,294
HYDROMETALLURGICAL RECOVERY OF METAL VALUES
Laurence G. Stevens, assignor to UOP, Inc., Des Plaines, Illinois
(Hydroprocessing of sea nodules incorporating a prereducing roast in HC1
(halide) to facilitate recovery in subsequent ammoniacal leaching. The novel
feature appears to be the method of recycling the HC1.) -
4,069,296
PROCESS FOR THE EXTRACTION OF ALUMINUM FROM ALUMINUM ORES
Wen H. Huang, Texas A & M University, College Station, Texas
(Recovers and purifies aluminum values from ore using HF leaching-complexing
and hydrometallurgical purification of the leachate resulting in a hydra ted
aluminum hydroxide product.)
4,070,182
RECOVERY OF PRECIOUS METALS FROM METAL SULPHIDES
Roman M. Genik-Sas-Berezowsky, Verner B. Sefton, and Lynton S. Gormely,
assignors to Sherritt Gordon Mines Limited, Toronto, Canada
(Features ^4^203 treatment of copper sulfide ores, or leach residues
from these, to recover gold in soluble form.)
4,070,183
METHODS OF SEPARATING AND RECOVERING COPPER FROM MATERIALS CONTAINING COPPER
Alan James Parker and David Michael Muir, assignors to Anumin Pty. Ltd.,
Canberra, Australia
(A method for recovering copper from ores involves treating an impure, preg-
nant leach liquor with sulfite to precipitate copper sulfite, separating
this, redissolving the sulfite in acetonitrile or 2-hydroxycyanoethane water
to yield cuprous sulfate, then disproportionate the cuprous salt to
metallic copper and cupric sulfate for recycle.)
42
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4,070,260
PROCESS OF SULFURIC ACID LEACHING SILICATED ZINC ORES
Noel Dreulle, assignor to Compagnie Royale Asturienne des Mines, Brussels,
Belgium
(A hydroprocess for zinc from siliceous ores. The silica gel problem is
overcome by evaporation of 60 percent of the water to crystallize the silica,
thence resolutioning to allow removal of the Zn $04.)
4,071,278
LEACHING METHODS AND APPARATUS
Neil L. Carpenter, Kerrville, Texas, and Clark Goodman, Coronado, California
(This claims a process and apparatus for electrolytic-assisted leaching of
ore bodies in situ.)
4,071,611
CONTINUOUSLY LEACHING AN ORE COLUMN
Richard E. Chi 1 son, Tucson, Arizona
(A mechanohydraulic scheme and apparatus for continuous vat leaching of ore,
with built-in washing of the residue.)
4,072,503
THERMAL TREATMENT OF LEACHING RESIDUE FROM HYDROMETALLURGICAL ZINC PRODUCTION
Stig Arvid Petterson, Tor Lindstad, Fr0ystein Dyvik, and Georg Steintveit,
assignors to Det Norske Zinkkompani A/S, Odda, Norway
(For residues from a hydroprocess for zinc (containing lead and residual
zinc); this is a combination controlled oxidation-reduction roasting process
to recover and separate metallic lead and zinc values.)
4,072,504
METHOD OF PRODUCING METAL FROM METAL OXIDES
Orn Gunnar Perdahl and Sven Oscar Santen, assignors to Aktiebolaget Svenska
Kullagerfabriken, Goteborg, Sweden
(The claimed process for producing metals from oxides of tungsten, chromium,
manganese, nickel, and/or iron combines direct reduction and an "inverse
blast furnace" process. A shaft furnace is charged with a solid reductant
(e.g., coke), and the prereduced (at least "33 percent reduced") oxides are
blown through tuyeres into the reductant bed where reduction is completed.
Molten metal accumulates on the hearth. Offgas is used for prereduction.)
4,072,507
PRODUCTION OF BLISTER COPPER IN A ROTARY FURNACE FROM CALCINED COPPER-IRON
CONCENTRATES
Harold P. Rajcevic, William R. Opie, and Dominic C. Cusanelli, assignors to
Amax, Inc., Greenwich, Connecticut
(Rotary-furnace smelting of dead-roasted copper ores is claimed. The furnace
charge is the dead-roasted concentrate (CuO + Fe203 + some gangue), a
43
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particulate reductant sufficient to reduce CuO to copper and Fe?03 to FeO,
and SiOo sufficient to flux the FeO at an Fe-Si02 ratio of 1.2:1 to 4:1.
The loaded rotary furnace, resembling a converter, is heated by an oxyfuel
lance to the smelting temperature, where blister copper and slag is formed.)
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FOREIGN TECHNOLOGY
(The articles listed are from foreign-language journals, with titles and
abstracts printed in English.)
J. Czernecki, Z. Smieszek, and S. Sobierajski: "Thermodynamic Analysis of
Lead Elimination from Copper in a Fluidized Bed (sic) Process"
Rudy Metale, 22 (11) (1977), 583-595 (Polish)
In calculations of selective lead oxidation from copper-bearing material
(concentrates?) in what appear to be shaft furnace operations at refining
temperatures from 1280 to 1380 C, the lowering of the metallic lead content
to less than 0.2 percent requires that the oxygen content of the resulting
copper would be in the range of 0.52 to 1.2 percent, expressed as dioxide (?).
It appears that experimental results supported the calculations.
B. Czajka, J. Borkowski, and M. Szczap: "Technology of Xanthation in the
Flotation Process of Lead Minerals"
Rudy Metale, 22 (11) (1977), 595-598 (Polish)
For a particular lead-zinc ore containing oxidized lead minerals, xanthation
parameters were developed to optimize the selective flotation collection of
lead minerals while suppressing zinc collection.
M. Oktawiec, T. Izdebska, and T. Grabowski: "The Role of the Institute of
Non-Ferrous Metals in Studies on Flotation Agents"
Rudy Metale, 22 (11) (1977) 625-627 (Polish)
Research on collecting agents for flotation of copper and lead-zinc ores,
including pilot trials, is described.
W. Pajak: "The Actual State and Prospects for a Thermal Enrichment Process
of Zinc-Lead Materials"
Rudy Metale, 22 (11) (1977) 627-633 (Polish)
Present use of the Waelz process in Poland is described. Emphasis is on
process adaptation for improved economy; substituting less expensive reduc-
tants for coke breeze is cited as one example. Discussion of Waelz-kiln
treatment to upgrade low-grade zinc-lead ores and to recover values from
zinc and lead-plant wastes is presented.
T. Kozubowski: "Zinc Strip Manufacutre Straight from Molten Metal"
Rudy Metale, 22 (11) (1977) 636-638 (Polish)
A continuous zinc sheet casting installation in Poland is described. This
comprises an induction melting (or holding) furnace, distributor, a roll
stand for solidification to sheet blanks up to 43 inches wide x 1/4 to
3/8-inch thick, a roll leveler, a guillotine shear, and a roll coiler. This
is designed to produce up to 10,000 tons per year.
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M. Duczmal and J. Starosta: "Properties of Isolated Thionic Bacteria in
the Area of the Legnica-Glogow Copper District"
Rudy Metale, 22 (12) (1977) 681-683 (Polish)
The capabilities of Th. thiooxidans, Th. ferrooxidans, and Th. thioparus for
oxidizing Ci^S were compared. Microbiological acidification and leaching of
copper from regional ores were investigated.
6. Sokalaska, E. Doroszkiewicz, and P. Lelowski: "Leaching of Lead, Silver,
and Copper by Alkaline Chloride Solutions"
Rudy Metale, 22 (12) (1977) 690-694 (Polish)
Residues from acid leaching of copper concentrate were further treated by
leaching with salt (and other additions) at 80-90 C to extract residual cop-
per, silver, and lead values. In 20 minutes, about half of the silver and
copper and most (^90 percent) of the residual lead were extracted. Silver
recovery can be increased to about 80 percent by first treating the residue
to remove the ferrous ions.
R. Bertram, M. Clement, N. Galitis, and H. Illi: "Leaching of Chalcopyrite
with Adding Current"
Erzmetall, Vol. 30 (T977) No. 11, 491-496 (German)
Various particle-size fractions of Chalcopyrite from the Mitterberg (Austria)
ore deposit were leached anodically at various current-potential conditions.
Feeder-anodes of coal, lead, and gold were investigated in especially
developed packed-bed reactors at various (^$04 concentrations. The results
of the electrochemical process are discussed, and proposals for the further
development of the research studies are made.
A. Yazawa: "Trends in Modern Copper Smelting Processes"
Erzmetall, Vol. 30 (1977) No. 11, 511-517 (German)
After discussing traditional copper smelting processes (reverberatory, elec-
tric or blast furnace), flash smelting is described, together with the expe-
rienced disadvantages. Various, newly proposed smelting processes are clas-
sified into four categories, and detailed critical evaluations are given for
two promising processes, Noranda and Mitsubishi. Combining observations
with the theoretical considerations, desirable conditions for a copper smelt-
ing process are summarized.
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TECHNICAL AWARENESS BULLETIN - NONFERROUS METALS
This is a bimonthly publication of the USEPA's Metals and Inorganic
Chemicals Branch, Office of Research and Development, designed to spotlight
selected events and concerns of the nonferrous metals industry.
HIGHLIGHTS
» ThiAd-quaAteA opeAoting to£&&> and facility clo&uAU Ae.file.ct
the. continued depAej>&e.d domestic coppeA maAket. Relie.fi uxu>
de.nied by CongAeA* in late, action ui 1977 .
9 Ve,pAeA&ed zinc_ moAketA and pAiceA e.fifie.ct fiuAtheA
The. Fe.deA.ai Mine. Safety and Health Ame.ndme.nts> Act ofi 1977
put& new te.&th in pe.ction apeAat and punitive,
biJUMju by the. goveAme.nt to zm>u>ie. &a.fa p^acXtcei by
tou 0
QUA. te.ad tanit& £nt&nde.d to pH.ote.ct c.hitdx.e.n' t> health
one, expected to be. &et by EPA at 1 .5 ug/m3 i.yi June. o£ 197 'B.
Le.ad and coppe/t &mntteA& c.oo€d be AevesieZy, 4xnpacte.d, and borne.
plant cto&usL.
WM domestic Bounce, oj tungAt&n £*> the. Tung&te.n
M/cne6 operation by GAaham and AAAociateA ne.aA Hidge.cAeAt,
oAvuja. At capacity, c.on.c.e.ntAate, pAoduction oi 70-BO tpd
be. £hJjppe.d to Union Catbide. fao
impAove.d P-225 computeA-(iontAolle.d aluminum potline.
te.c-hnology ii> beting o^eAe-d to
OSEPA hai> it>&wi.d a jinaJL Auling that ex.wptt> coppeA
unusual emAbion* a&&ociate.d with AtaAtup, shutdown, OA mal-
function faAom violation o& new-AouAce, aiA pollution
Individually contributed news items may be submitted to Mr. Fred Craig,
Metals and Inorganic Chemicals Branch, Industrial Environmental Research
Laboratory, USEPA, 5555 Ridge Avenue, Cincinnati, Ohio 45268, 513-684-4491.
Prepared by Battelle's Columbus Laboratories under EPA Grant R8Q5095.
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NON-FERROUS METALS INDUSTRIES
IN THE NEWS (&
Aluminum
(1) The Mobile Alabama Works of Alcoa, which converts bauxite to alu-
mina, plans to curtail production 25 percent because of drouth-induced power
shortages at its smelting units in Alcoa, Tennessee, and Warrick, Indiana.
(2) Poor conditions in the industry, coupled with overcapacity, especi-
ally on the West Coast, has resulted in Apex International Alloys, Inc.'s
closing its secondary aluminum smelting operation in Carson, California.
"No great thought" has been given to a possible reopening of this plant;
however, Apex is opening a new dross and salt recovery plant in Bicknell,
Indiana, on January 1, 1978.
(3) The P-225 aluminum smelting technology developed by Alcoa is being
offered to industry. The potline system with self-adjusting anodes, each
under the control of a process computer, results in improved production
efficiency, labor, and energy savings. Already in use at Alcoa's operations
in Massena, New York, and Alcoa, Tennessee, the process affords the recovery
of 99 percent of the fluorides generated in the smelting.
Antimony
(4) Asarco's $7 million facility for leaching antimony from copper-
antimony-silver ore at its El Paso smelter has been completed. Capacity is
1200 tons of antimony per year. Concentrates come from the Coeur and Galena
silver mines in Idaho.
Copper
(5) A study to be conducted by Environmental Research and Technology,
Inc. will assess the effects that a copper-zinc underground mine will have
in the area of Exxon Minerals' Penos Altos discovery in Grant County, New
Mexico.
(6) Occidental Minerals Corporation (Oxymin), the owner of the Van Dyke
copper deposit 1100 to 2000 feet beneath the town of Miami, Arizona, has,
since 1968, been conducting an exploration program. In 1976, it was decided
to begin in situ leach pilot testing of the approximately 100 million tons of
0.5 percent grade ore. Weak sulfuric acid injected into a hydrofractured
zone of the ore body through two drill holes proved the feasibility of the
method of recovering the copper. However, further testing and evaluation are
48
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necessary to determine engineering data needed to economically justify pro-
ceeding with the development stage.
Two wells have been sunk to monitor the effects of the operation on
ground water in the area and analytical data show that no significant change
in chemical composition has occurred during the leaching activities.
Although the deeds to the land above the deposit absolve Oxymin of any lia-
bilities, the company has agreed to assume full responsibility for any damage
to surface property caused by the underground mining.
(7) Kennecott's new Magna copper smelter near Salt Lake City, Utah, has
just completed a $280 million project to control emissions. To save
Kennecott some $10 million in interest payments and at no cost to the tax-
payers, Salt Lake County commissioners are lending Kennecott the county's
credit rating and issuing $70 million in tax exempt industrial revenue bonds
with the guarantee that Kennecott will pay the debt.
(8) Continental Oil Co. has exchanged 3,066 acres of its land (and
$353,742 cash) for 5.699 acres of state land northwest of Florence, Arizona.
Conoco plans to use the state land for a mine dump, leaching pad, and ancil-
lary services for its copper deposit near Florence. Questions of water
rights must be resolved with the nearby Gila River Indian Reservation before
development can proceed.
(9) To remain competitive in copper production, Kennecott's Ray mines
in Arizona has recently acquired a 15-yard electric shovel and six 250-ton
and one 120-ton trucks.
(10) A legal fight appears imminent between federal, state, and copper
industry officials over legislation passed in the form of amendments to the
national Clean Air Act. The aim of the amendments, passed in August, 1977,
is to guarantee that by 1988 no sulfur dioxide is released into the air by
copper smelters. Industry will be allowed to postpone for up to 10 years
spending the large sums of money necessary to eliminate the smelter pollu-
tion, providing it does a better job now of reducing pollution with equip-
ment currently in use, and providing it agrees in advance to pay the
penalties.
(11) On October 7, 1977. President Carter lifted the government mora-
torium on copper stockpiling purchases, a move, it is felt, that will bolster
the copper industry. However, on October 20, 1977. an amendment by Senator
Domenici of New Mexico, that would have authorized federal purchases of
copper for the depleted national stockpile, was defeated. Domenici's plan
was for the government to sell some of its tin stockpile (tin is at a record
high price) to purchase copper, but it failed because Domenici and Udall
tried to "railroad" the bill through Congress without committee discussions
and debate, a process that invoked the skepticism of too many senators.
(12) The Smelter Control Research Association (S.C.R.A.) has announced
the results of a 2-year pilot investigation conducted at the Magma Copper
Company in San Manuel, Arizona, on the removal of sulfur dioxide from copper
reverberatory furnace gases. Differing from other double-alkali processes,
49 '
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the S.C.R.A. process uses limestone for regeneration of scrubbing liquor.
The precipitation of calcium salts which cause scaling and plugging are
minimal, and are confined to the regeneration system.
(13) The crisis in the copper industry continues to make news.
Anaconda has announced it will close its Arbiter hydrometallurgical refinery
in Anaconda, Montana, on December 9, with the leaching and precipitating
operation at Butte to be phased out over a 2-3 month period. Cities Service
announced that it is terminating all nonhydrocarbon exploration. However,
no change in plans for its operations at Copperhill, Tennessee, and Miami,
Arizona, is anticipated. Ranchers Exploration and Development Corp. is
curtailing mining operation at the Bluebird Mine near Miami, Arizona. This
is the company's only significant copper operation. Huge losses highlighted
the third quarter financial reports^ of Amax, Asarco, Cities Service, Cyprus,
Hecla, Inspiration, Kennecott, Magma, and Phelps Dodge. The only somewhat
brighter news was that Asarco would resume operations on a reduced basis at
its Sacaton Unit near Casa Grande and its Mission and Silver Bell Units near
Tucson, Arizona, and that Inspiration plans to resume some of its Arizona
mining operations early in January, 1978.
Some market analysts appear hopeful that the copper market has bottomed
out and the industry is now ready for a sustained, slow recovery with copper
prices at about $0.70 a pound late in 1978. The industry, however, is not
as optimistic, and capital spending projections show they will invest little
more than that necessary to maintain mines and meet environmental standards
for 1978.
(14) The EPA has ruled, in resolution of a court challenge, that emis-
sions from copper smelters during periods of start-up, shutdown, and mal-
function will not be considered a violation of new-source air pollution
standards.
Lead
(15) A new concept developed by a Bunker Hill geologist for finding ore
in the Coeur d'Alene Mining District, has been announced. Although still in
the development stage, it has met with success at Bunker Hill. The criteria
is based on the theory that folding or bending of the earth's crust causes
breaks to occur in the rocks, and it is in these fractures that ore deposi-
tion takes place. Wasteful and costly drilling programs could be prevented
in unfavorable areas if this concept proves to be acceptable.
(16) The 72 lead and copper smelters in the U.S. will be hit hardest
by an EPA proposed standard that would limit concentrations of lead in the
air by 1982 to 1.5 micrograms per cubic meter of air. The standards are
expected to be issued in final form in June, 1978, with the states having
9 months to draft plans for meeting the EPA standards.
It is estimated that $600 million will be needed to clean up point
source lead pollution. Necessary investments would be prohibitive for some
50
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smelters and would result in their closure. The expected standards have
been forced by a court ruling that stems from increasing concern over high
lead contents in the bloodstreams of children.
Molybdenum
(17) Processing of tungsten-molybdenum ore at Black Horse Mine. Nevada,
was begun in September. 1977. Average grade was 0.19 percent tungsten and
0.65 percent molybdenum with 60 percent recovery. Recovery improvement to
85-90 percent is expected.
Precious Metals
(18) A vein of quartz-siderite containing significant quantities of
silver-bearing tetrahedrite has been exposed in a crosscut driven at the
Royal Apex property in the Two Mule area north of Auburn, Idaho. Sampling
and diamond drilling is being planned.
(19) Exploration work began in May, 1977, and drilling will start in
1978 on 1872 acres of land recently acquired by Helena Silver Mines, Inc.
in Montana.
Good progress has been made by Helena Silver at the Ruby Creek, Montana,
placer gold operation with the installation of a suction dredge and related
equipment. Production will begin in 1978 at the rate of 1000 yards per day.
(20) The richest gold deposits known in interior Alaska are those north
of Fairbanks in the Chandalar District, recently acquired by Little Squaw
Gold Mining Co. Its success depends on the availability of financing, which
Little Squaw has not had since it began development work in 1973.
Tungsten
(21) Tungsten Peak Mines near Ridgecrest. California, has recently
begun production of 40-50 tons of tungsten concentrate daily. This produc-
tion capacity will be increased to 70-80 tons per day of 25-60 percent tung-
sten. The mine is complete, from extraction of the ore through the primary
and secondary milling processes, with the concentrate being packaged in
steel drums and shipped to the Union Carbide Corp. (Editor's Note: At
capacity, about 75 tons per day, at 45 percent concentration, and assuming
the scheelite contains approximately 20 percent tungsten, a production capa-
city of 5000 tons of tungsten per year is calculated. As an indication of
the scale of this operation, 5000 tons per year tungsten production is nearly
one-third of the domestic consumption.)
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Zinc
(22) Mysterious illnesses in humans, deaths in animals, and sterility
in gardens near the electrolytic zinc smelter in Bartlesville, Oklahoma, led
to an investigation by the EPA. They reported excess metals in the soil and
in the tissues of one calf that died. However, the USDA and the Oklahoma
State Department of Health also made investigations. The State agency
claims, to date, that no metals have been found in animals processed for
food. The USDA has not yet released their report.
(23) On November 30, 1977, Asarco, Inc. closed its New Market zinc
mining unit near Jefferson City, Tennessee, for an indefinite period. Last
year the New Market unit produced 13,000 tons of zinc contained in concen-
trate, or 13 percent of Asarco's total mine production. Escalating produc-
tion costs, plus continued depressed conditions in the zinc market, were
given as reasons for the closing. The Young and Immel mines in the Knoxville
area will continue to operate for the present time.
(24) The Gilman, Colorado, zinc mine, owned by the New Jersey Zinc Co.,
a Gulf and Western Industries, Inc. unit, will close on December 31. 1977.
A 24 percent decline in the selling price of zinc, the high cost of labor,
and depleted ore reserves are given as reasons for the closure.
Miscellaneous
(25) TheResource Conservation and Recovery Act, signed into law on
October 21, 1976, contains-a large number of guidelines, criteria, and regu-
lations, many of which will have definite implications for the mineral
industry, especially those governing the disposal of solid wastes.
The mining industry generates solid wastes, disposes of them in sites
which could be classed as dumps, and some of these wastes could be classi-
fied as "hazardous". Sometime during 1978. guidelines, definitions,
descriptions, etc, of the various aspects of waste disposal will be pub-
lished by the EPA to clarify the issues.
At this time, the only thing known for certain is that the cost of min-
ing and treatment of minerals will increase, thus increasing the consumer
prices for mineral-based goods.
(26) The Federal Mine Safety and Health Amendments Act of 1977 was
recently signed into law by President Carter.Under this law, federal
inspectors will have greater power to close down mining operations; safety
training becomes mandatory, and miners will be paid for accompanying federal
officials on four annual mine inspections. Penalties may be assessed up to
$10,000 per violation, plus $1,000 for each day a violation is not corrected.
Companies are prohibited from taking punitive action against employees who
file complaints or refuse to work under existing unsafe conditions.
52
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(27) While House hearings continue over the controversial hardrock
mining issue (HR-5831, the Ruppe Bill favored by American Mining Congress
vs. Barton's HR-9292, the Administration's leasing version), Idaho's Senator
McClure has introduced a Senate version that will (1) provide maximum non-
exclusive access for exploration of public lands, (2) provide exclusive
individual exploration rights by area assignment, (3) grant exclusive devel-
opment rights to successful prospectors, and (4) guarantee tenure for mining
ventures.
Sea Nodules
(28) The insurance provision was stricken from the Murphy-Breaux deep
seabed mining bill.
This provision would have indemnified the United States mining firms
who engaged in seabed mining under government permits, but whose rights
might be overridden by an international agreement to which the United States
might subsequently become a party. The bill is gutted as far as the mining
industry is concerned, as financing cannot be obtained unless investment
guarantees are written into law.
53
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REFERENCES
(1) U.S. Bureau Mines, Minerals and Materials, October, 1977, p. 46.
(2) American Metal Market, 85 (232), 1 (December 1, 1977).
(3) American Metal Market, 85_ (219), 8 (November 10, 1977).
(4) Arizona Paydirt, (461), 59 (November, 1977).
(5) Skilling's Mining Review, 66_ (49), 4 (December 3, 1977).
New Mexico Paydirt, (7), 12 (December, 1977).
(6) The Mining Record, 88_ (48), 4 (November 30, 1977).
Mining Engineering, 29_ (11), 13. 16 (November, 1977).
Ski 11 ing's Mining Review, 66_ (48), 17 '(November 26, 1977).
New Mexico Paydirt, (6), 10, 13-14 (November, 1977).
(7) Engineering Mining Journal, 178 (11), 257 (November, 1977).
American Metal Market, 85 (2T2T, 13 (November 1, 1977).
(8) Engineering Mining Journal, 178 (11), 251 (November, 1977)
(9) Engineering Mining Journal, 178 (11), 253 (November, 1977).
(10) Arizona Paydirt, (460), 22 (October, 1977).
(11) New Mexico Paydirt, (6), 20, 22-23 (November, 1977).
Arizona Paydirt, (460), 18 (October, 1977).
(12) Skilling's Mining Review, 66^ (52), 18 (December 24, 1977).
(13) American Metal Market, 85 (229), 19, 24 (November 28, 1977).
American Metal Market, 85_ (244), 31,40 (December 19, 1977).
•American Metal Market, 85^ (252), 1, 10 (December 30, 1977).
American Metal Market, 86_ (1), 28 (January 2, 1978).
Arizona Paydirt, (460), 16 (October, 1977).
Arizona Paydirt, (461), 1, 10-12 (November, 1977).
Mining Engineering, 29 (12), 19 (December, 1977).
New Mexico Paydirt, "(6"), 17, 42 (November, 1977).
Skill ing's Mining Review, 66_ (49), 23 (December 3, 1977).
The Mining Record, 88 (43), 3 (October 26, 1977).
The Mining Record, 88 (49), 5 (December 7, 1977).
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(14) American Metal Market, 85_ (214), 10 (November 3, 1977).
The Mining Record, 88_ (51), 3 (December 21, 1977).
(15) The Mining Record, 88 (46) 1 (November 17, 1977).
(16) The Wall Street Journal, LVIII (42), 2 (December 13, 1977).
(17) The Mining Record, 88_ (46), 1 (November 16, 1977).
(18) The Mining Record, 88 (44), 3 (November 2, 1977).
(19) The Mining Record, 88 (47), 1 (November 23, 1977).
(20) The Mining Record, 88 (44), 1 (November 2, 1977).
(21) The Mining Record, 88 (44), 3 (November 2, 1977).
(22) U.S. Bureau of Mines, Minerals and Materials, November, 1977, p. 49.
(23) American Metal Market, 85_ (229), 19 (November 28, 1977).
Skilling's Mining Review, 66 (49), 4 (December 3, 1977).
The Mining Record, 88_ (48), 1 (November 30, 1977).
(24) The Wall Street Journal, LVIII (49), 14 (December 22, 1977).
(25) Mining Congress Journal, 63_ (10), 26-30 (October, 1977).
(26) The Mining Record, 88_ (48), 2 (November 30, 1977).
(27) New Mexico Paydirt, (6), 28-31 (November, 1977).
The Mining Record, 88_ (45), 1 (November 9, 1977).
(28) American Metal Market, 85_ (209), 12 (October 27, 1977).
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RECENT PATENTS
4,054,446
PROCESS FOR THE REFINING OF A METAL SULFIDE MELT
Simo Antero livari Makipirtti, assignor to Outokumpu Oy, Outokumpu, Finland
(A process for refining molten copper sulfide by chlorine sparging, using
sulfur additions as necessary to maintain Cu2$ stoichiometry. Common
metallic impurities are preferentially removed as volatile chlorides.
Impurity condensation and collection systems not described in abstract.)
4,055,415
PROCESS FOR THE REMOVAL OF ALLOYING IMPURITIES IN A SLAG-COVERED COPPER
REFINING BATH
Mihaly Stefan; Tibor Nagy, and Sandor Daroczi, assignors to Csepeli Femmu,
Budapest, Csepel, Hungary
(This patent relates to slagging technology in producing fire-refined copper,
principally of secondary origin. Artificial slags, or fluxes, and metallic
reductants are apparently selected in view of impurities to be removed.)
4,056,261
RECOVERY OF GOLD AND SILVER FROM MINE-RUN DUMPS OR CRUSHED ORES USING A
PORTABLE ION-EXCHANGE CARBON PLANT
Robert M. Darrah, California
(A mechanical arrangement for counterflow extraction of gold and silver
values from an alkali-cyanide heap-leaching lixiviant with activated carbon.
Quantitative extraction information not given in the abstract. Barren
lixiviant is returned to the leaching cycle. Processing of the stripped
precious metal values is not covered.)
4,057,422
ORE TREATMENT PROCESS
Roll an Swanson, Santa Monica, California
(Processing of complex, multimetal ores involving (1) conversion to sulfides
of the highest oxidation states, (2) water leaching and cementation of water-
soluble metal sulfide values, (3) dissolution of selected metal sulfides in
molten alkali metal polysulfide followed by selective distillation, and (4)
selective distillation of metal sulfides not soluble in (3).)
4,057,611
PROCESS FOR RECOVERING ALUMINUM FROM ALUNITE
Larry D. Jennings and Wayne W. Hazen, assignors to Southwire Company,
Carrollton, Georgia; National Steel Corporation, Pittsburgh, Pennsylvania,
and Earth Sciences, Inc., Golden, Colorado
(Alumite is processed by drying, water-leaching to remove sulfur and alkali
metals, crushing and separation to two size fractions. The fines are caustic
leached, and the partly loaded liquor is used to then leach the coarse frac-
tion .A1(OH)3 is then precipitated from the pregnant liquor. From the brief
56
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abstract, this appears to be an adaptation of Bayer processing to a specific
al unite deposit.)
4,060,464
METHOD FOR EXTRACTING AND RECOVERING IRON AND NICKEL IN METALLIC FORM
Per Anders Herman Henningsson Fahlstrom, Thomas Konrad Widen, and Gotthard E.
Bjb'rling, Djursholm, assignors to Boliden Aktiebolag, Stockholm, Sweden
(Extraction of Fe and Ni values from sulfide ores by acid leaching in the
presence of ferric ion. Bleed liquor is reoxidized to Fe+3in anode compart-
ment of electrolytic cell, and balance of pregnant liquor is electrolyzed in
the cathode chamber to recover metallic Fe-Ni alloy containing at least
15 percent nickel. Depleted liquor is combined with reoxidized liquor frac-
tion and recycled to leaching stage.)
4,061 ,492
METHOD OF ORE REDUCTION WITH AN ARC HEATER
Maurice G. Fey and Edna A. Dancy, assignors to Westinghouse Electric
Corporation, Pittsburgh, Pennsylvania
(An apparatus for smelting/reduction of oxidic metal concentrates. The
smelting/reducing atmosphere is provided and heated by passing carbonaceous
feed through an electric arc into the smelting/reducing chamber. Reducing
off gas flows through a prereducing chamber where concentrate is partly
reacted in the solid state, and combustion of the reducing gas occurs. The
offgas from this is recuperated to preheat the incoming carbonaceous material,
cycloned, and vented.)
4,061,711
RECOVERY OF VANADIUM VALUES
Kenneth A. Morgan and Robert R. Frame, assignors to UOP, Inc., Des Plaines,
Illinois
(Leaching of fully oxidized vanadium concentrates in ammoniacal medium at
1 to 14 M. NH3, 50 to 300 C, and 1 to 200 atm. to form water-soluble ammonium
vanadate, which is subsequently crystallized and decomposed at 250 to 600 C
to yield a ^2^5 product.)
4,061,712
RECOVERY OF VANADIUM VALUES
Kenneth A. Morgan, Hoffman Estates, Illinois, and Marilyn Miller, Tucson,
Arizona, assignors to UOP, Inc., Des Plaines, Illinois
(A precursor to 4,061,711 above, this provides for caustic leaching of
vanadium ores/concentrates followed by NH3/C02 sparging at pH 6 to 7 to pre-
cipitate insoluble ammonium vanadate. Steam stripping allows recycle of
leach liquor and NH3 values.)
57
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4,062,675
ORE TREATMENT INVOLVING A HALO-METALLIZATION PROCESS
Abraham A. Dor, assignor to The Hanna Mining Company, Cleveland, Ohio
(This claims the recovery of cobalt or nickel from ores by blending the ground
and roasted ore with a halide, e.g., chloride, and a reducing agent, e.g.,
metallic iron, whereupon a portion of the nickel transfers from the gangue to
plate out on the iron. The merits of this process are not well-illucidated
in the brief patent abstract.)
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FOREIGN TECHNOLOGY
The articles listed are from foreign-language journals. The English abstracts
were taken directly from the Tables of Contents of the respective journals.
Barthel, G: Recovery of Copper From Mine and Smelter Water by Solvent
Extraction
Tech. Mitt. Krupp, Werks-Ber. Vol. 35 (1977), No. 2, pp. 25-36
A review is given of the processes used in removing copper from highly diluted
mine water and recirculated water from copper smelters. A comparison is made
between solvent extracton, cementation, and ion exchange using solid resins.
Various extraction reagents used in solvent extraction, typical test results
from the operation of a semi commercial plant, and the removal of organic
entrainment from raffinate and strip electrolyte are discussed.
R. Bortel: Flotation of the Polish Copper Ores
Erzmetall, Vol. 30 (1977) No. 9, 396-398
In particular consideration of the copper ore flotation, the development of
the flotation processes of nonferrous ores in Poland is described. The min-
eralogical and petrographic composition of the copper ores in the district of
Lubin (Legnica-Glogow) is discussed. After that, details are given on the
physico-chemical properties of the ores and their floatability. Furthermore,
the author describes the flotation results so far, the construction and the
equipment of the new copper ore dressing plants.
P. Halbach, K. Koch, H. J. Renner, K. H. Ujma: Pyrometallurgical Processing
of Manganese Nodules and Lateritic Nickel Ores Using Waste Materials as
Reducing Agents
Erzmetall, Vol. 30 (1977) No. 10, 458-464
Ores like deep-sea manganese nodules and lateritic nickel ores are mixed with
sewage sludge respectively with waste compost. These mixtures are agglomer-
ated. During thermal reaction, poor reducing gases are formed which are
suitable for a selective reduction. Metalized particles are formed. These
have grain sizes being great enough for the following beneficiation. First
results of some enrichment experiments are described.
H. J. Lange, K. Hein, D. Schab, B. Geidel: Anodic Secondary Reactions of
Silver in the Electrolytic Refining of Copper
Erzmetall, Vol. 30 (1977) No. 9, 369-374
Contents of silver in anode copper are dissolved anodically from the 0 solid
solution. In the electrolyte near the anode a reprecipitation takes place by
secondary reactions with anode slime formation. The precipitation of silver
59
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in contact with Cu, Cu+ ions, and Ci^Se, as well as CuAgSe by model experi-
ments with radiometric analysis after labelling the CuSC^ electrolyte with
the silver isotope Ag 110 m has been investigated. An extensive precipita-
tion was observed. The results enable conclusions to be reached about the
mechanism of reactions, reaction velocity, the form of bonding of silver in
the electrolyte and on its deposition in the cathode copper.
K. L. Sandvik: The Oxidation in Basic Sulfide Pulps and the Effect of the
Resulting Thiosulphates on the Flotation Properties of Some Sulfides
Erzmetall, Vol. 30 (1977) No. 9, 391-395
Thiosulphates in the tailings of selective sulfide flotation circuits are
known as contaminants calling for a long treatment. In this article, the
formation in the solution of thiosulphate, sulfite, and sulfide is inves-
tigated. The formation of thiosulphate proved to be dependent on the index
of pH, the supply of oxygen, the temperature, the reaction time and on the
grain size. The investigations included the feeding pulps of some Norwegian
copper zinc-ore dressing plants. In the initial cycles of the Cu-flotations,
thiosulphate was found within the range of 130 to 1120 mg/1. The results are
particularly discussed concerning the recirculation of the process water.
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TECHNICAL AWARENESS BULLETIN
NONFERROUS METALS
VOL. 3, NOVEMBER 16, 1977
This is a bimonthly publication of the U.S. EPA's Metals and Inorganic
Chemicals Branch, Office of Research and Development, designed to spotlight
selected events and concerns of the nonferrous metals industry.
HIGHLIGHTS
Voldmm* deepen {^01 the. battered and beteagueie.d coppeA 15 pioducel* announce cutbacks that have. tdled 4ome 8000
wolkeA* AJI Arizona atone.. Ba*4.c pioblem--£oie
environmental contlot and the le.ce.nt hike, -in labol late*.
Moni* (Idatt (Arizona) hat, n^dUL the. heat" — wUthdlw& hli> H.R. 5806
JLe.aA ale not placated; ie.call petition* continue to
ciicutate..
ASARCO ^tght& to feeep e.ni.c emL&*4.om> expected -en T978.
The. ApectAeA oft bauxite, caitetization and eneigy co&t* centime, to
pie** ioi nonconye.ntional aluuninum technology. Geoigta kaolin
ie*ouice* piovJjde, one. avenue; Alcaa/VOE embaik to £nve*tigate.
diAe.ct calbotheAiru.c induction place** .
Continued malket *tie.ngth £01 tung*ten, *4tveA, and gold 4*
e.ncouiag'ing fiuitheA e.x.ploiation and m-ine le-development activity.
Te*t mining and pioce**
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NON-FERROUS METALS INDUSTRIES
IN THE NEWS
September-October, 1977
Aluminum
(1) Intalco and other Washington State aluminum smelters will continue
to be impacted by energy shortages imposed by drouth in the Pacific Northwest,
as Bonneville Power is necessarily curtailing energy supplies.
(2) ERDA and Alcoa have a joint program to develop a carbothermic alumi-
num smelting process instead of electricity as its energy source. Using low-
grade ore such as clay and anorthosite, an aluminum-silicon alloy will be pro-
duced by direct reduction in a closed system. By-product CO gas will be col-
lected as a fuel or feedstock value. The joint program is priced at about
$5 million, and evaluation will require 5 to 7 years.
(3) It is now definite; the site of the projected 197,000 annual ton
Alumax aluminum smelter (reported in the July bulletin) will be in Berkeley
County, South Carolina, 20 miles north of Charleston. Initial construction
is targeted for the fall of 1978, with 32 months to complete the project.
Zero discharge of process water will be planned.
(4) Concern for the economic stability of foreign bauxite as an alumi-
num raw material continues to cause interest in nontraditional resources.
Georgia kaolins, variously estimated as from 5 to 15 billion tons, with
alumina contents from 30 to 40 percent, are adequate to support a substantial
aluminum industry. Husted of Georgia Tech anticipates the development of an
integrated aluminum-producing complex for the winning of aluminum from kaolin
by the last decade of this century.
(5) A modified scrubber-cooler has been installed at Kennecott's Maana
Utah, copper smelter. Used with the new Noranda type continuous smelting
vessels, the modified scrubber can handle over 200,000 actual cubic feet of
smelter gases per minute. Cleaned of particulate matter and cooled to 97 F,
these gases are used in .making sulfuric acid.
(6) The expected development of a major new copper operation by fluintana
Minerals near Hillsboro, New Mexico, has been postponed indefinitely due to
the depressed copper market.
(7) "There is plenty of copper today and there will be plenty of copper
in the foreseeable future", states an article in "World Mining" for September,
1977. The USBM estimates the world's copper resources which would be economi-
cally produced with future technology advances at 1,600,000,000 tons. A table
is given showing the projected increase in free-world copper mine production
capacity from 1976 through 1980. An account of the known world copper deposits
awaiting favorable conditons for development is also given.
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(8) Asarco is reported to have applied for a second 5-year variance from
state regulations to keep its Tacoma, Washington, copper smelter in operation.
Decision is expected by the end of October.
(9) Backed by the Bureau of Indian Affairs, the proposed development of
a new open-pit copper mine on the Papago Indian Reservation south of Casa
Grande. Arizona, by the Vekol Copper Mining Company (a subsidiary of Newmont)
is awaiting environmental approval by the Secretary of the Interior. An
annual production of 33,150 tons of copper and 1,200,000 pounds of molybdenum
in concentrates can be maintained from proven reserves of 105 million tons,
assaying 0.55 percent copper and 0.09 percent molybdenum per ton. Estimated
mine/mill development costs are $80 million. Waste removal to open the ore
body would be about 62 million tons.
(10) A plant is being designed for annual recovery of 143,000 pounds of
uranium oxide from the copper dump leach solution of the Kennecott Copper
Corporation mine and mill at Bingham Canyon, Utah. A 6,700 gallon per minute
counter-current resin ion exchange process, followed by solvent extraction,
will be used.
(11) The mining law bill HR-5806, written by Representative Morris Udall
of Arizona, which would have replaced the claim-patent system of 1872 for
mining on public land with a leasing system, has been withdrawn by Rep. Udall.
This bill was so very unpopular with all those concerned with the mining indus-
try,but, in particular, smaller miners, that petitions are being circulated
throughout his district seeking Rep. Udall's recall. Rep. tidal! promises to
work against a similar but tougher executive bill on a mineral-leasing system
proposed by Secretary of the Interior, C. D. Andrus. Larger industry fac-
tions favor a bill drafted by the American Mining Congress, introduced into
Congress by Rep. P. E. Ruppe of Michigan. This bill maintains the location
patent system, provides for modified free access of prospectors and miners to
public lands, but provides for a system of royalty payments and for the filing
of a mining plan. The smaller miners want no change made in the 1872 mining
law, particularly the payment of royalties.
(12) Because of the depressed prices in the copper market, coupled with
the increasing costs in wages and benefits, as the result of the recent strike
settlement, a large number"of copper mines and plants have been closed or the
number of employees drastically reduced, due to production cuts. Those com-
panies affected include Anaconda, Anamax, Asarco, Cities Services, Cyprus
Bruce, Cyprus Pima Mining, Duval, Hecla, Idarado, Inspiration Consolidated,
Kennecott, Kerramerican,Magma, and Phelps Dodge. The areas hardest hit by
these cutbacks are Arizona, where some 8,000 mine workers have been idled,
New Mexico, Utah, Nevada, Colorado, and Maine.
(13) Anamax and Asarco, jointly, are constructing a primary crusher, con-
veyor, and a sampling plant, to develop the Eisenhower group of claims, near
Asarco's Mission unit south of Tucson, Arizona. Production of large tonnages
of copper ore is planned to begin in 1978.
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(14) Idaho Copper and Gold Mines is reopening old copper workings in the
St. Joe mining district, Shoshone County, Idaho, where high-grade copper has
been mined. Rehabilitation of two old tunnels is planned, then Consideration
will be given to downward extension of surface veins.
(15) The EPA is charged to regulate toward lower arsenic enission levels
from copper, lead, and zinc smelters by August, 1978. An environmentalist
group (the Environmental Defense Fund) charges that the arsenic levels near
smelters have been as high as 0.354 micrograms/cubic meter. Smelter owners
claim the levels have been reduced as far as practicable and they will close
rather than pay the estimated $111 million per year for additional pollution
control required to meet a proposed OSHA standard should this be the basis
for forthcoming regulation.
Lead
(16) To eliminate sulfur dioxide gases produced in roasting lead and
copper-bearing materials,-an 800-tons-per-day sulfuric acid plant will be
built at ASARCO's El Paso, Texas, smelter. It is part of a previously noted
$98 million modernization and air quality program to be completed by mid-1978.
Magnesium
(17) Northwest Alloys (a subsidiary of Alcoa) has recently completed a
$100 million plant near Addy, Washington, for the production of 24,000 tons
per year of refined magnesium metal from dolomite. Included in the cost of
the plant was $20 million for pollution control equioment.
Molybdenum
(18) Amax Exploration has upped its estimate of the potential molybdenum
deposit located near Crested Butte, Colorado. It is now believed the deposit
contains 130 million tons of 0.4 percent molybdenum, a 40-million-ton increase
over that previously announced. The deposit is near Amax's Henderson complex,
recently dedicated, and in a line with the Climax mine near Leadville,
Colorado.
(19) Production ceased on September 1, at Molycorp's Questa mine in New
Mexico, due to rock and mud slides in June and July. About a year's supply
is stockpiled at the Questa complex, and molybdenum production is continuing
at a reduced rate. Ore reserves in the open-pit mine are nearing depletion,
and Molycorp is evaluating another molybdenum deposit at the Questa site in a
joint venture with Kennecott.
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(20) Low-water temperatures at the Climax molybdenum complex inhibits
conventional lime treatment of waste water to remove heavy metals. Pilot
studies of the Swift Lectra Clear process—electrocoagulation/
electroflotation--have been successful, and Climax is proceeding with the
installation of a full-scale, 2000 gpm Lectra Clear plant for use in series
with ion exchange to clean wastewaters prior to discharge from the Climax
property. This innovation is a first for the metal-mining industry.
Precious Metals
(21) The Nancy Lee silver mine near Superior, Montana, is being prepared
for reopening, with the construction of a 1260-foot shaft. Crosscuts will be
driven from the bottom of this tunnel to locate ore last mined in April, 1971,
when the mine was closed.
(22) The St. Elmo silver mine near the Coeur d'Alene mines in the silver
belt of Idaho is preparing to reopen. Col son and associates will open and
rehabilitate underground openings, map and sample the vein, prepare the prop-
erty for production, and mine any commercial ore found. : - •' <
(23) The "Sunshine silver mine in Idaho has acquired 42 acres of land near
the mine for its new tailings pond. Preparation of the property and construc-
tion of the pond will take 2 years to complete.
(24) The Alaska-Juneau gold mine, once the largest underground gold mine
in the world, will be permanently sealed, thus squelching nostalgic fantasies
that the low-grade ore might once again be worked at a profit. Work is begin-
ning on a $400,000 contract to seal one of the mine's main tunnels for use as a
municipal water reservoir.
(25) Lions Mines, Ltd., are beginning work on the Washington gold property,
which preliminary studies indicate contains upwards of 700,000 tons of produc-
tive gold-bearing material in the two upper zones. This ore assayed as much as
1.664 oz gold per ton. Open-pit mining is contemplated. The concentrator will
handle 200 tons per day.
(26) Volcanic Gold, Inc.. has reported purchase of the Miller Mountain
property in Broadwater County. Montana. Confererate Gulch, which drains this
area, is one of the major gold placer mining districts in Montana, with the
gold lodes localized at the heads of the streams drained by this gulch.
Volcanic Gold, Inc., also has gold mining claims in Churchhill County, Nevada,
which are being mapped and sampled.
Tungsten
(27) Activity on tungsten properties in Utah is increasing due to the
advance in price. In Box Elder County, ores are being mined at the Sun
Uranium property in the Newfoundland Range, the Blue Lady Mine near Park Valley,
and on the Glory Vein near Yost. A mill in Montello. Nevada, concentrates the
Sun Uranium and Glory Vein ores while Blue Lady ore is sold direct.
65
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Three properties are operating in the Gold Hill area of Tooele
County. Fraction Lode ore is concentrated in Ely, Nevada, while ore from the
Star Dust and B Estelle properties is sold without upgrading.
Zinc
(28) The Bunker Hill Company's Pend Oreille operation at Metaline Falls,
Washington, was shut down on September 1 for an indefinite period. This
action was precipitated by the depressed zinc market conditions and the strike
at the Kellogg facilities which consumes Pend Oreille's zinc concentrates.
(29) The Citrate process, developed by the USBM for scrubbing of SO? from
power plant stack gases, will be tested at the St. Joe Minerals Corporation
zinc smelter at Monaca, Pennsylvania. Attached to one of two 50-mw boilers
which generate electricity for the smelter, the test period will begin by the
fall of 1978. The SOp is absorbed by a water solution of sodium citrate and
citric acid and, by the addition of hydrogen sulfide to the solution, solid
elemental sulfur is obtained.
(30) Exxon is studying the feasibility of exploitingtheir Crandon,
Wisconsin, zinc-copper prospect at a mine production rate of 10,000 tons per
day. This equates to production of about 180,000 tons of zinc and 35,000 tons
of copper per year. Initial capital costs would be about $300 million (proba-
bly based upon open-pit mining, which may not appeal to state authorities on
environmental grounds). If Exxon proceeds with this, operations would come
on-stream no earlier than 1985.
(31) Callahan Mining is developing a zinc-lead orebody at the Van Stone
mine in Stevens County, Washington.
Miscellaneous
(32) Negotiations between seven of the largest chrome ore users in Japan,
and the largest processor in the United States, could lead to reactivation of
nearly 400 mines in the counties of Siskyou and Dee Norte in California and
Josephine County, Oregon. Crescent City, California, is a potential site for
the location of a chrome processing plant. (West coast chromite mines have
been inoperative since the days of government-subsidized production in the
1950's.)
(33) Sea trials are being conducted prefatory to mining tests with an
American-owned vessel designed to mine up to 1000 tons of manganese nodules
per day from the sea floor. The deposit selected for test mining lies 1200
miles southwest of San Diego and contains manganese, nickel, copper, and
cobalt, with lesser amounts of molybdenum, vanadium, zinc, and iron. Mate-
rial from the prototype mining operation will be processed in Belgium. If the
process proves economical, a full scale plant will be built in the U.S.
66
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(34) A major 1 ead-zinc-si1ver-cadmiurn find has been announced by General
Crude Oil and Houston Oil and Minerals at the base of the western Brooks
Mountain Range north of Katzebue, Alaska. No reliable estimate of tonnage or
grade of mineralization can be made without additional drilling and tests.
However, preliminary drilling has shown the following assays: lead 1.5-8.5,
zinc 5.8-25.5, cadmium .02-.25 percent, and silver .08-5.32 ounces per ton.
67
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REFERENCES
(1) U.S. Bureau of Mines, Minerals and Materials, September, 1977, pp. 56-57.
(2) American Metal Market, 85 (173), 12, 17 (September 7, 1977).
(3) American Metal Market, 85_ (187), 1, 11 (September 27, 1977).
(4) Mining Congress Journal, 621 (9), 28-33 (September, 1977).
(5) Chemical Processing, 4J) (10), 40 (September, 1977).
(6) New Mexico Paydirt (4), 8 (September, 1977).
(7) World Mining, 30 (10), 109-111 (September, 1977).
(8) Mining Journal, 289 (7413), 225 (September 16, 1977).
(9) World Mining, 30 (10), 172 (September, 1977).
(10) World Mining, 30 (10), 175 (September, 1977).
(11) Arizona Paydirt (459), 5 (September, 1977).
(12) Arizona Paydirt (459), 7-12, 14 (September, 1977).
New Mexico Paydirt (4), 14, 16 (September, 1977).
Mining Congress Journal, 63 (9), 7 (September, 1977).
American Metal Market, 85~Tl68), 1, 20 (August 30, 1977).
American Metal Market, 85 (176), 37s (September 12, 1977).
The Mining Record, 88 (38), 5 (September 24, 1977)
The Mining Record, 88 (39), 5 (September 28, 1977).
The Mining Record, 88 (41), 2 (October 12, 1977).
(13) Engineering Mining Journal, 178 (10), 149 (October, 1977).
(14) Engineering Mining Journal, 178 (10), 173 (October, 1977).
(15) Chemical Week, 121 (10), 10 (September 7, 1977).
(16) Arizona Paydirt (458), 64 (August, 1977).
(17) U.S. Bureau of Mines, Minerals and Materials, 55 (August, 1977).
(18) American Metal Market, 85_ (184), 1, 8 (September 22, 1977).
(19) New Mexico Paydirt (5), 14 (October, 1977).
(20) The Mining Record, 88 (38), 4 (September 24, 1977).
68
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(21) The Mining Record, 88 (36), 1 (September 7, 1977).
(22) The Mining Record, 88 (40), 1 (October 5, 1977).
(23) Skilling's Mining Review, 66_ (35), 6 (August 27, 1977).
(24) The Mining Record, 88 (36), 11 (September 7, 1977).
(25) The Mining Record, 88 (35), 1 (August 31, 1977).
(26) The Mining Record, 88 (42), 1, 3 (October 19, 1977).
(27) U.S. Bureau of Mines, Minerals and Materials, 55 (August, 1977).
(28) The Mining Record, 88 (36), 17 (September 7, 1977).
(29) Mining Congress Journal, 63_ (9), 12 (September, 1977).
(30) Skillingks Mining Review, 66_ (36), 5 (September 3, 1977).
The Mining Record, 88 (35), 1 (August 31, 1977).
(31) Engineering and Mining Journal, 178 (10), 173 (October, 1977).
(32) U.S. Bureau of Mines, Minerals and Materials, 48 (September, 1977)
(33) U.S. Bureau of Mines, Minerals and Materials, 4 (September, 1977).
(34) Engineering Mining Journal, 178 (10), 17 (October, 1977).
69
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RECENT PATENTS
4,040,950
CONCENTRATION OF ORE BY FLOTATION WITH SOLUTIONS OF AQUEOUS DITHIOPHOSPHATES
AND THIONOCARBAMATE AS COLLECTOR
Donald Edwin Zippen'an, James Allen Jones, and Thomas Brian Buza, all of
Tuscon, Arizona, assignors to American Cyanamid Company, Stamford, Connecticut.
(A flotation collector for copper sulfides wherein selected dialkyl dithiaphos-
phates are added to thionocarbonates used in aqueous flotation units is claimed.
The recovery of copper values is thereby improved.)
4,044,094
TWO-STAGE FLUID BED REDUCTION OF MANGANESE NODULES
Herbert E. Barner, Westford; David S. Davies, Andover, both of Massachusetts;
and Lester J. Szabo, Prince Edward Island, Canada, assignors to Kennecott
Copper Corporation, New York, New York.
(This invention relates to drying and conditioning copper- and nickel-containing
manganese (nodules) ore to reduce MnxOy to MnO and oxidize copper and nickel
values prefatory to ammonium carbonate extraction of the copper and nickel
values; i.e., a method for improved separation and recovery of copper and nickel
from manganese in sea nodule ores.)
4,044,096
SULFURIC ACID LEACHING OF NICKELIFEROUS LATERITE
Paul B. Queneau, Golden, and Eddie C. Chou, Arvada, both of Colorado, assignors
to AMAX, Inc., New York, New York.
(Claims pressurized leaching of 1 % nickel laterite slurry (2:l to facilitate downstream processing.)
4,045,215
METHOD OF REFINING MATTES CONTAINING NICKEL
Pierre Leroy, Saint-Germain-En-Laye; Jean Georges Morlet, Nevers; and
Jean Saleil, Saint-Etienne, all of France, assignors to Creusot-Loire, Paris,
France.
(Claims staged conversion of nickel mattes using a coaxial tuyere design to
introduce oxidative gas diluent as blowing for sulfur removal progresses for
more complete desulfurization; also for improved tuyere life. Offgas concentra-
tion profiles are not given; this technology could produce dilute offgas in
later stages and might impact gaseous effluent management.)
70
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4,045,216
DIRECT REDUCTION OF MOLYBDENUM OXIDE TO SUBSTANTIALLY METALLIC MOLYBDENUM
Harry W. Meyer, deceased, late of Weston, Connecticut, by Elizabeth Jane Meyer,
executrix; Jerry D. Baker, Ann Arbor, Michigan; and William H. Ceckler, Orono,
Maine, assignors to Amax, Inc., Greenwich, Connecticut.
(This patent claims gas-flow control and temperature control in a moving bed
reactor to sequentially reduce Mo03 pellets to MoOp (exothermic), thence to
Mo (endothermic). The concept is apparently directed toward improved energy
efficiency in production of metallic molybdenum without altering environmental
circumstances.)
4,046,851
TWO STAGE SULFURIC ACID LEACHING OF SEA NODULES
Kohur Nagaraja Subramanian, Mississauga, and Gerald Vernon Glaum, Oakville,
both of Canada, assignors to The International Nickel Company, Inc., New York,
New York.
(Claims a two-stage (100 C/260 C), controlled pH, H^SO^ leaching orocess for
recovering Ni, Co, and Cu values from sea nodules with'a "reduced tendency for
scale formation".)
4,047,934
BENEFICIATION OF THE NONFERROUS METAL VALUES OF OXIDE-CONTAINING MATERIALS
Leslie John Pollard, Lower Templestowe, and Donald Fergusson Stewart,
Doncaster, both of Australia, assignors to ICI Australia Limited, Melbourne,
Australia.
(Selective carbothermic reduction of iron oxide in a fused (alkali metal/
alkaline earth metal) chloride bath at 750 to 1300 C to beneficiate "a non-
ferrous metal oxide" is claimed.)
4,047,938
PROCESS FOR REFINING MOLTEN METAL
Andrew Geza Szekely, Yorktown Heights, New York, assignor to Union Carbide
Corporation, New York, New York.
(Claims a turbo-injector for refining/cleaning gas for use in nonferrous metal
refining. The object is to maximize the refining efficiency of injected gas.
This mechanical device appears to have potential for decreasing the volume and
increasing the concentration of offgases in nonferrous metal-refining
operations.)
4,047,940
SEPARATION AND RECOVERY OF COPPER METAL FROM AMMONIACAL SOLUTIONS
Alkis S. Rappas, Arlington, and J. Paul Pemsler, Lexington, both of
Massachusetts, assignors to Kennecott Copper Corporation, New York, New York.
(Claims a process for copper recovery from ammoniacal solutions involving
(1) conversion to and precipitation of copper acetylide, (2) converting the
acetylide to a cuprous-nitride solution, and (3) disproportionate to recover-
able metallic copper and a recyclable cupric complex.)
71
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4,049,438
NONFERROUS METAL RECOVERY FROM DEEP SEA NODULES
Ramamrithan Sridhar, Mississauga; John Stuart Warner, Oakville; and
Malcolm Charles Evert Bell, Sudbury, all of Canada, assignors to The
International Nickel Company, Inc., Delaware
(This appears to be a "brute-force" method for recovery of Ni, Co, Cu, and
170 values from sea nodules involving (1) selective reduction of the metal
values, (2) smelting to generate Mnxby-rich slag, (3) oxygen converting the
crude metal to remove additional manganese, and (4) converting the semi-
refined metal regulus to sulfides to facilitate separation of metal values.)
4,049,444
PROCESS FOR TREATMENT OF LATERITIC ORES
Malcolm Charles Evert Bell, Sudbury, and Ramamritham Sridhar, Mississauga,
both of Canada, assignors to The International Nickel Company, Inc., New York,
New York.
(Claims moving hearth gaseous reduction of pelletized nickeliferous silicate
laterites at 1295 to 1320 C to achieve >80 percent nickel recovery as ferro-
nickel particles. The pelletizing process incorporates 1 to 12 percent by
weight reducing agent, including at least 1 percent liquid hydrocarbon, along
with an "alkali metal compound" or an "alkaline earth-metal compound" as a
"reagent".)
4,049,445
METHOD FOR THERMAL TREATMENT OF NICKEL ORE
Horst Weigel, Cologne, Germany, and Anton Spitz, deceased, late of Cologne,
Germany, by Barbara Wilhelmine Spitz nee Schiirmann, legal representative,
assignors to Klockner-Humboldt-Deutz Aktiengesellschaft, Germany.
(This patent covers thermal reduction of nickel laterite ore in a three-zone
furnace to accomplish (1) preheating, (2) heating, and (3) reduction. The
method of reducing/heating/preheating countercurrent gas flow appears to
provide the unique feature of this patent.)
4,049,770
RECOVERY OF COPPER AND ZINC AS SULFIDES FROM COPPER-IRON SULFIDES
Godefridus Maria Swinkels, Rossland; Robert Arthur Furber, Edmonton;
Edward Francis Godfrey Milner, Warfield; Roman Michael Genik-Sas-Berezowsky,
Edmonton; and Charles Ray Kirby, Rossland, all of Canada, assignors to
Sherritt Gordon Mines Limited, Toronto and Cominco Ltd., Vancouver, both of
Canada.
(Claims hydrometallurgical processing to recover copper and zinc values from
thermally activated iron-copper-zinc sulfide concentrate. Covers autogenous-
pressure leaching, with a leachate containing 20 to 100 gpl copper and 5 to
35 gpl HpS04. This precipitates CuS and dissolves Fe and Zn. Zn is
recovered by reacting the leach liquor with H2S to precipitate ZnS.)
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4,049,771
EXTRACTION PROCESS FOR RECOVERY OF RHENIUM
L. Rita Quatrini and Martin B. Maclnnis, both of Towanda, Pennsylvania,
assignors to GTE Sylvania, Incorporated, Stamford, Connecticut.
(Liquid-liquid extraction of rhenium at <50 mg/i from an aqueous Re:Mo
solution at relative concentrations between 1:2000 and 1:3000 is covered.
The organic rhenium extractant, a quaternary ammonium compound with an
alkyl (8-10 C) compound and a mineral acid anion, is claimed. Extractant
concentration is 0.05 to 0.1 percent by volume in a carrier comprising at
least 50 volume percent benzene. Rhenium stripping is accomplished with-
out substantial loss in extraction capacity, so the stripped extractant
solution is recyclable.)
4,051,220
SODIUM SULFIDE LEACH PROCESS
Enzo L. Coltrinari, Arvada, Colorado, assignor to Equity Mining
Corporation, Vancouver, Canada
(This patent covers leaching of Sb/As/Au/Cu/Ag containing sulfide concen-
trates with NapS. This dissolves Sb, As, and Au values, rejecting Cu and
Ag sulfides. Oxy-sulfur compounds are further processed and refined.
Gold is recovered by LIX.)
4,053,305
RECOVERY OF COPPER AND SILVER FROM SULFIDE CONCENTRATES
Gary A. Smyres, Sparks; Philip R. Haskett, Reno; Bernard J. Scheiner,
Sparks; and Roald E. Lindstrom, Reno, all of Nevada, assignors to The
United States of America as represented by the Secretary of the Interior,
Washington, D.C.
(A process for recovering copper and silver from complex sulfide ores or
concentrates containing copper, zinc, silver, lead, arsenic, antimony, and
iron comprising (1) treating a slurry of the ore or concentrate in an aque-
ous solution of ferrous chloride with gaseous oxygen at a temperature of
about 100 to 115 C and a pressure of about 20 to 80 psig for a time suffi-
by solvent extraction and recycling the resulting ferrous chloride solution
to step (1), (5) treating the residue from step (2) with an alkaline solu-
tion of sodium cyanide to solubilize the silver, and (6) electrolyzing the
silver solution from step (5) to recover metallic silver.)
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NON-FERROUS METALS INDUSTRIES
IN THE NEWS
ISSUE NO. 2, August, 1977
A bimonthly pu.btic.ation AeA.vlc.& by thu USEPA MztaU and Inorganic. C/tmtco£4 BMwc.h ojj the.
O^ce. o& R&>e.aSLC.h and Vzve£opme.nt dulgnzd to ApottiQht 4e£e.cte.d e.vent&, ac£iv-itlu, and
conceAn-6 Jan. tke. non^nfiAouJ> m&tat!>-ptLodu.cA,ng i.nduAtru,eJ>.
HIGHLIGHTS: • Because of escalating costs and slump-
ing prices, several copper facilities are closing or
curtailing production operations. • Zinc market con-
ditions and prices are also forcing production cut-
backs in several domestic plants. I Discovery of a
large zinc-copper-sulfide deposit near Crandon,
Wisconsin, was announced by Exxon. I Continuing
strong market and attractive pricing are sparking new
and renewed activity in silver operations.
74
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NON-FERROUS METALS INDUSTRIES
- '
IN THE NEWS
ISSUE NO. 2, August, 1977
A bimonthly publication AeAvice. by the- USEPA Me-ta£i and Inofiganic. Chemicals, Branch o^ the.
0^-i.ce. 0(5 Runajick and Development duigntd to spotlight &nle.cte.d even;t6, activities, and
conc.eA.nl, xn -#te non&WiouA mntaLk-pn.oduiCA.nQ
Aluminum
(1) Alumax, in cooperation with Mitsui of Japan, is planning con-
struction of a 187,300 ton per year smelter in Umatilla, Oregon, pending
environmental impact statements by the Bonneville Power Administration
(suppliers of the electrical power). Also in planning by Alumax is an
88,000 ton per year potline at Eastalco's smelter in Frederick, Maryland,
a joint venture with Howmet Aluminum.
(2) An automated system for control of aluminum electrolysis has
been introduced at the Volkhov Aluminum Plant in Kirov, USSR. Increased
purity is obtained together with 50 percent greater production. (No
further details were given.)
(3) Alcoa has built a 15,000 ton per year demonstration unit at
Palestine, Texas, to recover volatile chlorides from fly ash. Magnetic
separation removes the iron oxides; then the nonmagnetic material is
chlorinated at high temperature.
(4) All permits, except for the tailings pond discharge and several
roads, have been obtained by Quintana Minerals, for the development of a
copper mining and processing project at Hillsboro in Sierra County,
New Mexico.
(5) Construction is already underway by Anaconda near Tooele, Utah,
(Carr Fork Project) for a multimillion dollar underground copper mine and
surface metallurgical processing facilities. Operations are to commence
by mid-1979.
(6) Exhaust heat from power plant engines is being used to heat the
fabric covering to 180-190 F on .three vacuum drum filters for dewatering
copper concentrate. This new system is being installed at the Twin Buttes,
Arizona, concentrator of Anamax Mining Company to replace gas fired driers
and solar drying ponds. Water is collected for recycle.
(7) The first commercial copper smelter designed and engineered by
Dravo using the TBRC smelter oxygen-oriented technology will be operated
by Afton Mines. Ltd., Kamloops. B.C. Originally developed in Sweden to
produce steel from high phosphorus iron ore, and known as the Kaldo
Process, it was converted to nickel processing by Inco, then to copper
smelting by Dravo and Inco in 1973. The TBRC Process produces a purer
product and cleaner slags, improved process control, higher S02 concentra-
tions, better exhaust gas collection, high energy efficiency, and lower
capital and operating costs.
75
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(8) The chances at this time appear quite favorable that the "Ely
Amendment" to the Clean Air Act will be enacted. This amendment exempts
smelters in business prior to 1910 from extensive plant alterations to
lower sulfur oxide emissions. Closure of the Phelps Dodge Douglas
Reduction Works and the McGill, Nevada, smelter would thus be prevented,
as neither could afford the investments in pollution controls that were
to be required.
(9) Adverse effects of recent economic trends will affect a number
of copper operations. The Cyprus Bruce Copper and Zinc Company mine near
Bagdad. Arizona, will close because of the depressed prices, escalating
smelter and refining costs, and the depletion of ore reserves.
On September 1, Anaconda's Victoria, Nevada, mine will close
indefinitely because of the present economic conditions in the copper
market. Resumption of operations will depend on the future market price
for copper and development of ore reserves in the area. In 1981,
Anaconda will close permanently its Weed Heights, Nevada, operation. Lay-
offs will begin as early as 1979 as oxide ores begin to give out. The
Duval Corporation will close three western mines for 6 weeks (August 8-
September 18), then follow with a 5-day work week indefinitely until there
is a notable improvement in the depressed state of the copper market. Pro-
duction will be cut 33 percent as a result. Phelps Dodge's Morenci,
Metcalf, and Ajo mines in Arizona and its Tyrone, New Mexico, mine will go
on 5-1/2-day shifts indefinitely, thus cutting production to 85 percent of
capacity.
Cities Service Miami operations in Arizona will not reopen its
Pinto Valley mine and mill due to the high cost of the strike settlement.
The solvent extraction electrowinning plant will continue operations.
(10) Phelps Dodge will be allowed to continue capacity operation of
its Playas, New Mexico, copper smelter until December 31, 1977, while it is
constructing an additional sulfuric acid plant to help control sulfur
emissions.
Molybdenum
(11) In July, the Henderson mine/mill complex of Amax, Inc., and
Climax Molybdenum Company was dedicated. At full scale production in 1980,
30,000 tons of 0.5 percent molybdenum disulfide ore will be mined and pro-
cessed per day. One of the first mines designed to meet the environmental
standards of the past decade, the ore is hauled by a 15 mile railroad to
the mill across the Continental Divide to prevent pollution of a key water-
shed in the area.
(12) Kennecott Copper and Molycorp jointly are proceeding with Phase 2
of the plan to develop the Questa, New Mexico, mine property. This calls
for mining 15,442,000 tons of 0.154 percent molybdenum sulfide ore between
May, 1977, and the end of 1979. This figure includes 9,370,000 tons of
stockpiled,0.132 percent ore. The partnership has also been studying the
76
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Goat Hill area nearby, for an underground mine, with reserves of 100,900,000
tons grading 0.32 percent molybdenum desulfide.
(13) A portable "Mud Cat" dredge operated by only two workers is being
used to clear sludge from a secondary holding pond at the Amax Henderson
molybdenum mine west of Denver, Colorado. Mounted, on a floating barge, it
can clean to a depth of 10-1/2 feet at the rate of 80 cubic yards per hour
and does not interfere with the operation of the pond while being used.
(14) Amax Exploration reports a possible major molybdenum deposit on
Mt. Emmons near Crested Butte, Colorado. In nine of ten drill holes assayed,
mineralization ranging from 0.2 to 1 percent molybdenum disulfide was found.
At an average depth of 1200 feet, the mineralization was 300 feet thick and
contained an estimated 90 million tons. Additional study of the deposit is
being made to determine its continuity and feasibility for mining.
Silver
(15) Heel a Mining Company has reported a possible major silver strike
directly under the old abandoned Gold Hunter mine in the Coeur d'Alene dis-
trict of Idaho.
(16) Reserves of 10 million tons of silver ore (averaging 3.2 oz/ton)
on the Taylor property of Silver King Mines in Nevada have been reported.
Feasibility and costs studies for building a 2000-tons-per-day cyanide leach-
ing plant on the site have been made.Cost is estimated at $7.7 million .
Silver-gold ore from the East Robinson property and silver from the East
Hamilton property will also be processed here.
Silver King is also conducting test drilling on the Ward prop-
erty where 10 million tons of ore reserve is indicated, averaging 1.8 ounces
silver, 60 pounds zinc, and 30 pounds of copper per ton.
(17) Production is being resumed at the Deer Trail mine at Marysvale.
Utah, after being closed since 1971. The lead-zinc-silver ore, ranging
from 500 to 800 tons per month is being shipped to the flotation plant at
Park City, Utah.
Zinc
(18) What is believed to be one of the five largest massive zinc-
copper sulfide deposits in North America has been discovered near Crandon,
Wisconsin, by Exxon. About 75 million tons of ore analyzing 5 percent zinc
and 1 percent copper are indicated.
(19) Recent equipment failure in the concentrate roaster sulfuric acid
recovery system of the Amax Zinc Company. Sauget. Illinois, plant will force
plant shutdown in September. This will reduce zinc production by 15 percent.
77
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(20) Because of the continued weakness of the domestic zinc market
and worldwide oversupply, a number of zinc producers throughout the world
have reduced operations. In the U.S., Bunker Hill will operate its mines
and refinery at 70 percent capacity; St. Joe Zinc Company began cutbacks
in June; and Asarco is believed to have cut back 60 percent.
Zirconium
(21) Unacceptably high levels of radioactivity in the form of radium-
226 was found in the Albany, Oregon, zirconium plant of Teledyne Wah Chang.
Hazardous levels of chlorine, phosgene, and ammonia were found in the plant
and, in addition, a landfill of zirconium waste caught fire while being
bulldozed. A fine was levied for the violations.
Miscellaneous
(22) The USSR has developed a superconducting infrared radiometer for
ore prospecting in an airplane flying at 200-300 meters. The bolometer is
encased in a cryostat at a temperature of -269 C. A superconductor magne-
tometer has also been developed. One measures the earth's magnetic field
variations outside the ore anomaly, the other in the area of the anomaly.
A comparison of the two instruments provides data for calculating the ore
deposit.
(23) A new process developed by the Permutit Company, the Sulfex pro-
cess, removes heavy metals from wastewaters by precipitation as sulfides.
The process removes most chelated metals and reduces hexavalent chromium as
the other metals are precipitated as sulfides. Two units are used; the
first removes a large part of the metals as hydroxides, the second precipi-
tates the remainder as sulfides. Permutit will install two 40 gpm plants
by the end of this year.
(24) There is a vast energy-saving potential through recycling of
metals, and American industry has just scratched the surface. Environ-
mental and economic dividends are the conservation of natural resources,
80-90 percent less air pollution and 75 percent less water pollution,
relative to primary processing, reduced reliance on foreign sources, alle-
viation of balance of payments problems, and increased employment. A ton
of aluminum or copper, made from scrap, saves 95 percent of the energy
needed to produce a ton from virgin material. The energy savings in
equivalent barrels of oil from recycling aluminum, copper, zinc, lead, and
iron and steel last year was 126,000,000.
78
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REFERENCES
(1) American Metal Market, 85 (124), 1 (June 28, 1977).
(2) Ekonomecheskaya gazeta, (23), 6 (June, 1977).
(3) Chemical Engineering, 84 (15), 102 (July 18, 1977).
(4) New Mexico Paydirt, (2), 9 (July, 1977).
(5) Arizona Paydirt, (456), 43 (June, 1977).
(6) Mining Congress Journal, £3 (7), 10 (July, 1977).
(7) Dravo Trade Literature "TBRC Smelter Process for Copper".
(8) Arizona Paydirt, (456), 20 (June, 1977).
U.S. Bureau of Mines, Minerals and Materials, 50-51 (July, 1977).
(9) Wall Street Journal, LVII (182), 8 (June 29, 1977).
Arizona Paydirt, (457) 42 (July, 1977).
Skillings Mining Review, 66 (31), 6 (July 30, 1977).
American Metal Market, 85~Tl40), 1 (July 21, 1977).
American Metal Market, 85 (138), 10 (July 19, 1977).
U.S. Bureau of Mines, Minerals and Materials, 51 (June, 1977).
American Metal Market, 85 (155), 1, 10 (August 12, 1977).
Skillings Mining Review, 66 (34), 8 (August 20, 1977).
New Mexico Paydirt, (3), 1 (August, 1977).
(10) New Mexico Paydirt, (1), 38 (June, 1977).
(11) American Metal Market, 85_ (131), 1, 11 (July 8, 1977).
American Metal Market, 85 (134), 9 (July 13, 1977).
(12) American Metal Market, 85 (150), 1, 8 (August 4, 1977).
(13) 33 Metal Producing, TJ5 (7) (55) (July, 1977).
(14) American Metal Market, 85. (161), 17 (August 19, 1977).
(15) Mining Congress Journal, 63 (6) 12-13 (June, 1977).
(16) Skillings Mining Review, 66 (29), 4 (July 16, 1977).
The Mining Record, 88 (3317 1 (August 17, 1977).
(17) U.S. Bureau of Mines, Minerals and Materials/A Monthly Survey, 55
(July, 1977).
(18) U.S. Bureau of Mines, Minerals and Materials/A Monthly Survey, 56
(June, 1977).
79
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(19) Mining Journal, 289 (7408), 127 (August 12, 1977).
(20) American Metal Market, 85 (133), 9 (July 12, 1977).
American Metal Market, 85 (143), 1, 8 (July 26, 1977).
(21) U.S. Bureau of Mines, Minerals and Materials/A Monthly Survey, 52
(July, 1977).
(22) Pravda Ukrainy, (112) 4 (May 13, 1977).
(23) Environmental Science and Technology, H (7), 642 (July, 1977).
(24) American Metal Market, 85 (128), 20 (July 4, 1977).
80
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RECENT PATENTS
4,032,330
PROCESS FOR RECOVERY OF COPPER
Gerald F. Fountain; Jaime Veloz; Harry R. Dahlberg, and Edward A. Bilson,
all of Inspiration, Arizona, assignors to Inspiration Consolidated Copper
Company, Morristown, New Jersey.
(A process for the leaching and recovery of copper values from sulfidic
copper ore.)
4 032 331
PROCESS FOR CONSERVING QUINOLIC COMPOUNDS IN AN ORGANIC EXTRACTANT COPPER
RECOVERY SYSTEM
John N. Gerlach, Burlington, Massachusetts, assignor to Kennecott Copper
Corporation, New York, New York.
4 032 332
PROCESS FOR INCREASING THE RATE OF COPPER METAL PRODUCTION IN A QUINOLIC
EXTRACTION SYSTEM
John N. Gerlach, Burlington, Massachusetts, assignor to Kennecott Copper
Corporation, New York, New York.
4,033,757
CARBOTHERMIC REDUCTION PROCESS
Robert Milton Kibby, Richmond, Virginia, assignor to Reynolds Metals
Company, Richmond, Virginia.
(An electric furnace carbothermic process for the production of aluminum
from an aluminum oxide.)
4,033,761
PROCESS FOR THE SEPARATION OF COPPER SULFIDE FROM METALLIC LEAD ENTRAINED
IN A DROSS
Carl Richard DiMartini, Piscataway; William Lafayette Scott, Lebanon, and
Leo James Bulvanoski, Fords, all of New Jersey, assignors to Asarco
Incorporated, New York, New York.
4,033,846
APPARATUS FOR GAS COLLECTION IN ALUMINUM SMELTING FURNACES
Arne Engesland, Mosjoen, Norway, assignor to Lista Og Mosjoen Aluminiumverk,
Elkem Aluminum A/S & Co., Oslo, Norway.
4,034,063
PROCESS FOR CONTROL OF SOX EMISSIONS FROM COPPER SMELTER OPERATIONS
Edward C. Rosar, Lakewood, Colorado; Jacques M. Dulin, Libertyville,
Illinois; Joseph M. Genco, Gahanna, and Harvey S. Rosenberg, Columbus, both
of Ohio, assignors to Industrial Resources, Inc., Chicago, Illinois.
(Soda-scrubbing of stack gas, and using the (NaSxOy) product to remove iron
from spent leach/cementation liquor, allowing liquor recycle.)
-------
4,036,636
PYROMETALLURGICAL PROCESS FOR SMELTING NICKEL AND NICKEL-COPPER CONCENTRATES
INCLUDING SLAG TREATMENT
Paul R. Ammann, Boxford, and Jonathan J. Kim, Chelmsford, both of
Massachusetts, assignors to Kennecott Copper Corporation, New York, New York.
4,036,639
PRODUCTION OF COPPER
William J. Yurko, Edmonton, Canada, assignor to Sherritt Gordon Mines Limited,
Toronto, Canada.
(A hydrometallurgical process for recovering copper from cupriferous sulphidic
material.)
4,036,931
BAYER PROCESS PRODUCTION OF ALUMINA
Morris L. Roberson; John W. Beck; Jack S. Maples, all of Baton Rouge;
Anthony Savariste, Plaquemine, all of Louisiana; Donald J. Donaldson, Orinda,
California; David L. Stein and Allan C. Kelly, both of Pleasanton, California,
assignors to Kaiser Aluminum & Chemical Corporation, Oakland, California.
(Slowdown of spent liquor with C02 to recover ^2^3 as sodium dawsonite, pro-
ducing environmentally acceptable waste with pH from 8.6-9.)
4,038,039
PRODUCTION OF ALUMINA
Andrew Nicolson Carruthers, Dollard des Ormaux; John Edward Deutschman, and
Michael George Willis, both of Arvida, all of Canada, assignors to Alcan
Research and Development Limited, Montreal, Canada.
(A procedure for controlling the sodium oxalate level in the liquor employed
in the Bayer process for the production of alumina from bauxite ore.)
4,038,070
LOW TEMPERATURE AND PRESSURE CONTINUOUS REDUCTION OF COPPER IN ACID SOLUTIONS
Alkis S. Rappas, Arlington, and J. Paul Pemsler, Lexington, both of
Massachusetts, assignors to Kennecott Copper Corporation, New York, New York.
(Hydrogen reduction to" Cu+, complexing, and disproportionate.)
4,038,361
RECOVERY OF NITRIC ACID SOLUBLE TRANSITION METALS FROM SULFUR AND IRON
CONTAINING ORES OF THE SAME
John G. Posel, Everett, Washington, assignor to International Ore Technology,
Inc., Highland Mills, New York.
(A pressurized hydrometa11urgical method of recovering one or more metal
values of the group consisting of copper, silver, nickel, cobalt, and zinc
from a sulfur and iron containing ore.)
82
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4,039,401
ALUMINUM PRODUCTION METHOD WITH ELECTRODES FOR ALUMINUM REDUCTION CELLS
Koichi Yamada; Tadanori Hashimoto, and Kazuo Horinouchi, all of Niihama,
Japan, assignors to Sumitomo Chemical Company, Limited, Osaka, Japan.
(A method for producing aluminum by molten salt electrolysis of aluminum
oxide using ceramic electrodes.)
4,039,404
CYCLIC PROCESS USING A.C. FOR SELECTIVE RECOVERY OF METALS FROM MATERIALS
CONTAINING SAME
Kenneth Julian Richards, Salt Lake City, and Don Richard Clark, Centerville,
both of Utah, assignors to Kennecott Copper Corporation, New York, New York.
4,039,405
LEACHING COPPER ORES AND SOLVENT EXTRACTION OF THE COPPER-BEARING SOLUTIONS
Soon Y. Wong, Ponca City, Oklahoma, assignor to Continental Oil Company,
Ponca City, Oklahoma.
4,039,406
RECOVERING COPPER FROM CONCENTRATES WITH INSOLUBLE SULFATE FORMING LEACH
Robert W. Stanley, Kirkland, and Kohur Nagaraja Subramanian, Mississauga,
both of Canada, assignors to Noranda Mines Limited, Canada.
(A hydrometallurgical method of recovering copper values from copper sul-
phide concentrates.)
4,042,664
METHOD FOR SEPARATING METAL CONSTITUENTS FROM OCEAN FLOOR NODULES
Paul H. Cardwell, Zanoni, and William S. Kane, Wicomico, both of Virginia,
assignors to Deepsea Ventures, Inc., Gloucester Point, Virginia.
(Carbo-halogenation dissolution and liquid-liquid extraction.)
******
InctivMucUUy ton^U-batid new* Uw* mat/ be. lubmWiid to M*. Faerf C/uug,
and -Lnon.QanA.c. Chemical* faanck, IERL, USEPA, 5555 lUrfcje Avenue,
Ohio 4526B (Phone. 513-684-4491).
Prepared by Battelle's Columbus Laboratories under EPA Grant R805095-1.
83
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USEPA AWARENESS BULLETIN
'lECHNOLOGY $ I RENDS
IN THE NONFERROUS METALS INDUSTRY
The following pages are abstracts of nonferrous metals technology and
operations appearing in the literature within the past 2 or 3 months. The
indexing system is designed to facilitate filing according to user interest
by a "primary-secondary-tertiary" coding system for "metals-processes-environ-
mental concern" as follows:
Metals
1. Cu (and As, Se, Te)*
2. Pb, Zn (Sb, Cd, Tl)
3. Al (Ga)
4. Ti (Zr, Hf)
5. Mo (Re, Sn)
6. Rare Earths and Y
7. Be
8. Hg
9. Ag, Au, Pt, Pd
10. W
11. V, Cr
12. Cb, Ta
13. Ni (Co, Mn)
14. Mg
15. Multiple
16. Unspecified
Process
.1 Mining (P)**
.2 Beneficiation (P)
.3 Smelting/Extraction (P)
.4 Refining (P and S)
.5 Ingot Melting (P and S)
.6 Preparation (S)
.7 Smelting/Extraction (S)
.8 General Recycling (S)
.9 Multiple (P and S)
Environmental Concern
.1 Air (Human)
.2 Air (Ecology)
.3 Water (Human)
.4 Water (Ecology)
.5 Solid (Human)
.6 Solid (Ecology)
.7 Noise
.8 Multiple
.9 Not Determined
* ( ) = common byproducts
** ( ) = primary or secondary
84
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USEPA TECHNOLOGY AMP TRENPS ABSTRACT Index 1 1 8
for the NONFERROUS METALS INDUSTRY Page 1
Subject: New Techniques in Copper Mining
At the present time, about 55 percent of the copper mine production is
from underground mines and 45 percent from open pit. Depending upon the
method used in underground mining, the cost per ton of ore ($1.60) will
generally be 1-1/2 to 6 times that of open pit mined copper. Worldwide,
decline in the overall average grade of copper mined (0.53 percent in the
U.S.) will increase production costs, necessitating improvement in production
techniques. This paper describes some of these new techniques.
Underground Mining. The newest technique in shaft sinking involves
large diameter rotary drilling, eliminating the need for blasting and per-
sonnel below ground level. Holes for ventilation or secondary service shafts
have been drilled to 8 meters in diameter and 500 meters deep. Other
improvements in shaft sinking are mechanical devices to remove broken rock
from shaft bottoms and the drilling of pilot holes and their subsequent
enlargement.
Self-propelled rock cutting machines, similar to those used in the coal
mines, are being used in place of the drilling and blasting formerly used.
Boring machines are 4 to 5 times faster than conventional blasting techniques
in tunnel driving.
Haulage of the ore to the surface in diesel-powered trucks up inclined
surface drifts is replacing the small cars pulled by locomotives, or vertical
shaft lifts. Hydraulic transport and hoisting, already used in coal, iron,
and gold mining, may become used for copper in the future.
Open Pit Mining. Innovations in above ground mining include the use of
the explosive ANFCf (ammonium nitrate and fuel oil), smaller and more mobile
rotary drills, bucket-wheel excavators, and off-highway trucks with load
capacities of up to 300 tons.
Heap leaching is being increasingly used to extract copper from the ore.
In heap leaching, the ore is stacked in piles through which the leaching
solution is passed. In situ leaching is of continued interest, and several
sites are being developed with in situ leaching in mind. In this process,
the explosive-shattered mineralized rock is leached in place. Fragmentation
of copper ore deposits may, in the future, be done by nuclear explosives.
Environmentally, solution mining is advantageous as there are no tail-
ings to dispose of, no smelting to cause air polution, and little surface
disturbance.
Reference: R. C. Howard-Goldsmith, Mining Magazine, 138 (2), February 1978,
pp. Ill, 113, 115, 117, 118
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USEPA AWARENESS BULLETIN TwnFV 1.2.3/.4
1ECHNOLOGY $ I RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE I
SL'B-JECT- T^e TL Leaching Process
A new leaching process, called TL (for thin layer), has been developed by
Holmes and Narver of Anaheim, California. The first commercial TL plant will
be built in Santiago, Chile, to handle 2,500 tons of copper ore per day.
After crushing, the ore is contacted with concentrated acid in a rotating
drum, allowed to "cure" for 24 hours, then spread to dry in 3-foot deep leach
beds. During the leaching cycle, water or weak leach liquor is periodically
sprinkled over the bed, and the leachate is collected beneath the bed.
Exhausted beds, which are quite dry, are dumped into a landfill. Because dis-
posal of the exhausted beds is done in the dry state rather than impoundment
of wet tailings as conventional processes, the chance of ground water contami-
nation is virtually eliminated.
REFERENCE: Mining Journal, 289, (7404), July 15, 1977, pp. 47-48.
Chemical Engineering, 84, (15), July 18, 1977, p. 53.
86
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USEPA TECHNOLOGY AWP TREWPS ABSTRACT Index 1 2 4
for the NONFERROUS METALS INDUSTRY Page V
Subject: Pinto Valley Tailings Disposal Project Underway
With an eye to future requirements, work is proceeding on the $6 mil-
lion tailings impoundment project at the Cities Service Pinto Valley Arizona
copper operations. Scheduled for completion in January, 1978, the structure
will cover 525 acres and is designed to contain 234 million tons of tailings,
(20 years production from the Pinto Valley concentrates). Flowing at a rate
of 13,700 gal per minute, the tailings will flow through 3 miles of 24-inch
concrete-lined steel pipe into the tailings pond which, when filled will run
650 feet, believed to be the world's deepest.
As an environmental protection feature, a 13,300-foot<-long pollution-
control ditch is being constructed around the tailings disposal pond. Nearly
one-half million cubic yards of excavation will be required for the control
ditch.
Reference: Skill ing's Mining Review, 66, (44), October 29, 1977, p. 17
87
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USEPA TECHNOLOGY AHV TREWS ABSTRACT Index 1.2.4
for the NONFERROUS METALS INDUSTRY Page 2
Subject: Cyprus Bagdad's $240 Million Expansion
NearIng Rated Production
In the early 1970's, with a 6000 tpd operation facing a declining ore
grade, increasing cost, and obsolete facilities, but with a 300-mi11 ion-ton
(0.49 percent copper) reserve, Bagdad decided to expand its operation. A
merger with Cyprus Mines and an arrangement with Phelps Dodge to smelt the
concentrate at its new Hidalgo smelter in New Mexico were preliminary steps
to the beginning of the $240 million expansion in the spring of 1975.
The old mill was closed in August, 1977, with the new concentrator
beginning operation in September. As additional circuits came on line, pro-
duction increased and stood at 38,000 tpd at the end of February, 1978.
The processing facilities consist of (1) primary crushing and conveying,
(2) autogenous primary grinding with crushed ore recycle, (3) ball-mill
secondary grinding, (4) copper-moly flotation, (5) moly flotation, (6) con-
centrate filtering and drying, (7) tailings disposal and water reclaim, and
(8) ancillary facilities. Details of each of the processing facilities are
given in the article, together with a concentrator flow diagram.
The mining operation is a high volume one, 1-1/2 tons of waste rock must
be removed for every ton of. ore or 10 pounds of copper metal. Loading is
done with four 20-yard electric shovels and hauling with twenty-two 170-ton
trucks over well-maintained roads. Grades at the shovel are maintained by
laser beams and slope movement is detected by an infrared distance meter,
which can detect movements of 0.001 foot at 10,000 feet.
The four primary reasons given for success in meeting its goal of "mov-
ing muck" are (1) open door personal relations policy, (2) excellent preven-
tive maintenance policy, (3) excellent haul road maintenance, and (4) using
shovels to load, not to dig.
Reference: Arizona Paydirt (465), March, 1978, pp. 4-9.
88
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USEPA AWARENESS BULLETIN IND£X Q1 2/3/4
1ECHMQLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 1
SUBJECT: Cyprus Bagdad's Solvent Exchange Process
Cyprus Bagdad is completing a $240 million solvent exchange expansion
program designed to recover 20 tons per day of cathode copper from dump-leach
operations for its oxide/sulfide ores mined at the Bagdad, Arizona, site.
Earlier operations were based on iron cementation followed by smelting/refining.
Copper/iron price changes, the scarcity of cement iron, and cost and capacity
Constraints relative to smelting were ingredients that contributed to the deci-
sion to invest in the LIX-electrowinning route.
The new plant design will process about 3200 gpm of dilute sulfuric
(1.89 g/L) leach liquor containing 1.07 g/L copper. Dumps are contained in
narrow canyons and are treated with acid at an initial concentration of 7.73 g/L
at a rate of 1 gallon of acid per 44 square feet of dump area applied through a
"wiggler" over the surface of the dumps. Percolating leach liquor is collected
in sumps without measurable seepage to ground water, and pumped to a surge pond
(750,000-gallon capacity) which feeds the extraction and electrowinning plant.
Extraction is done in four modules, each operating at a flow of pregnant
liquor at 800-325 gpm. The extractant, 6.36 percent LIX64N in 93.64 percent
Napoleum 470, is counterflowed at a 1:1 ratio against the throughflowing preg-
nant leach solution. The LIX exchanges a hydrogen ion for copper, at once
extracting the copper and regenerating the acid for recycle. Disengagement
settling occurs at a rate of greater than 2 gpm per square foot area of the
settling vats. The recovered pregnant extractant i.s stripped and regenerated
by an acid copper sulfate solution prior to recycle. The enriched stripper
solution passes to the tankhouse where starter sheets and cathodes a:-e p-educed
while decreasing the copper concentration of the electrolyte from about 60 g/L
to about 30 g/L before it is recirculated to the stripper plant. The quality
of the cathodes thus electrowon is comparable with electrorefined cathode.
Several problems encountered in start-up of this plant were briefly dis-
cussed. These included hydrostatic leakage from miles of-piping (corrected by
segmental isolation and correcting), cleansing the extractant solution of solu-,
ble organics (operational "nurse-maiding"), and learning to treat striooer
sludge to preserve organic values.
A bottom-line comparison of actual with'projected costs for this ope»"3-
tion showed excellent agreement,and significant operating cost advantages for
solvent extraction and electrow.inning over the previous method of cementation
and smelting/refining were indicated. (Cost of capital and deoreciation com-
parisons were not included, however.)
REFERENCE: R. L. Jones, Mining Engineering, 29 (9), September, 1977, DO. 38-42,
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USEPA AWARENESS BULLETIN iwnFV 1-3.1
INDEX
1ECHNOLOGY $ I RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
SUBJECT• Asarco Takes "Zig-Zag" Path to Improve
In-Plant Control of Participate Pollution
Asarco has installed Patterson-Kelley zig-zag continuous liquid-solids
blenders at three points in its Tacoma, Washington, smelter and at two other
facilities. Although used primarily for blending and agglomerating in the
chemical processing industry, distinctive features of the zig-zag process
suggest its use in pollution problems.
The blender consists of a stationary inlet and stationary discharge with
a rotating eccentric drum and a series of legs mounted on a slightly inclined
frame in between. Liquids are injected into the blender through adjustable
orifices inside the rotating drum. This action coats every particle, however
small, with liquid. Located in the discharge line from electrostatic pre-
cipitators, the zig-zag blender not only provides a simple means of agglomer-
ating the precipitator product but also eliminates a laborious and dusty mate-
rials handling operation.
At the Asarco copper smelter in Tacoma, arsenic oxide from the electro-
static precipitators is agglomerated in the blender and advanced to the roasting
plant for processing to arsenic trioxide. In two other operations at the Tacoma
facility, dusting problems have been solved and valuable dust recovered.
As Asarco has proven in these installations, the pollution problem of vari-
ous smelter dusts can be greatly alleviated by the use of. the zig-zag blender.
REFERENCED Engineering Mining Journal, J7£[ (7), July, 1977, pp. 101-102.
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USEPA TECHNOLOGY ANt? TRENDS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Subject: Cyprus Reveals Details
Index 1.3.1
Page 4
of New Copper Process
As reported in the September-October 1977 issue, Cyprus Copper has
developed a new hydrometallurgical copper process. Some additional informa-
tion has been forthcoming and is presented here.
The copper ore concentrate (sulfide or oxide) is slurried in strong
ferric and cupric chlorides. When leached at atmospheric pressure and tem-
peratures below 100 C with cupric chloride, cuprous chloride, ferrous
chloride, elemental sulfur, and free acids are formed. After hot filtration,
lowering the temperature of the filtrate results in crystallization of the
cuprous chloride.
Hydrogen reduction of the cuprous chloride takes place in a fluidized
bed of sand, at less than 1000 C. The copper agglomerates with the sand
particles and the agglomerate is removed from the bed when the copper-sand
ratio becomes 92%:8%. In a commercial plant, the agglomerates would be
melted in a reverberatory furnace with sand and minor impurities removed as
slag during fire refining.
The sulfur is recovered as free sulfur; consequently, no S0£ pollution
takes place. The hydro circuit is closed, and water is required for evapora-
tive makeup and cooling only. Iron is removed as stable jarosite, which,
along with sulfur, smelter slag, and leach tailings, is the predominant solid
waste.
Reference: Engineering and Mining Journal, 178. (11), November, 1977, pp. 27,
31, 33
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USEPA TECHNOLOGY AND TRENDS ABSTRACT Index 1.3.1
for the NONFERROUS METALS INDUSTRY Page 5
Subject: Chronic Sulfur Dioxide Exposure in a Smelter
A detailed review and assessment of airborne pollutants and respiro-
physiological effects within a copper smelter is presented. Historical data
are given which resulted in a significant lowering of S02 levels near a
reverberatory smelting furnace that was associated with the provision of
positive ventilation in 1969.
Although area measurements indicated mean shift S0£ concentrations
varying from about 1 to 32 mg/m3, sampling units worn by workers and deacti-
vated when respirators were used showed much more uniform personal dosages
from about 2 to 4 mg/m3. The workers obviously avoid breathing S02s do not
linger in areas that are apt to have high S0£ levels, and wear respirators
when performing functions in such areas.
For comparison purposes, 953 smelter workers were surveyed and physio-
logical responses compared with a "control" group of 252 mine equipment
maintenance shop workers (S02 levels % 0.2 mg/m3). For these comparisons,
S02 level in the workplace was the principal difference. Sick-leave statis-
tics and spirometric evaluations were among the comparative evaluation
criteria. Three factors were found to be significant in the analysis: (1)
smelter versus shop location, (2) smoking habits, and (3) years worked
(either smelter or shop). Within this matrix, it was concluded that chronic
S02 effects do accrue to the S02 dosage associated with smelter (as opposed
to shop) work. The severity of effects from smoking and SC>2 inhalation
appear similar, and both become more pronounced with continued exposure
Ge.g., the difference between the <10-year population and the >20-year popu-
lation is notable). Further, the effects of S02 exposure and smoking are
approximately additive. Some anomalies were apparent in the spirometric
evaluations (e.g., nonsmoking shop workers have higher forced vital capaci-
ties and forced expiratory volumes relative to predictions as they grow
older), but these are not sufficient to invalidate the principal conclusion
that neither smoking nor S02 inhalation is a particularly healthy practice.
As a result of this study of chronic (versus acute) effects, the authors
suggest reconsideration of the time-weighted average of SO? environmental
standards.
Reference: j. Smith, W. Wagner, and D. Moore, J. Occupational Medicine, 20
(2), Feb. 1978, pp. 83-95. ~
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USEPA TECHNOLOGY AWP TRENPS ABSTRACT Index 1 3
for the NONFERROUS METALS INDUSTRY Page 5
Subject: Arsenic Poses Tricky Recovery Task
The toxicity of arsenic has become a very controversial subject, both
in Canada and the U.S. New governmental regulations are expected momentarily
in both countries.
Gold smelters in Canada are the source of most of the arsenic trioxide
fumes, and these smelters have pioneered the technology for A$203 removal
from the air. An arsenic recovery unit, built at Campbell Red Lake Mines in
Balmertown, Ontario, is the latest of many such units built by gold pro-
ducers. It is claimed to reduce arsenic concentration at ground level to
<1 ppb.
Initial cooling of roaster gases to 370 C allows dusts and gold to be
collected by an electrostatic precipitator while arsenic remains in vapor
form. A mixture of 12,000 m3/hr roaster gases and 18,000 m3/hr of cooling
air is then passed through a specially designed mixer which lowers the tem-
perature to 100 C, resulting in the condensation of the arsenic trioxide
vapor into a powdery solid. The powder is collected by a bag filter from
the gas stream.
Reference: H. Goodfellow, M. Gellender, Canadian Chemical Processing,
6£ (2), February, 1978, pp. 26-27.
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USEPA AWARENESS BULLETIN INDEX
1ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
SUBJECT: Cyprus Completes New Copper Process
A new hydrometallurgical copper process was announced by Cyprus Mines.
Applicable to a spectrum of copper concentrates, the process embodies
(1) ferric chloride leaching to produce dissolved cuprous chloride,
(2) crystallization of CuCl from the leach liquor, (3) hydrogen reduction
of CuCl to metallic copper in a fluidized bed, and (4) fire refining.
Wire bar produced by this method has been drawn to wire that meets indus-
trial specifications.
According to estimates made by Jacobs Engineering Co. for Cyprus, the
capitalization necessary for a 75,000 ton/year plant to process output from
the company's Bagdad, Arizona, mine and concentrator would be $73 million,
or slightly less than $1000/AT. This is less than half the cost estimated
for a pyrometallurgical plant. Operating costs would be about one-half of
what Cyprus pays for toll smelting and refining. Particularly attractive
features include no S02 emissions (sulfur is recovered in elemental form),
hydrogen reduction rather than electrowinning of copper, and recovery of
byproducts such as molybdenum, silver, lead, zinc, and gold.
Cyprus hopes to license this pollution-free process to other operators.
Skillings1 Mining Review, 66_ (38), September 17, 1977, p. 33.
Sellings' Mining Review, 66^(42), October 15, 1977, p. 18.
REFERENCE:
Skill ings' Mining Review
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USEPA AWARENESS BULLETIN INDEX 0] 3
2ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 1
SUBJECT: New Oxidatlve Leaching Process
Uses Silver to Enhance Copper Recovery
Bench tests at C-E Lummus of a hydrometallurgical process for copper are
described. Chalcopyrite or mixed chalcocite/chalcopyrite concentrates were
oxidation-leached in acidified ferric sulfate at ambient pressure to dissolve
copper as cupric sulfate, producing elemental sulfur which may be recovered
as a byproduct. The key to effective leaching was the addition of 200-300 ppm
of silver to the leach slurry. Extraction of up to 97 percent of the copper
in single-stage, and 99 percent in two-stage leaching has been demonstrated.
The silver apparently catalyzes the leaching. It selectively (97 percent)
reports to the tailings cake, from which it is recovered to levels of about
99 percent for recycle. Based on the laboratory bench tests, silver consump-
tion (loss) on the order of 2 to 3 oz per ton of copper produced might be
expected.
The pregnant leach liquor containing copper values is pH-adjusted and
oxidized to regenerate ferric sulfate for recycle. This also generates some
iron oxide, basic ferric sulfate, and calcium sulfate as solid waste products.
Copper is extracted from the liquor (LIX-64) and electrowon after stripping
(and regenerating) the extract with h^SO^.
The leach tailings circuit comprises stripping the elemental sulfur
with hot-water washing (to melt the sulfur) and pressure filtering. The
tailings are then leached in hot concentrated ^$04 and washed to remove the
dissolved silver. Silver is cemented from the filtered liquid and separated
by decanting or filtering, redissolved, and recycled to the primary leaching
stage.
A schematic flow diagram is presented for the total process. As is
characteristic of hydrometallurgical processing of copper concentrates, a
major desirable feature is the lack of gaseous S02 emissions. Major effluents
would be process waters with contained solids (Fe203, Fe(OH)S04, and CaSO^,
and process tailings, stripped of sulfur, silver, and precious metals, if
warranted. Rigorous material balances have not yet been developed.
REFERENCE: G. J. Snell and M. C. Sze, Engineer and Mining Journal, ]78_(10),
nrtnhpr. 1Q77. DD. 100-105.
October, 1977, pp. 100-105.
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USEPA AWARENESS BULLETIN INDEX 1.3.2
ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
The Evaluation of Four Potential
Hy drome tallurgical Processes for Copper
Production
A recent renewal of interest in hydrometallurgical processes for copper
production has taken place. In the U.S., the drivin-g force behind this
renewed interest is sulfur dioxide pollution from smelters.
At the present time, there are about ten hydrometallurgical processes for
copper recovery in the development stage. Flowsheets of four of these processes
are shown in the article. The Cymet and Arbiter methods are the most advanced.
For hydrometallurgy to be economically viable, a capitalization of no more
than $800/ton and operating costs less than $.05/kg of copper must be achieved.
Hydrometallurgy is generally uneconomical based on these criteria.
Presently, none of the four hydrometallurgical processes are competitive
with established large-scale pyrome tallurgical practice, with the possible
exception of the Cymet process. However, specific conditions (ore type, metal
recovery, disposal problems, by-product utilization, and plant capacity) could
produce particular circumstances where a "tailored" hy drome ta 11 urgical process
would be competitive.
Elimination of sulfur dioxide emissions is the prime advantage of hydro-
metallurgy over pyrome tallurgy.
REFERENCE-' 0. Sitnai and P. K. Peeler, Proceedings of the Australasian
Institute of Mining and Metallurgy, (2167. March, 1977, pp. 21-30.
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j- INDEX
1ECHMOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
. Copper from Chalcopyrite by Direct Reduction
Direct reduction of chalcopyrite flotation concentrate is a proposed pro-
cess for "pollution free" copper production.
Water vapor is the only gaseous reaction product according to the equation
for the reaction:
CuFeS2 + 2 CaO + 2 H2 •*• Cu + Fe + 2 CaS + 2 H20
In research studies, the chalcopyrite concentrate was pelletized and
reacted with H2 and CaO in a rotary kiln at '800 C. The original pellet form
was retained, allowing the copper and iron to be removed by screening or by a
magnet. The iron was leached from copper with HC1. The resulting FeCl2 could
be spray oxidized in a special furnace to FepC^ and HC1, with the HC1 being
recycled to the leaching step. The CaS can be oxidized at 500 C to CaSO/i-
Environmentally, this is a potentially clean process, with water vapor as
the only gaseous effluent and gypsum and Fe20s the only solid by-products.
Although technology has been demonstrated, economics were not addressed in this
paper, nor were process specifics treated to the degree required to allow
assessment of requirements for overall environmental control.
REFERENCE: F. Habashi and B. I. Yostos, Journal of Metals,29 (7), July, 1977,
pp. 11-16.
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USEPA TECHNOLOGY ANP TREWPS ABSTRACT Index 1.3.2
for the NONFERROUS METALS INDUSTRY Page __5
Subject: Smelting Practice at Anaconda. Montana
From its beginnings in the late 19th century, Anaconda's copper concen-
trating and smelting operations at Anaconda and Butte, Montana, have under-
gone numerous additions and modifications. In 1977, electric furnace smelt-
ing totally replaced reverberatory furnace smelting. A review of the opera-
tions practiced by the smelter at Anaconda is presented in this article.
About half of the smelter feed comes as a slurry from Anaconda's nearby
C. E. Weed concentrator in Butte, with the rest coming from more distant
Anaconda facilities. Feed includes cement copper from dump leaching and a
variety of copper-bearing minerals. Some toll smelting is also done at
Anaconda. Feed is pumped from storage bins at a repulping station, thence to
surge tanks prior to entry in a fluidized roaster for partial roasting. The
hot roasted feed is then conveyed and charged in the electric furnace for
smelting to a matte that typically contains 50 to 55 percent copper. (This
is higher-grade than the prior reverb matte that contained about 35 percent
copper.) Optimum production scheduling calls for blowing of the matte in
two converters, although a third converter was implied to be necessary at
times. Converter slags are returned to the electric furnace to recover the
contained copper. Blister copper proceeds to anode furnaces for additional
refining and casting into anodes for electrorefining. Unit operations for
the fluosolids reactor (roaster) and the electric furnace smelter are given
along with monthly materials flows and compositions.
In 1970, it became necessary to upgrade the gaseous effluent treatment
and control system due in part to the antiquity of the original system, and
in part to anticipated regulatory actions. The current system includes a new
flue system and baghouse, wet-scrubbing tower, venturi precipitator, and
double-contact acid plant. Prior operations seldom violated ambient air
standards, partly because of the "highest stack in the world", but the new
system was installed at a cost of $66.5 million to date. The acid plant is
presently being modified to treat gases containing up to 9 percent S0o» and
will have a capacity of 1320 tpd of
Reference: J. B. McCoy, Mining Congress Journal, 63^ (10), October 1977,
pp. 45-50.
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USEPA TECHNOLOGY AMP TRENPS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 1.3.g
Page 6
Subject: Automation Aids Inspiration's Clean Air Program
Process control features of the Inspiration Consolidated Copper
Company's 3-year-old copper smelting complex in Arizona are described. Tem-
perature, pressure, offgas, and acid plant measurements and apparatus are
discussed. The complex features a large electric furnace smelting furnace,
five large Hoboken syphon converters (of which three operate simultaneously,
but only one blows at a time), and a double contact acid plant. Its con-
struction was guided by the need to employ process controls to permit con-
formance to ambient air regulations. Control systems are continually up-
graded and maintained to achieve optimum operations commensurate with these
regulations.
Unit operations are controlled from local stations that monitor indi-
vidual operations. In addition, all instrumentation feeds the main control
room from which overall plant operations are monitored. Temperature (24
stations) and pressure (four stations) controls guide operation of the
smelting furnace, and temperature and air flow are the guides for converter
operation.
Offgas monitoring after gas cleaning operations and of the acid plant
tail gas is routinely done, with S0£ levels recorded. The plugging of moni-
toring lines for gas sampling prior to cleaning is a problem that has not yet
been resolved, and this is an area receiving "maximum effort" at Inspiration.
•»• i I.. •• "'•" • —•
Reference: Mining Engineering, 30. (2), Feb. 1978, pp. 157-158.
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USEPA TECHNOLOGY ANP TREWPS ABSTRACT Index 1.3.2
for the NONFERROUS METALS INDUSTRY Page 7
Subject: Kennecott Chooses Microprocessor
Control at Utah Smelter
As part of the Kennecott Utah Copper Division's $280 million smelter
conversion to Noranda-type smelting to achieve EPA compliance, an extensive
and elaborate control system, using digital microprocessors with simulation
and both computer and manual control capabilities, has been installed. This
article describes the criteria and system characteristics upon which this
selection (as opposed to analog or direct digital control systems) was based.
The Kennecott system comprises a Honeywell TDC-2000 microprocessor that
interfaces over twin lines to dual Data General Nova 830 process control com-
puters located at various process stations. Three types of control are pos-
sible: (1) Central control from the main computer keyboard, (2) Local con-
trol via individual control computer inputs, and (3) Manual override at each
local station. The data output includes an alarm and out-of-tolerance sys-
tem as well as an information terminal. Both smelting and offgas handling
operations can be simulated for personnel training and for system debugging.
This control system allows more efficient smelting operations and
reduced smelter emissions.
Reference: Mining Engineering, 30 (2), February, 1978, pp. 159-160.
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USEPA TECHMOLOGV AWP TREWPS ABSTRACT Index 1
for the NONFERROUS METALS INDUSTRY Page (
Subject: The Sherritt-Cominco Copper Process
Features of the Sherritt-Cominco (S.C.) hydrometallurgical process are
described in a technical trilogy which defines and describes the process
technology (Part I), relates the results of a 9-ton per day pilot plant cam-
paign conducted in 1976 (Part II), and analyzes the economic and commercial
implications of the process (Part III). The process is applicable to a wide
range of sulfide concentrate, including low-grade materials that are not
attractive for conventional smelting, and features good recoveries of metal-
lic by-products, such as zinc, precious metals, molybdenum, nickel, and
cobalt. It satisfies major objectives of environmental and plant safety and
health aspects without the generation of large amounts of sulfuric acid that
would require neutralization if ready markets are not available. (Most of
the sulfur is reclaimed in elemental form.) Analyses indicate at least eco-
nomic parity with flash smelting processes with acid production.
Principal elements of the overall process, starting with concentrates
are
(1) Pelletizing and reduction roasting with hydrogen
(2) H2S04 leaching at ambient pressure to selectively remove
iron, which is then converted to stable jarosite waste
(3) Activation and oxidation pressure leaching to convert
the sulfide to cupric sulfate
(4) Purification of the pregnant liquor by high temperature
oxydrolysis to effectively remove residual iron, tel-
lurium, selenium, and other impurities, and
(5) Electrowinning of the copper
Zinc is recovered as the sulfide from a second stage of ambient-pressure
leaching. Oxidation leach residue contains precious metals, gangue, and free
sulfur. The gangue is separated by flotation, and sulfur is xylene
extracted, leaving the precious metals concentrate. Sulfur is also recovered
from a Claus plant that treats H2S evolved during leaching to dissolve FeS04.
The H2S04 needed for leaching is derived from the SC^-rich roaster topgas.
Pilot-plant operation during a 30-day demonstration run resulted in 90
percent on-stream time, and confirmed stable operation of the S.C. process
as an integrated unit. Average concentrate composition was 23.7 percent Cu.
Reference: CIM Bulletin, 71_ (790), February, 1978, pp. 105-139.
Part I: The Process, Swinkels, G.M., and Berezowsky, R.M.G.S.
101
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Index 1.3.2
Page 8a
27.6 percent Fe, 3.1 percent Zn, and 31.5 percent S, with 5.1 g/tonne Au and
13.8 g/tonne Ag. Cumulative extractions of 98.4 and 96.3 percent were
demonstrated for copper and zinc, respectively. Based on the precious
metals concentrate produced, about 96 percent recovery of silver and gold
were projected. Cathode copper produced contained 10 ppm S, 3 ppm Pb,
0.2 ppm Se, and had 102 percent IACS and a Spring Elongation value of 400 mm.
Roughly, 1/4 of the sulfur is removed in roasting for acid plant conversion
to H2S04 for leaching. Another 1/4 (approx.) reports to the jarosite waste,
with the balance being recovered as elemental sulfur.
A hypothetical 75,000 tpy plant was estimated, based on the results of
pilot-plant studies. As with other hydroprocesses, the S.C. process is more
energy-intensive than pyro processes. However, comparisons among capital
requirements, operating costs, and revenues show the S.C. process to compare
favorably with flash smelting in 1977 dollars. For remote operations, with-
out ready markets for ^$04, wnicl1 would necessitate acid destruction the
S.C. process ;is even more attractive. Environmental and health constraints
are readily met with the S.C. process, and more effective utilization of
material resources is possible. Copper process variants using various unit
operation portions of the S.C. process are discussed as possibilities.
Additional Reference: Part II: Pilot-Plant Operation, Kawulka, P., Kirby,
C. R., and Bolton, G. L., Part III: Commercial Implications, Maschmeyer,
D. E. G., Milner, E. F. G., and Parekh, B. M.
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for the NONFERROUS METALS INDUSTRY
Subject: The Role of Computers at the
Hidalqo Smelter
Index
Page
1.3.2
9
This paper describes the development, installation, and implementation
of the computer system at the Hidalgo smelter of the Phelps Dodge Corporation
in New Mexico. Considerable detail is given with a number of diagrams.
A unique application of its kind for the copper industry, the Hidalgo
computer system was designed by Outokumpu Oy of Finland to control operating
parameters in the production of elemental sulfur to insure maximum recovery.
Phelps Dodge operating personnel also received the benefit of Outokumpu
experience with computer control. The scope of the computer's capabilities
as an operating tool has grown significantly since start-up of the smelter,
and now includes on-line control, data acquisition, and report preparation.
Judging from this paper, in addition to facilitating operational control, a
most important aspect of the computer function at Hidalgo is its service as
a data and reporting system. Among other features, ambient air sampling at
remote weather stations reports through the computer as a check on S02 col-
lection system operation at the smelter.
Reference: W. J. Chen, AIME-TMS Paper No. A 78-24.
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1ECHMOLOGY $ I RENDS ~~~
IN THE NONFERROUS METALS INDUSTRY PAGE '
- Purity of Copper Produced by Fluid Bed
Electrolysis of a Heap-Leach Solution
Fluid bed electrolysis is a possible technique for the recovery of copper
from dilute leach streams, eliminating the current practice of cementation or
concentrating the copper in solution by solvent extraction prior to electrowinning.
Laboratory tests have been made in a partitioned electrowinning cell using
copper particles in the catholyte section as the cathode. The particles were
fluidized by upward-flowing dilute leach solution.
Spectrographic and metallographic analysis of copper particles removed from
the bed showed that, with the exception of lead (about 5 ppm higher than normal
electrorefined copper), impurities are within or very close to quality specifica-
tions, and the copper had a uniform, fine-grained structure with no impurity segre-
gation. These tests prove that fluid bed electrolysis can recover in one step,
good quality copper from the leaching of low-grade mine materials.
The potential simplicity of this process suggests lowering of environmental
burdens relative to current production practice of cementation or concentration/
electrowinning.
REFERENCE: C. C. Simpson, Jr., Journal of Metals,29 (7), July, 1977, pp. 6-9.
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' 1ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY
INDEX 1.3.8 (Ger.)
PAGE
. liquid/Liquid Extraction of Copper and Nickel
with a Selective Reagent
SHE 529 is a highly selective reagent for the extraction of copper from
acidic medium and of nickel and copper from ammoniacal solutions. It reacts
with these metal ions through chelation. After a short discussion of the
chemistry of the reagent and the reaction, a survey is given, inter alia, of
equilibrium data, the effect of contaminating ions in the feed, and the
influence of the diluents. The use of the reagent is illustrated with the
results of continuous mixer/settler experiment.
REFERENCE: A. J. van Zeeuw, Erzmetall, 30 (4), April, 1977, pp. 139-145.
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1ECHNOLOGY $ 1RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 2
- Vibratory Mill as High-Efficiency Reactor for
Copper Cementation
Tests are described for the cementation of copper with iron from a cop-
per sulfate solution, using a vibratory mill in discontinuous and also con-
tinuous operation. The test results show that the reaction velocity in the
vibratory mill is in the range of 10 to 100 times higher, compared with
other conventional processes. In the course of the continuous operation
cementation tests, a lower iron consumption and a higher purity of the cement
copper was established, apart from the substantially higher cementation rate
in the vibratory mill. The solution can be decopperized to below 1 mg Cu/1.
From the planning, it could be calculated that, with large-scale technical
application of the vibratory mill, the capital expenditure and operating
costs can be considerably reduced in relation to conventional cementation
processes.
REFERENCE: M. Esna-Ashari, E. Kausel, R. Nissen, and P. Paschen, Erzmetall, 30.
(6), June, 1977, pp. 262-266.
106
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USEPA AWARENESS BULLETIN INOEX
1ECHMOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
SUBJECT• Possibility of Obtaining Selenium by Sinterlpg
Results of investigations are presented on the possibility of recovering
selenium by sintering loose selenium-bearing materials with a mixture of spda
and zinc oxide as a result of which soda selenites and soda selenates are
obtained. These water-soluble compounds may easily be separated from the
remaining components by water leaching. The reduction of selenites and sele-
nates with an adequate reducer leads to obtaining free selenium.
REFERENCE: Panek M. Jarosinski K., Rudy Metale, 22 (6), June, 1977,
pp. 274-275 Tabl.
107
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USEPA TECHNOLOGY AND TREWPS ABSTRACT Index 1.3.8
for the NONFERROUS METALS INDUSTRY Page 5
Subject: Flash Smelting - A World Beating Finnish Process
Almost 30 years ago, flash smelting of copper or nickel ore was intro-
duced in Finland by Outokumpu. Today, 20 plants are in operation and five
under construction throughout the world, which combine the roasting, smelting,
and partial converting processes in one furnace.
Research and development has produced continuous improvement of the
flash smelting process, and it is these improvements which are reviewed in
this article. The research has concentrated on preheating air (to 200 to
500 C) and oxygen enrichment. A 60-70 percent increase in the flash smelter
capacity has been realized with the use of 30-40 percent oxygen-enriched air.
The control of the temperature and the matte grade is made easier by the use
of the oxygen-enriched air, and this, in turn, allows greater flexibility to
accommodate changes in concentrate grade and inpurity content.
Other research is being done on smelting of copper concentrates contain-
ing various percentages of iron, lead, or zinc. Copper concentrate with low
iron content can be smelted directly to blister copper, while high-iron cop-
per concentrate presents problems which are being researched intensively at
the present time. In copper concentrate with lead and zinc content, high-
grade matte is made in the flash smelter (over 70 percent copper) with the
zinc and lead recovered in the slag. Reduction of the slag in an electric
furnace produces, after fuming, a low-copper-content lead and zinc dust.
Research in slag cleaning is also being undertaken by electric furnace
or by flotation. The combination is uneconomical; a choice between either
method is very complicated. Slag cleaning by flotation is 50 percent higher
in cost than by the electric furnace and copper content is 0.1 to 0.2 percent
lower. Electric furnace energy consumption is more than double that of flo-
tation; however, the electric furnace can operate in a continuous process
with the flash smelting furnace. Both processes could present environmental
problems, the flotation process in the disposal of tailings and the electric
furnace process in the disposal of off gases.
Reference: World Mining, 3j_ (3), March 1978, pp. 42-43,
108
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USEPA AWARENESS BULLETIN „,
1 ECHNQLOGY $ 1 RENDS*
IN THE NONFERROUS METALS INDUSTRY RAGE
SUBJECT: Kydrometallurgical Treatment of Port Kembla
Copper-Smelter Fume
A laboratory investigation of the recovery of metal values from copper
smelting fume was conducted by researchers in Australia. Dilute sulfuric
acid leaching has been used commercially to recover-about three-fourths of
the zinc value as useful zinc sulfate, but substantial of the greater than
$1 million metal value of the 5500 tons of baghouse fume from Electrolytic
Refining and Smelting Company of Port Kembla, N.S.W., Australia, was not
treated by Hardman Chemicals, Sydney, the by-product principal. Beaker
tests showed that residual zinc, lead, tin, copper, bismuth, and cadmium
values can be upgraded to concentrations that would make their recovery more
attractive, by additional leaching with strong hydrochloric acid. The tin
value (at 2.5 percent in fume, the tin alone from the ER&S operation is worth
>$1 million/year) was the primary target of these studies.
A two-stage HC1 leach dissolved essentially all of the tin in beaker tests
(50-g sample). This was precipitated by oxidative conditioning and injection
of zinc oxide to prepare a tin-rich concentrate which, when dried, contains
25 percent tin. This treatment also returns most of the bismuth at a concen-
tration of about 3 percent as opposed to 0.4 percent in the original fume.
Additional treatment, including zinc cementation, may be used to concentrate
copper and cadmium for later recovery. Lead values are extracted from the
lead-rich residue of the second-stage HC1 leach by washing with boiling water
followed by crystallization as lead chloride.
A flow diagram for the postulated treatment circuit was developed and
shows the quantities of reagents required per metric ton of tailings remaining
after the dilute ^$04 leach (initial zinc removal).
10M HC1 - 1425 a
Hot water - 2625 i
Cl2 (28 kg) or H202 (50 a)
ZnO - 142 kg
Zn dust - 40 kg
The finished liquid waste contained about 40 g/)i of zinc (sulfate and
chloride) and 4 mg/«. of arsenic, the only detectable metals. With thorough
washing used in the beaker tests (neither necessary nor desirable in hypothe-
sized plant operations), the liquid effluent generation rate was 4«,/kg.
This report of beaker tests may be construed as demonstrating only the
technical feasibility for treating fume from a specific operation for concen-
trating metal values for later recovery. Economic and environmental considera-
tions were not the intent of this report and would depend on further definition
and development.
REFERENCE: D. E. Giles and A. Boden, Proc. Australas. Inst. Min. Metal!., (262),
June, 1977, pp. 39-47.
109
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USEPA TECHNOLOGY AMD TRENDS ABSTRACT Index 1.3.9
for the NONFERROUS METALS INDUSTRY Page 2
Subject: Minicomputer Application at the
Hitachi Smelter
This paper describes the use of an off-line minicomputer at the custom
Hitachi copper smelter of Japan as a guide for smelter operation, for data
analyses, for production scheduling, and for computation. Its primary use
in smelter operation is in concentrate blending calculations, material bal-
ance, charging calculations, heat balance, and gas calculations.
The use of a conversation communication made in the minicomputer opera-
tion simplifies the computer use to such an extent that no specialized com-
puter operator is needed. The process engineers provide the computer with
concentrate and flux charge rates, flux ratio, hot blast (amount, oxygen con-
tent, and temperature), fuel oil required, waste gas (amount and sulfur
dioxide content), and slag forming speed.
In 4 years of operation benefits of the minicomputer system have been
(1) improved precision of operation, (2) operations flexibility, (3) lower
copper loss and energy consumption* and (4) constant matte grade resulting in
stable converter and refining operations. (Improved stability of operations
implies more manageable environmental control with fewer upsets.)
Reference: M. Higashi, K. Ichimaru, T. Ijyuin, AIME-TMS Paper No. A 78-33.
no
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USEPA TECHNOLOGY ANP TREWS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index
Page
1.3.9
3
Subject: Computerized Control of Flash
Smelting Furnace
Although the flash smelting process is not critically dependent on auto-
mation, automatic control becomes more profitable for the following reasons:
the process is more complicated than conventional smelting, smelting of com-
plex concentrates is facilitated, capacity is maximized, and larger through-
puts are possible.
The most important tasks that can be computer controlled in flash smelt-
ing are control of material feed mixing, furnace feed, oxygen/concentration,
fuel flow, oxygen percentage of process air, furnace temperature, control of
flue dusts, and furnace pressure. Computer automation of these tasks was
carried out at the Kokkola Works of Outokumpu in Finland. This paper is a
detailed account, using flow sheets and numerous diagrams, of the computeriza-
tion at this plant.
As a result of 2 years' operation at Kokkola, a 2 percent increase in
profit is projected as a result of using the computer. The main benefit in
copper and nickel smelters is gained via better energy control of the blast
smelting furnace and increased capacity of converters due to stabilized matte
grade. At the Kokkola works, increases in capacity and minimization of sul-
fur losses were the primary benefits.
Outokumpu staff cite the following costs and savings (1971 dollars)
associated with installation, development, and operation of the computer con-
trol system:
Investment (hardware and adaptation): $383,000
Operating costs (service and labor): $51,000/year
Direct savings (sulfur revenues and savings in
fuel oil; 1971 prices): $230,000/year.
The above benefits do not consider the advantages of the computer pro-
cess reporting system.
V. Appelberg, S. Ojalehto, J. Daavittila, K. Saarhelo,
AIME-TMS Paper No.
Ill
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USEPA TECHNOLOGY AWP TRENPS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 1.3.9
Page 4
Subject: Utilization of Computer for Smelter and
Refinery Operations at Onahama
To achieve labor saving and higher operational efficiency, and to cope
with the enlargement and complexities of the facilities, a computer system
was introduced at the Onahama Smelting and Refining Company of Japan in 1973.
This paper, containing diagrams and calculations, explains the application
of the computer in the following areas: weighing and sampling control in
the raw materials receiving system, furnace blending calculation for optimum
reverb furnace and converter operation, contour maps of the reverb furnace
bottom to show magnetite buildup, sulfur dioxide strength for environmental
effects regulation, minimization of power consumption, material balance of
copper and sulfur, and data storage.
Reference: M. Goto, T. Hori, AIME-TMS Paper No. A 78-2,
112
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USEPA TECHNOLOGY AMP TREWPS ABSTRACT Index 1 .4.8
for the NONFERROUS METALS INDUSTRY Page ]
Subject: Comparative Analyses of HvdrometaTlurqical Processes
Pressures to eliminate S02 pollution from smelters of sulfide ores have
brought to the forefront a number of hydrometallurgical processes. Extrac-
tion/refining processes using hydrometallurgy are being successfully operated
in a few cases, and with less success in others.
In this article, general characteristics of hydrometallurgical processes
are described (with emphasis on applicability to the extraction and refining
of copper ores). Operations common to hydroprocessing are (1) feed prepara-
tion, (2) liquid-solid contact and leaching, (3) liquid-solid separation and
washing of solids, (4) metal recovery from pregnant liquor, (5) regeneration/
recycle of barren liquid, and (6) disposal of barren solids. Three broad
classifications of hydrometallurgical processes are ammonia, chloride, and
sulfuric (or nitric) acid. Ammonia-based processes are slow, and good yields
are difficult to achieve. Autoclave leaching improves performance, but with
attendant higher costs. Chloride processes require expensive corrosion-
resistant equipment; regeneration is complex, as is the production of
cathode-grade copper. Sulfate leaching is generally more simple, but
requires more capitalization. Energy-intensive electrowinning is a serious
cost impediment to all hydrometallurgical processes (except the recently-
announced Cyprus process—a chloride process using fluidized-bed hydrogen
reduction; see index 1.3.1, pp. 3-4.
In general comparisons between hydro- and pyrometallurgical practices,
hydro processes are more fuel-, power-, and process-material-intensive, but
less labor-intensive than pyro processes. For moderate plant sizes, bottom-
line capitalization is about equal, with small plants favoring hydro pro-
cesses and large plants, pyro processes. In some regards, hydro processes
are more flexible, but their control is more demanding.
Pvrometallurgical processes remain the basis for most domestic opera-
tions, and are well-developed and "comfortable". The principal incentive
favoring hydrometallurgical processes is the present and possible f^ure
regulatory pressure for elimination of S02 emissions. To make hydrometallur-
gical processes attractive in the face of entrenched pyrometallurgical prac-
tice, the authors opine that capitalization of no more than two-thirds and
operating costs no more than about 80 percent of those associated with con-
Jentional smelting of copper will be required. These fiscal targets are not
yet apparent (possible exception: see 1.3.1, pp. J-4j.
Vancouver, B. C., August 1977,
113
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USEPA TECHNOLOGY ANP TRENPS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index
Page
1.4.8
2
Subject: Vacuum LiftrRefinina in Conner Smeltim
A research treatise describing and analyzing the results of a laboratory
program to evaluate the removal of metallic impurities from blister copper,
matte, and white metal by vacuum refining has been presented by Japanese
researchers. The ideas upon which the laboratory studies and apparatus were
based were derived from the D-H vacuum refining process used commercially for
VR steel production. Experiments were conducted on melts of 4 to 6 kg; the
researchers acknowledge difficulties in conducting experiments on such a
small scale and gaining meaningful extrapolation to plant-scale operations.
However, the results are interesting and suggest new ways of refining copper
that would influence the deportment of by-product values from copper smelting
and refining operations, such as arsenic, antimony, bismuth, lead, and zinc.
The experiments were conducted by evacuating a column submerged in the
molten bath to subject an expanded surface to vacuum, thus selectively remov-
ing impurity metals, sulfides, and/or oxides by distillation in the closed
system. The refined portion was returned to the melt by isolating the vacuum
pump and pressurizing the column with nitrogen. The process was reported
several times during a run, with the progression of refining (removal of
impurities) monitored by chemical analysis. With a recirculation factor of
about 12 (e.g., 20 lift-refining cycles in a run--a rather modest campaign
compared to D-H processing of steel), roughly 90 percent of the lead, 50 per-
cent of the zinc, 85 percent of the arsenic, 60 percent of the antimony, and
80 percent of the bismuth were removed from a 45 percent copper matte. Simi-
lar results for lead and zinc removal from blister copper were observed.
Lowering of arsenic, antimony, and bismuth from blister copper (or from white
metal) appeared rather less effective, but certain of the data suggested that
equipment or experimental difficulties may have precluded good and stable
refining in these cases.
Much of this paper is devoted to theoretical aspects of the research
(thermodynamics, kinetics). The authors do, however, schematically indicate
several concepts for the use of vacuum lift refining of in process copper
values in, for example, a continuous flash smelting operation.
(This paper is useful for suggesting boundaries of a potentially new
nonferrous refining technology. The results cannot be reliably extrapolated
to potential industrial application for assessment of economic, energy,
health, or environmental impacts.)
Reference: Kametani, H., and Vamauchi, C., Trans. National Research Inst.
for Metals, 20_ (1), January, 1978, pp. 22-59.
114
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USEPA TECHNOLOGY AMD TRENPS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index
Page
1.4.9
1
Subject: Automatic Anode Castina at MAGMA
The Magma Copper Company of Arizona completed in 1974 the installation
of a system, designed by Outokumpu, for the automatic pouring of copper
anodes. Details, with drawings of the equipment and a block diagram of the
system,are included in this paper.
The system consists of a casting and weighing mechanism, a hydraulic
power unit and Servo system, a control desk, and an electronic control unit.
The basis of the system is an electro-mechanical weighing balance which accu-
rately measures the weight of copper to be cast; the casting speed is regu-
lated by a program controller and averages about 50 seconds for two anodes of
825 and 785 pounds, respectively, with ± 2 percent variation.
Refinery performance is adversely affected by anode weight variations.
Before the automatic system, 100 pound variations were common, which resulted
in unequal consumption time of the anodes and monthly scrap averages of nearly
20 percent. The new automatic casting system has reduced scrap by 50 percent.
The copper pulled from each section (pull weight) in a 14-day period has risen
steadily since the new system was instituted as has the electrolytic effi-
ciency (92-95 percent).
The addition of an ultrafine graphite colloidal suspension in water to
the mold surface has increased the anode weight, reduced anode sticking in
the molds, and reduced mold wash carryover on the anode surfaces, resulting
in more concentrated slimes in the electrolytic cells.
Reference: I. A. Rana, AIME-TMS Paper No. A 78-16.
115
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USEPA TECHNOLOGY AND TREWPS ABSTRACT Index 1 .7.1
for the NONFERROUS METALS INDUSTRY Page 1
Subject: Application of a Continuous Technique
to Secondary Copper Smelting
A laboratory model of a continuous, single-unit furnace for smelting and
converting secondary copper values from low-grade scrap and copper-containing
residues has been demonstrated at the University of Birmingham, U.K. The
principle of this 25 kg capacity model involves charging copper-bearing scrap
and residues through a covering slag at the high end of a sloping hearth. As
the scrap melts, it flows down the hearth through a reaction zone that is
agitated by an air (or enriched oxygen) lance, where impurities (principally
iron, aluminum, and zinc) are oxidized and partition to the sand/lime slag.
Converted metal containing typically 88-95 percent copper continuously flows
out of a small opening at the base of the sloping hearth. (In the first lab
studies, the small unit was operated in a repetitive batchwise manner, how-
ever. Continuous operation apparently was not achieved.) Couhterflowing
slag is discharged through a slag port at the other end of the furnace. In
lab operations, it was found that lead, nickel, and tin values report pre-
dominantly to the metal, iron, aluminum, much of the zinc report to slag, and
some of the zinc value is fumed. Purity of the metal depends on blowing rate.
At high blowing rates, metal contains as much as 95-96 percent copper, but
copper bases to the slag were unacceptably high (>5 percent).
In this small unit, the heat required for initial smelting in trial runs
was reduced by 50 percent as autogenous heating contributed significantly
toward the process heat requirements. In production-sized furnaces for typi-
cal charges (which would run up to 40 to 50 percent oxidizable tramp metals
and materials), fully autogenous operations seem possible in some cases, and
no added fuel would be needed. In the experiments, air blowing rates varied
from zero (product was typical of black metal and contained about 80-85 per-
cent copper) to 120 £/kg of charge. At blowing rates of 30 to 60 £/kg, the
product contained 90-95 percent copper, and approached typical secondary con-
verter quality for feed to anode furnaces, thence to electrorefining. The
effects of oxygen-enriched blows were not studied. On the basis of the
studies conducted, it seems possible that blast furnace and converter tech-
nology and equipment used in secondary copper smelting could be replaced in
some instances with continuous operations of this type for improved energy,
materials handling, and capital efficiencies. Environmentally, direct
impacts of this process should be less than those for conventional blast fur-
nace (or reverb) plus converter practice, as fewer and smaller units should
be involved. Subsequent electrorefining slimes processing technology might
be adversely affected, however.
Reference: C.I.M. Bulletin, 70, 788, December 1977, pp. 122-134.
116
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USEPA TECHNOLOGY ANV TRENDS ABSTRACT Index 1.7 8
for the NONFERROUS METALS INDUSTRY Page 1
Subject: The Recovery of Secondary Copper -
Its Technology and Economics
This British article broadly reviews secondary copper refining and ingot-
making operations, and briefly describes R&D and emerging technology in rela-
tion to these operations. In the area of charge preparation, the removal of
insulation from wire and cable by burning, pyrolysis, softening and scraping,
and chopping is mentioned. Sweating to separate zinc, lead, and aluminum
from bimetallic copper-bearing scrap has been enhanced by the use of a Coreco
metal separator furnace. Assessments of the use of molten salt sweating
operations are also briefly described.
Pyrometallurgical smelting for making certified ingot from pedigreed,
high-grade scrap involves only modest refining, and is typically carried out
in small reverbs, rotary, or crucible furnaces. Arc melting and induction
melting is also viable. Low-grade scrap, mixed scrap, drosses, slags, dusts,
and low-grade residues are treated by secondary metal refiners. Smelting and
slagging are conducted in reverberatory furnaces or blast furnaces in line
with converting furnaces. The impure copper product is further upgraded in
anode furnaces, with the product passing to final electrolytic refining.
Oxygen enrichment of blast air and fuel injection are technically attractive
for their effects on thermal efficiency, production rates, and lower equipment
requirement, but probably are only economical in large operations. Byproduct
recovery from converting is enhanced by process adaptation according to the
composition of the charge.
The Birmingham continuous smelter (see Index Item 1.7.1, page 1) is a
potential alternative that might combine blast furnace and converter practice
in one unit operation. The British Non-Ferrous Metals Technology Center has,
since 1973, piloted an in-line, fire-refining unit based on selective slagging
practice for the removal of impurities (for similar technology, see U.S.
Patent 4,055,415, this issue). This technology combines converter and anode-
refining steps in one unit operation.
Slag technology is discussed with regard for its potential in minimizing
nonferrous metal loss to slags on the one hand, and recovery of metal values
in postsmelting slag-cleaning operations. Hydrometallurgical processes are
attractive for recovering metal values from effluents and residues. Where
effluent treatment is required for ecological reasons, processes that reclaim
marketable metal values help to offset the cost of such treatment. Specific
types of scrap, e.g., copper-clad aluminum wire, are also amenable to selec-
tive lixiviation.
Reference: Metals and Materials, September 1977, pp. 45-49.
117
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USEPA AWARENESS BULLETIN INDEX 1.9.9 (Pol.)
1ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE ]
. Economic Effectiveness of New Technical and
Organizational Solutions in Copper Processing
(No abstract available.)
REFERENCE: Z. Hasinska and H. Pilcer, Rudy Metale, 2£ (5), May, 1977,
pp. 256-259.
118
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USEPA TECHNOLOGY AMP TREWS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 2.1.8
Page 1
Subject:
Zinc-Copper Resources of Wisconsin
Discoveries in the past decade of zinc and copper sulfide ore reserves
in northern Wisconsin have been put in perspective by Mudrey. The principal
finds are (1) 1968 - Kennecott—a 4 percent copper lens deposit near
Ladysmith contains an estimated 5 million tons of ore that could support pro-
dcution of 11,000 tons of copper per year, (2) 1974 - Noranda--a 4-1/2 per-
cent zinc, 1 percent copper deposit containing in excess of 2 million tons of
ore, and (3) 1976 - Exxon—5 percent zinc, 1 percent copper in a very large
deposit estimated at 70 million tons that could support the annual production
of 160,000 tons of zinc and 35,000 tons of copper. Although Kennecott filed
for a state mining permit, county legislation, designed to encourage greater
revenue return from the state to local government, has blocked further
development. The project is at an impasse, pending resolution of revenue
distribution issues by the Wisconsin legislature.
\
If Exxon pursues development of their zinc and copper sulfide holding,
which ranks among the larger North American sulfide deposits, it could
account for a substantial fraction (-^25 percent) of the domestic\zinc produc-
tion by the late 1980's, with significant influence on domestic prices and
balance of payments. Such an increment of domestic zinc concentrate would
require a sizable increase in domestic refining capacity, as existing plants
and those soon to come on-stream are geared to handle present mine produc-
tion. Obstacles against revitalization of a zinc-copper industry in
Wisconsin include costs and markets in view of world competition, local
environmental constraints, and the tax climate and mineral policy of the
state.
Reference- M. 6. Mudrey, Jr., Skillings' Mining Review, 67 (12),
March 25, 1978, pp. 15-19, 28.
119
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USEPA AWARENESS BULLETIN INDEX £.1/4.9 (Ger.)
1ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 1
SUBJECT• Hydrometallurgica1 Processing of Red Sea
Sediments
Containing approximately 70 to 90 g/1 of extremely fine-grained solids
with close to 1 percent Cu and 4 to 5 percent Zn in-the form of sulfides, Red
Sea sediments may be enriched by flotation to yield a concentrate with 4 per-
cent Cu, 30 percent Zn, 20 percent Fe, and 25 percent S. For the recovery
of copper and zinc, a hydrometallurgical process was developed on the basis
of laboratory tests, consisting of the following steps: Leaching of the
desalinated concentrate at 110°C under oxygen pressure with recycled sulfuric
acid from the zinc electrolysis, copper recovery by solvent extraction and
electrowinning, purification of the raffinate and zinc electrowinning. A
cost estimate for processing 300,000 mtpy of concentrates showed that the
metal recovery from Red Sea sediments according to the proposed concept will
only be feasible economically at metal prices distinctly above the present
level.
REFERENCE: D. Neuschiitz and U. Scheffler, Erzmetall, 3JD (4), April, 1977,
pp. 152-157.
120
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USEPA AWARENESS BULLETIN INDEX 2 3
1ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
' Trace Metal Particulate Emission Test Results
from a Number of Industrial and Municipal
Point Sources
As part of the RANN Cadmium Research Project conducted by Purdue, particu-
late stack emissions from a 90,000 MT/yr vertical r.etort zinc smelter were
analyzed for metallics (copper, zinc, lead, and cadmium). Sinter plant efflu-
ent was sampled after being cleaned only by twin cyclones and also by cycloning
followed by electrostatic precipitation. Coking plant stack gases were, not
treated, nor were the retort gases. Results were as follows: j
!
Mean Emission Factors, kg/MT Zinc j
Source Cd P_b Zn_ C±
Sinter (cyclone) 3.2 2.2 4.8 0.01
Sinter (cyclone & ESP) 1.1 0.7 1.6 0.003
Coker 1.2 0.6 12.8 0.01
Retorts 0.03 0.2 3.2 0.001
In the sinter plant, the use of the electrostatic precipitator reduces metallics
to about one-third of the level experienced with cyclone separation alone.
Particulate size analyses indicated that more than half of the metal emis-
sions were 2 ym or less (respirable). In terms of unit production, some 2 per-
cent of the product is discharged as gaseous effluent, with more than half of
this in what is judged to be a respirable size. A significant fraction of this
is lead and cadmium. It is important to note that these are end-of-pipe
quantities. The paper did not deal with either concentrations, dispersion, or
impact on ambient air quality.
REFERENCE•* R B Jacko and D. W. Neuendorf, Journal of the Air Pollution
Control Association, 27 (10), October, 1977, pp. 989-994.
121
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USEPA TECHNOLOGY AMP TREMPS ABSTRACT Index 2.3.2
for the NONFERROUS METALS INDUSTRY Page 3
Subject: Treatment of High Iron Containing
Zinc Ore in a Waelz Plant
A plant, using the Waelz Process, for the reduction of zinc and lead
ores, has recently been added to Turkey's first zinc smelter near Kayseri,
Turkey. This paper describes the plant and equipment with flow sheets and
data from the two test runs made before the process was incorporated into
the regular smelting plant schedule.
This Waelz installation is a zinc-lead ore reduction process that uses
a large excess of carbon (coke) and two parallel rotary kilns at 900-1100 C.
With a diameter of 4.3 meters and length of 70 meters, the nominal load of
the kiln is 371 tons per day of dry ore plus coke, limestone, and settlings.
Both the zinc and lead are reduced, volatilized, and reoxidized at this tem-
perature; the high iron content of the Turkish ores is also reduced to metal-
lic iron.
Two identical densifying lines in parallel similar to the Waelz kilns,
but smaller, accept the exhaust gas dust, Waelz oxide, zinc sulfide, and
skimmings in a reroasting process similar to the primary roasting. Neither
the temperature nor details of the output of this densifying process is
given.
The collection of dust formed in the process, in a baghouse, and its
reuse in the densifying process precludes any excessive air pollution.
Reference: K. B. Chaudhuri, F. W. Guttmann, AIME-TMS Paper No. A 78-40.
122
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USEPA AMARENESS BULLETIN
1ECHMOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
SUBJECT: Zinc Via Imperial Smelting Process Wins
Support
The Imperial Smelting Process (ISF) has p/oven itself throughout the world
as a competitive zinc smelting technique vis a vis the electrolytic method.
The ISF method uses the blast furnace to smelt zinc and has the ability to
smelt mixed lead-zinc ores, which are increasing in prevalence, producing zinc
containing 1.3-1.4 percent lead, while recovering copper, silver, and other by-
products. The lower quality lead-zinc ores being mined today do not lend them-
selves to easy flotation and separation that precedes the electrolytic process.
Consequently, the blast furnace with its lower energy costs (coke prices are
lower than electricity) is expected to remain competitive, despite economic
penalties associated with further refining to high-grade zinc.
Both processes have environmental control problems. Of prime importance
in the ISF method, lead contamination has been overcome at considerable expense.
Disposition of the gelatinous residue,formed from the jarosite process for sul-
fur removal, .has not been solved by the electrolytic refiners.
REFERENCE: T. Walsh, American Metal Market, 85 (136), July 15, 1977, p. 7.
123
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USEPA AWARENESS BULLETIN INDEX .02.3.8
1ECHNOLOEY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
SUBJECT: Environmental Trace Metal Contamination In
Kellogg, Idaho. Near a Lead Smelting Complex
A large lead smelting complex is located at Kellogg, Idaho, in the heart
of the Coeur d'Alene River Basin. The principal source of heavy metal aerosols
in the air is the main stack of the lead smelter which averaged about 11.7
metric tons of emissions per month from 1965-1973.
Following incidents of lead toxicity in children of Kellogg, a detailed
survey was made. Air particulate samples were taken over a 1-year period. Core
samples, to a depth of 26 cm, were taken at varying distances from the plant site,
as were grass samples. Analyses of trace elements were made with neutron activa-
tion analysis and X-ray fluorescence analysis equipment.
Conclusions were that the smelter operation has been the major source of Cd,
Sb, Ag, Pb, Au, Zn, Se, As, In, Ni, Cu, and Hg in soil, grasses, and the air in
the Kellogg area.
The synergistic effect of these high-air concentrations of metals on humans
in Kellogg should be addressed, and the body burden of these metals should be
investigated.
REFERENCE" R. C. Ragaini, H. R. Ralston, and N. Roberts, Environmental Science
and Technology, TJ. (8), August, 1977, pp. 773-781.
124
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USEPA AWARENESS BULLETIN
1ECHNOLOGY $ I RENDS
IN THE NONFERROUS METALS INDUSTRY
INDEX 2.3.8 (Ger.)
PAGE
SUBJECT: State and Trends of the Hvdrometallurcrical
Zinc Extraction
The author gives a review on the process of the hydrometallurgical zinc
extraction. The still existing deficiencies for the- different partial pro-
cesses and possibilities for solution are described.
REFERENCE: V. Wiegand, Erzmetall, 30 (4), April, 1977, pp. 135-139.
125
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USEPft AHARENESS BULLETIN ,NDEX 2.3.8 (it.)
TECHNOLOGY $ 1RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 4
Hydrometallurgy of Zinc. Recovery of the
Metal from Leaching Residues: Energetic
Comparison Between Hydrometallurgical and
Pyrometallurgical Processes
Slime residues of electrolytic zinc plants are often treated at high tem-
peratures by mixing them with coal to volatilize the-ir zinc and lead content
as oxides; both metals are then recovered by treating the fumes thus obtained.
Recently, other methods have been successfully introduced, based on the
leaching of the slime with hot sulfuric acid: iron—which is solubilized
together with zinc--is precipitated by special methods, and the solutions--
consisting of zinc sulfate--is used for recovering the metal by electrolysis.
By using data drawn from already operative plants and from pilot plant
experiments, a comparison is made between energy consumption of both alterna-
tive methods.
REFERENCE-' G. Binetti, M. Civera, and A. Vaschetti, Metalurgia Italiana,
69 (4), 1977.
126
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USEPA TECHMOLOGV AMP TREWS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 2.3.8
Page 5
Subject: Electrolytic Recovery of Zinc From Oxidized Ores
Most primary zinc operations are based upon roasted sulfide concentrates.
Various easily mined ore bodies are oxidized zinc minerals, most often asso-
ciated with silica. Some processes have been developed to treat siliceous
oxides, but these are typically complex and not amenable to operations on
totally oxidic ores. An exception is the EZ process, demonstrated by the
Electrolytic Zinc Company of Australia to process willemite ore (2ZnO.Si02)
from Baltana, South Australia. Encouraged by the success of the EZ opera-
tion, New Jersey Zinc has piloted a modified EZ process for use by its Thai
Zinc, Ltd. subsidiary in producing zinc from the oxidized zinc deposit at
Mae Sot, Thailand. In this process, ground ore is leached with sulfuric acid
to extract zinc. Siliceous residues maintain their physical stability with-
out polymerizing to a gel when pH is maintained at about 2. Rapid neutrali-
zation precipitates silica, which is removed by filtration.
Ore, typically assaying 25 percent zinc, is ground to 65-80 percent,
-200 mesh, and is cascade leached at 40-50 C with a retention time of about
4-1/2 hours. About 96 percent recovery of the zinc is achieved in 4.5 hours.
Neutralization is done with basic zinc sulfate (recovered from the residue
wash) and finely ground limestone to a pH of 4.5. Several filtration options
were explored, each with its advantages and disadvantages. Roughly 4-5 times
as much solid residue is associated with processing of the Mae Sot ore as
occurs with conventional sulfide processing where most of the gangue is
rejected in ore beneficiation.
The filtrate is purified by cementation to lower the copper, nickel, and
cadmium contents to less than 1 ppm prior to electrolytic recovery of the
zinc. The resulting cathode zinc from pilot operations contained 15 ppm lead,
6 ppm Cd, 4 ppm Cu, and 5 ppm Fe as principal impurities. Current efficiency
averaged 89 percent; power consumption was 3230 kWh-a.c./m.t.
A 60-kmt plant is being planned for Tak, Thailand. Capitalization will
be $800-1000/annual ton of zinc.
The environmental implications of this process weighed against those of
a conventional sulfide operation include no S0£ emissions. The major efflu-
ent will be the washed filter cake residue, largely silica and gypsum. To
this will be added bleed streams containing impurities removed from the
system. The bulk of the residue should require little treatment and should
solidify as a stable solid material.
Reference: S. T. Wood, P. L. Kern, and N. C. Achdown, J. of Metals, 29_ (11),
November 1977, pp. 7.
127
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USEPA AWARENESS BULLETIN ,NDEX 2.3,9
1ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 1
SUBJECT: The Processing pf Residual Products of the
BBU Zinc and Lead Smelting Works in the
Revolving Reverberatory Furnace
At the Bleiberger Bergwcrks Union, the mixed oxides of zinc, lead, cadmium,
and germanium are extracted from residual products of the zinc and lead ore
smelting in open flame revolving furnaces. The program of operation, which was
developed during long years of operation, is described and the most important
working data are indicated. Because of the low metal content of the final slag,
the two metallurgical plants show a favorable total recovery of metal.
REFERENCE: P. Miillner, Erzmetall, 30 (7/8), July/August, 1977, pp. 326-329,
128
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US EPA TECHNO LOGV ANZ? TREWS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 2.4.9
Page J
Subject: Mechanization of Lead Cell Room Operation and Slime
Treatment at Kami oka Smelter
The Kamioka lead smelter of Japan uses a conventional sintering-blast
furnace process, an electrothermic slag fuming process for zinc recovery,
and Betts electrolytic refining process, with a 26,700 tons production rate
per year.
In 1975, a new electrolytic lead refinery began operation designed to
save in labor costs (only 12 men in the cell room) and to be completely
mechanized. A new shape was designed for the anode to facilitate changing.
This necessitated redesign of the anode casting machine. By prevention of
bending of the electrodes, both anode and cathode, determination of the most
suitable electrode thickness, and control of electrolytic level, it was found
possible to operate on a 6-day schedule of anode and cathode change, and this
simultaneous change could be made automatically with no operators present.
The lead electrolysis produces slimes which adhere to the electrodes.
These slimes contain copper, arsenic, antimony, bismuth, gold, and silver.
In 1970, slime treatment modifications were made to increase capacity and
reduce labor consumption. Dehydrated slime is reduced with coke to molten
metal; then by a technique of sodium hydroxide reaction, chlorination, and
oxidization, the various metals in the slime are separated, leaving crude
silver. The largest fraction after refining this silver will analyze 99.999
percent pure while bismuth, the predominant impurity in the silver, after
refining, will also analyze 99.999 percent.
The results of complete mechanization of the Kamioka smelter are the
highest rate of lead production in plant history, fully automatic cell room
operation, and a longer electrolysis period with large-sized cells and
electrodes.
Several flow sheets, diagrams, illustrations, and tables of production
data and analyses are given in this detailed description of the Kamioka
smelter and new lead electrolytic plant.
Reference: S. Hirakawa, E. Nomura, T. Mori, Y. Hirayama, AIME-TMS Paper
No. A 78-14.
129
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USEPA TECHNOLOGY ANP TRENDS ABSTRACT Index 2.4.9
for the NONFERROUS METALS INDUSTRY Page 2
Subject: Progress of Zinc Residue Treatment
in the li.iima Refinery
With a capacity of 13,000 tons/month of electrolytic zinc (98 percent
recovery), the lijima zinc refinery of Japan is concerned with the recovery
of cadmium, silver, copper, lead, gallium, and indium from the zinc concen-
trate. This paper examines the recovery in detail with three flow sheets
included.
After sulfur dioxide leaching of the zinc residue, the copper is precipi-
tated by hydrogen sulfide. The quantity of hydrogen sulfide is critical as
separation of copper and lead becomes poor with excess gas. Lime neutraliza-
tion of the filtrate produces gypsum. A second stage of neutralization, to
pH 5, coprecipitates gallium and indium with gypsum. The gallium and indium
are extracted and separated by organic solvent extraction. Removal of iron
from the remaining neutralized filtrate (Hematite Process) is accomplished by
autoclaving at--180 C with 18 atmospheres of oxygen. This process is used
only at lijima.
Flotation of the copper residue from the hydrogen sulfide precipitation
with n-alkyl-triethyl-diamine separates the copper and lead. The concentrate
contains 98 percent of the copper and 88 percent of the gold and silver,
while the tailings contain lead. Total recovery of copper, silver, and lead
are nearly 100, 97, and 83 percent, respectively.
Reference: T. Ohtsuka, T. Yamada, H. Abe, K. Aoki, AIME-TMS Paper
No. A 78-7.
130
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.USEPA AWARENESS BULLETIN
INDEX 2-7-1
ECHMOLOGY $ 1 RENOS'
IN THE NONFERROUS METALS INDUSTRY PAGE
SUBJECT: Flash Agglomeration of Flue Dust
A system for automatic handling of flue dusts in secondary lead smelters
is described in qualitative terms in this paper. Dusts removed by filtration
from blast furnace stacks are fed by a closed screw-conveyer through a roof
port onto a sloping hearth of the "Bergsoe Flash Agglomeration Furnace",
where the particles melt, agglomerate, and flow directly to a cast iron mold.
The brittle cast product easily breaks into chunks for convenient recharging
to the blast furnace, thus overcoming the problem of dust recirculation when
unagglomerated fires are recharged directly. This system avoids manual handl-
ing of the easily ingested fines and has significantly reduced lead uptake by
smelter workers. Additives to the screw conveyor system are selected for
fluxing purposes to control the remelt temperature of the agglomerate for
smooth blast furnace operation. Quantities and types-of flux additions vary
according to the charge schedules for the blast furnace.
REFERENCE: T. S. Mackey, Australian Mining, 6£ (6), June, 1977, pp. 52-54.
131
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USEPA AUARENESS BULLETIN ,NOEX 3.3.2 (Ger.)
ECHNOLOGY $ I RENDS
IN THE NONFERROUS METALS INDUSTRY
PAGE
SUBOECT: Pry Cleaning .of Aluminum Smelter Potoases
with Circulating Fluid Bed and Electrostatic
Precipitator
Due to the good adsorption conditons in highly expanded alumina fluid
beds, a high efficiency of fluorine removal can be achieved with a small amount
of alumina. After the fluid bed reactor, an electrostatic precipitator may be
used under certain conditions, by means of which the main quantity of harmful
accompanying elements may be separated.
REFERENCE: E. Bohm, L. Reh, V. Sparwald, and 6. Winkhaus, Erzmetall, 30. (6),
June, 1977, pp. 247-251.
132
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USEPA TECHNOLOGY ANP TRENPS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 3.5.1
Page 2
Subject: Consolidated Aluminum's "Selee" System:
Two Syllables that Could Change Your Life
Conalco's Selee system for filtering aluminum alloys to remove non-
metallic particulates is gaining acceptance on the part of aluminum producers
around the world. Heart of the process is an 80 to 95 percent open ceramic
filter that is replicated from a polyurethane foam by slurry-impregnation,
squeezing,'and firing. The filter is a one-shot, throwaway unit that is
easily inserted and removed from an inexpensive filter chamber installed in
a holding furnace launder. Cast sizes may range from 15,000 to 85,000 pounds.
The system cost is from $3,000 to $15,000, depending on size, operating costs
are 30 to 75 percent less than other filtration systems, and product quality
is very good. The system is small, energy-efficient, tamper-proof, and
enjoys good operator acceptance.
It is expected that Conalco will use Selee as a core around which to
design a cast-shop package, including in-line degassing and other refining
technology. Presumably, this package will be competitive with the British
FILD, Union Carbide's SNIF, and other systems designed to minimize the use
of chlorine degassing, which has in the past presented discomfort in the
plant environment.
Reference: 33 Metal Producing, 16 (3), March, 1978, pp. 49-51.
133
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USEPA AWARENESS BULLETIN INDEX 3.5.1/2
1ECHNOLOGY $ 1 RENDS ~~
IN THE NONFERROUS METALS INDUSTRY PAGE '
SUBJECT: New Aluminum Process
Nitrogen degassing of molten aluminum has been developed by the British
Aluminum Company and bears the acronym FILD (Fumeless In-Line Degassing). It
is beginning to supplant chlorine gas and pellet degassing practice, both of
which generate noxious, corrosive, difficult-to-manage plant fumes.
As described in this reference, the molten aluminum from the alloying
furnace flows through a two-chambered crucible where it is sparged with nitro-
gen gas to remove hydrogen. The molten aluminum, under the action of its own
head, percolates first through flux-coated A^OS pellets, thence through
uncoated A1203 pellets to remove inclusions and entrapped flux.
Among the advantages claimed for FILD are substantial cost reduction,
increased furnace productivity, and much alleviated environmental problems.
In this article, however, the issues of product quality comparisons were not
addressed, nor was the use of chlorine for demagging discussed. The use of
chlorine for removing magnesium from recycled aluminum is large.
REFERENCE: The Indian and Eastern Engineer, 119 (4), April, 1977, pp. 179-182.
134
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USEPA AWARENESS BULLETIN
1ECHMOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY
INDEX 3.7.2 (Ger.)
PAGE
<:iiR.it:rT-About tne Appearance of a Chlorination Maximum
During the Removal of Magnesium from Aluminum
Melts by Gaseous Chi on'nation '.
Since the legislation of environmental protection is growing stricter and
stricter, the process of magnesium removal from aluminum melts by gaseous chlo-
rination becomes questionable, too. Investigations concerning the chlorination
process have shown a chlorination maximum whose practical utilization would be
a proposal to solve the problem of waste gas control.
R. J. Bauer and H. Winterhager, Erzmetall, 30 (6), June, 1977, PP
135
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USEPA TECHNOLOGY AMP TREMPS ABSTRACT Index 3.8.6
for the NONFERROUS METALS INDUSTRY Page ]_
Subject: Continuous Extruder Thrives on Scrap
Use of a Conform machine, designed and built under license by the
United Kingdom Atomic Energy Authority, will permit the Macklandburg-Duncan
Company, Inc., of Oklahoma City, to continuously extrude $0.15 per pound
aluminum scrap into $0.75 to $0.80 per pound weatherstripping. This year,
the company expects to recycle 500,000 pounds of scrap into weatherstrip.
The acceptance of any soft metal chips, particles, powder, or rod up
to 3/8 inch, by the Conform machine, should produce a ready market for scrap,
thus ridding the environment of much metallic scrap and junk and, at the same
time, produce a useful and saleable item from this waste.
Reference: Larry Kahaner, American Metal Market, 86_ (15), January 23, 1978,
p. 16.
136
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USEPA AWARENESS BULLETIN
'1ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY
INDEX 3.9.9 (Ger.)
PAGE 1
SUBJECT: Concentration of Efficacy. The Italian
Aluminum Industry Reorganized—Results of
Research and Development
(No abstract available.)
_____*———mm••—~
REFERENCE: Metaii, n <6)> June» 1977' p' 653>
137
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USEPA TECHNOLOGY AND TRENDS ABSTRACT Index 5.2.9
for the NONFERROUS METALS INDUSTRY Page i
Subject: Hydrnmetallurgical Process for Recovery of Tin From
Low-Grade Concentrates
This article describes laboratory experimentation toward developing a
hyd^metallurgical process for tin recovery from concentrates containing up
to 20 percent tin, as typical of Cornish lode concentrates. Three major
process steps (reduction, leaching, and cementation) were examined in small
bench tests with tables of data given for each process.
Reduction. It was found that reduction roasting at 700 C for 1-2 hours
in hydrogen produced the highest Teachable SnO yield, up to 99.5 percent tin,
compared with a low of only 65 percent with a H2-CO-N2 reducing gas mixture.
Preroasting at 700 C was necessary to remove the sulfur and pelletization was
important to prevent dusting during the roasting.
Leaching. Crushing of the pellet from the roasting and reduction step
is essentials Hydrochloric acid was found to be the most effective leaching
agent, but sulfuric acid with sodium chloride or ferric chloride (to prevent
passivation of the aluminum in cementation) proved to be the most economical.
Cementation. Aluminum swarf was used to precipitate the tin from the
leach solution in the ratio of 0.3 g of aluminum to 1 g of tin.
As the process is only in the laboratory stage, production implications
cannot yet be assessed. In any event, potential U.S. environmental implica-
tions are negligible.
Reference: G. Holt and D. Pearson, Transactions of the Institution of Mining
and Metallurgy Section C, 86_, June, 1977, pp. C77-C81.
138
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USEPA AWARENESS BULLETIN
ECHMOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY
INDEX -09.1/3.8
PAGE
. Heap Leaching will Produce 85.000 oz/Year of
Dore Bullion for Smoky Valley Mining
Approximately $8 million in gold has been mined from placer and underground
mines, since its discovery in 1905 at Round Mountain near Tonopah, Nevada. This
year (1977) the Smoky Valley Mining Company has revived gold production at Round
Mountain by heap leaching low grade ores to produce 85,000 oz/year of dore bullion
assaying 67 percent gold, 33 percent silver from ore, averaging 0.06 ounce of gold
per ton.
Processing includes open-pit mining, crushing to 100 percent minus 1/2 inch,
cyanide-lime trickle leaching, carbon adsorption and desorption, electrowinning,
and refining.
No mention is made of pollution controls at the crushers or at the electro-
winning and refining sections of the plant. However, a well below the leach pads
does monitor the ground water to assure that no cyanide escapes the leaching
system.
——— ——
L. White, Engineering and Mining Journal, 178 (7), July 1977,
__ in T)
139
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USEPA TECHNOLOGY AWP TREWPS ABSTRACT Index 9.3.8
for the NONFERROUS METALS INDUSTRY Page 2
Subject: DeLamar Silver Mine—Third Largest in United States
Now Pouring Bullion
As noted in previous news items, the DeLamar (SW Idaho) silver mine was
recently reactivated by Earth Resources Company. This recent publication
summarizes the mine, mill, and smelter operations.
The DeLamar silver mine is located 90 miles southwest of Boise, Idaho,
and is the largest open-pit silver mine in the U.S. with an ore body of an
estimated 8,000,000 tons, assaying 2-6 ounces of silver and less than 1/10
ounce of gold per ton.
Seventeen hundred tons of ore are processed by the plant per day.
After crushing, cycloning, and ball milling, the slurry is given a cyanide
leach and filtered. Barren solids are washed, thickened, and discarded to
the tailings pond. Pregnant liquor is clarified and deaerated prior to
cementation of the silver and gold values according to the Merrill-Crowe pro-
cess. The resulting filter cake is smelted to Dore. Weekly production of
about 50,000 ounces of Dore is shipped to Belgium for refining.
Flue gas effluents are treated in an AAF Rotoclave; solids are pro-
cessed or sold, and liquids are neutralized and pumped to tailings disposal.
An 11,000,000-ton tailings pond to hold all wastes from the mill and surface
runoff was formed by building an embankment across a gulch. No outlet or
spillway is provided; however, a flow by-pass will be constructed for safety
upon abandonment.
Reference: World Mining, 3£ (12), November, 1977, pp. 59-61
The Mining Record, 88 (48), November 30, 1977, p.
140
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USEPA TECHNOLOGY ANP TRENPS ABSTRACT Index
for the NONFERROUS METALS INDUSTRY Page
10.2.8
1
Subject: Flotation of Floes of Ultrafine Scheelite
In anticipation of future needs for improved recovery from fine-grained,
low-grade ores, the authors investigated shear flocculation as a means for
upgrading flotation recovery of scheelite fines. Experiments were conducted
on both unflocculated and flocculated pulps. Sodium oleate and sodium sili-
cate flocculating agents combined with turbulent stirring resulted in a
severalfold increase in the apparent particle size. In flotation experiments,
about 80 percent of the flocculated material was floated in 8 minutes, com-
pared with 20 to 35 percent of the dispersed fines. Flotation kinetics
indicated that flotation rates of effectively flocculated material is 15 to
20 times more rapid than for dispersed material.
Direct environmental implications of this technology demonstration are
negligible. However, when major technology centers become based upon ultra-
fine particle processing, concentrator tailings will have different character
than they now have, and will gradually evolve some aspects of ecological
impacts that may not be readily appreciated at present.
.- . — —
Reference: P. T. L. Koh and L. J. Warren, Instn of Mining and Met. Trans.,
Sect. C, 86, June 1977, pp. C94-C95.
141
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USEPA TECHNOLOGY AMD TRENDS ABSTRACT Index 10.2.9
for the NONFERROUS METALS INDUSTRY Page 1
Subject: New Technology Overcomes Obstacles in the Alps
The first integrated tungsten operation in Europe, owned by Wolfram-
Bergban and Huettengesellschaft of Bergia, Austria, began production of •
paratungstate in August, 1977. The scheelite ore, mined near Mittersell,
Austria, is Europe's largest deposit and assays 0.7 to 1 percent tungsten.
A major obstacle to be overcome in the development of this plant is
the high altitude which necessitates that all mining be done during the
summer months. The ore is concentrated to low-grade (30 percent trioxide)
concentrates for processing at a remote site.
A brief description of the beneficiation process is given; a unique
feature is an impact crusher which reduces boulders from 1 meter to 10 milli-
meters in size in one stroke, thus reducing a usual five-step process to two
steps.
By 1980, all mining work will be underground and year-round operation
will be possible. The end productsof the W.B.&.H. operation are tungsten
powder and tungsten carbide-
Reference: Tom Walsh, American Metal Market, 86_ (3), January 5, 1978,
pp. 9, 16.
142
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USEPA TECHNOLOGY AMP TRENDS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 1Q.2.9
Page 2
Subject:
New Technology Tries to Tap
Tungsten Trove
Last month, the USBM began pilot-plant testing of a new ion exchange
process for the extraction of tungsten from the brines of Searles Lake,
California. Using the ion exchange resin HERF (hydroxyquinoline-ethylene-
diamine-resorcinol-formaldehyde), 95-100 percent recovery of tungsten can
be realized from brine containing only 70 ppm tungsten trioxide. Elution
of the resin with soda ash is followed by the addition of ferric chloride,
resulting in the coprecipitation of ferric iron with the tungsten.'- After
filtration and drying, the iron-tungsten concentrate is suitable for sale
to the refiners.
Some process bugs will be addressed in this operation. Process eco-
nomics will be critical. However, if an economic process for extracting
tungsten from the Searles Lake brines can be developed, a major increase in
domestic tungsten reserves would be realized.
Reference: chemical Engineering, 85 (5), February 27, 1978, p. 71-72.
143
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USEPA AWARENESS BULLETIN INDEX 13.1.4
1ECHNOLOGY $ 1RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE '
SUBJECT- Minnamax Project Progressing on Schedule
Massive low-grade copper-nickel deposits in the Duluth Gabbro Complex are
of ever-increasing interest as a major source of domestic nickel, with copper
as a coproduct of economic necessity. Development of this recognized resource
will require that rather monumental ecological problems be satisfactorily
managed. The Minnamax test mining project of Amax is described in this article.
A 1700-foot test shaft has been finished, and, by year end, 3600 feet of drift-
ing will have been completed, including 2100 feet within the mineralized zone.
Extracted bulk samples will be evaluated by the University of Minnesota,
Lakefield Research of Canada, Ltd., and U.S.B.M.-Twin Cities. Concentrate will
be tested for flash smelting in Outokumpu-Oy-type furnaces.
Prior to starting the test operations and during the project, monitoring
of surface waters and groundwater is being conducted to provide a basis for
evaluating environmental impacts. Six low-grade leach piles, 1600 tons each,
of potential lean are (0.35% Cu, 0.11% Ni, representative of low-grade surface
stacks that are anticipated) have been prepared. Leaching action on these
dumps is being monitored. The environmental studies include—in addition to
surface and groundwater hydrology—assessment of impacts on aquatic and terres-
trial biology, soil evaluation, climatology, vegetation, and wildlife.
Trial mining assessments, including the evaluation of environmental
impacts, are expected to be completed during 1981. In 1982, a decision will
be made whether or not to proceed with development leading to the start of
production in 1985. The potential at Minnamax is for a 15,000-25,000 ton-per-
day mining capacity, with ore grades from. 0.6 to 1% Cu + Ni at a 4-to-l ratio.
Initially, small operations would be open pit, but major production would be
entirely from underground mining.
REFERENCE: Skillings1 Mining Review, 66_ (41), October 8, 1977, pp. 12-14.
144
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USEPA AWARENESS BULLETIN
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. Actual Problems of Dressing low E
INDEX 13.2.9 (Ger.)
PAGE
Nickel Ores
The energy which is needed to produce nickel from oxides is at least twice
as high as is necessary for a production from sulfides. This led to a repeated
examination of low grade sulphidic ores as a possible resource of nickel. Ores
of this type are to be found in many parts of the world. The enrichment of
nickel from these ores leads to a number of special problems in connection with
the occurring minerals of pentlandite and pyrrhotite as well as of the deadening
of matrix. These problems are discussed.
REFERENCE: „. j. Roorda, R. A. Kuhnel T Kater and M. 0. Jioping, Erzmetall,
-292.
. . , . .
30 (7/8), July/August, 1977, pp. 287-292.
145
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USEPA TECHNOLOGY AWP TRENVS ABSTRACT Index 13.2.9
for the NONFERROUS METALS INDUSTRY Page 2
Subject: SMM Ammonia Leaching Process for
Lateritic Ore
Sumitomo Metal Mining Company has recently developed and piloted
(10 tpd) an ammonia leaching process for lateritic nickel ore, which greatly
improves the presently used Nicaro Process. Replacement of the dust produc-
ing multiple hearth furnaces and external reducing gas generators of the
Nicaro Process with an annular vertical kiln and self-reducing, coal contain-
ing, lateritic nickel ore pellets promises to reduce capital costs, simplify
plant operation, and improve nickel recovery.
Pellets, 8-20 mm in diameter, of the nickel ore and 12 percent or more
coal, are heated in the annular vertical kiln for 30-60 minutes at tempera-
tures of 700-850 C with oxygen content less than 0.5 percent. It was found
that the addition of 0.2 to 1 percent sulfur raised the reduction rate of
nickel by over 15 percent.
After cooling, the reduced nickel pellets are ground and leached by
ammonia-ammonia carbonate. Research indicated that a CT source from NaCl
or NH4.C1 was effective in increasing the nickel extraction, and can reduce
the leaching time by a third. The final leach product occurs as basic nickel
carbonate (BNC) after removal of iron, manganese, and cobalt as sulfides and
the stripping of the ammonia (aided by the addition of sodium carbonate).
Details of the laboratory and pilot plant investigation are given in
this paper. Numerous graphs, data tables, and a flow sheet are included.
Reference: T. Shimizu, Y. Okajima, AIME-TMS Paper No. A 78-11.
146
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USEPA TECHNOLOGY AND TRENDS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 13.3.3
Page 1
Subject: The Kinetics of the Sulphuric Acid Leaching of Nickel
and Magnesium from Reduction Roasted Serpentine
The kinetics of atmospheric pressure sulfuric acid leaching of the ser-
pentine mineralization of reduction roasted nickel laterite of Caledonian
origin has been examined in a laboratory study. (Because of high magnesium
content, the serpentine or unleached layers of lateritic deposits are usually
considered more amenable to pyrometallurgy practice than to hydrometallurgy.
The upper, limonitic layers are more suitable to hydrometallurgy.) The
objective was to evaluate the selectivity of nickel extraction compared to
magnesium extraction as a function of acid strength and leaching temperature.
Limonite was rejected from the ore by screening out fines. The serpentine,
sized at -65 + 100, contained 1.65 percent Ni,~6.1 percent Fe, 20.2 percent
Mg, and 20.4 percent Si, after having been reduction roasted to convert 85
percent of the nickel and about 40 percent of the iron to the metallic state,
and to convert the serpentine to olivine.
Leaching kinetics for nickel followed a logarithmic rate law according
to -dC|\|-j/dt = Kfj-jCw^, where Cj^-j is the residual percentage of unleached
metallic nickel ana KM-J is the rate constant. For magnesium, kinetics obeyed
the expression l-(l-a;1/3 = K|v|gt, where x is the fraction of the magnesium
silicate reacted at time t, ana Kf/ig is the rate constant. Rate constants for
magnesium removal from the silicate were relatively lower than those for
metallic nickel leaching, to the end that leaching of the nickel was com-
pleted when the magnesium reaction was only about 20 percent complete. In
this regard, ambient pressure leaching may be considered selective. However,
mass-balance analysis suggested by the data presented indicates an acid uti-
lization efficiency of only about 20 percent based on nickel recovery alone.
The weight of magnesium converted to MgS04 in a given leaching period was
probably at least 50 percent greater than the weight of the nickel extracted.
The relative rates of nickel and magnesium leaching did not vary signifi-
cantly with either acid concentration or temperature.
Reference:
Apostolidis, C.
March, 1978, pp
I and P. A. Distin, Hydrometallurgy, 1(2),
. 181-196.
147
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USEPA TECHNOLOGY AND TREWPS ABSTRACT Index 13.3.9
for the NONFERROUS METALS INDUSTRY Page 1
Subject: Sulfuric Acid Pressure Leaching of
Nickeliferous Limonites
The chemistry and kinetics of pressure leaching of the limonitic layer
of Caledonian laterite ores was examined and reported in greater depth than
has been previously available. The ore sample contained 1.73 percent Ni,
0.16 percent Co, 41.6 percent Fe, 1.5 percent Mg, 2.6 percent Al, and 13
percent Si02- Samples were pressure leached in I^SC^ to extract the nickel
and cobalt at temperatures from 225 to 300 C. Variables included solids con-
tent (25 or 33 percent), acid addition (acid to ore weight ratios of 0.21 to
0.30), particle size of the ore sample, temperature, and agitation. Evalua-
tion criteria were the completeness of nickel extraction, the rates of
extraction, the quality of leachate (Ni/Fe + Al ratio), and sulfur loss to
residue. The important findings were as follows:
(1) Particle size. Neither nickel returns nor leaching rate
were influenced by the particle size of the ore. How-
ever, finer grinds apparently nucleated the removal from
solution of iron (and perhaps aluminum) by hydrolysis.
(2) Agitation. In thoroughly mixed slurries, agitation dur-
ing leaching had no effect on extraction or purity.
(3) Temperature. At 225 C, low leaching rates were found.
At 250 and 275 C, about 95 percent of the nickel was
extracted in the first few minutes, with the rate
being somewhat greater at 275 C. At 300 C, extraction
was not so high, perhaps as a result of nickel occlu-
sion on the hydrolyzed iron and aluminum products.
Cobalt extraction versus temperature was similar to
that of nickel. For a given leaching time, the Ni/Fe +
Al ratio (higher ratio is a better-quality pregnant
liquor) was higher at 275 than at 250 C. However, loss
of sulfate to the residue was greater at 275 than at
250 C.
(4) Acid/ore ratio. Higher acid/ore ratios result in more
rapid extraction, but also decrease the quality of
the liquor for a given leaching time. Economics dictate
a careful balance between these factors.
(5) Percent solids. Solids loading for effective leaching
(extracted amount and liquor quality) varies according
to the temperature of leaching. At 250 C, higher solids
Reference: E. C. Chou, P. B. Queneau, R. S. Rickard, Metallurgical
Transactions, B, 8B_ (4), December 1977, pp. 547-554.
148
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Index 13.3.9
Page la
loading (higher production rate) may be preferred, but at
275 C, leaching should be carried out at lower (20 to 30
percent) solids loading for optimum results. The higher-
temperature, lower solids route requires 10 percent less
acid for comparable extraction relative to the lower-
temperature, higher solids route.
The interactions among these variables upon leaching rate, product
quality, and acid efficiency have been described. In general, compared to
usual practice, this study suggests that somewhat greater leaching tempera-
ture and lower solids loading would be attractive.
(The fine-tuning of leaching circuits allowed by the described tech-
nology would probably have no significant environmental impact compared to
current practice involving hydrometallurgy of lateritic ores.)
149
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USEPA AWARENESS BULLETIN INDEX 13.4.8
1ECHMOLOGY $ 1RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 1
SUBJECT- Amax Nicke1 Refinery Approaches Full-Capacity
Capability
The first American pure nickel refinery is approaching its design capacity
capability at Port Nickel, Louisiana. Amax's nicke.l refinery will, at full
operations, produce 80,000,000 Ibs nickel, 45,000,000 Ibs copper, 1,000,000 Ibs
cobalt, and 100,000 tons of ammonium sulfate per year.
Built in 1959 to process Cuban ore, the plant remained idle until 1972
when taken over and revamped by Amax. Half of the feed now comes from Botswana,
Africa, and consists of matte containing 42 percent nickel, 37 percent copper,
and small quantities of cobalt. Other sources of matte are South Africa and
New Caledonia^.
Incoming matte is crushed, blended to control feed composition, remelted
for homogenization, shotted, and ground. It is then leached at atmospheric
pressure with a nickel and copper sulfate solution. About half of the nickel
and cobalt are dissolved; the solids (copper and the balance of the nickel) are
pressure leached. Copper is recovered from the sulfate solution by electrowin-
ning, and dissolved nickel is returned to the first leaching stage. The nickel-
cobalt solution from the primary leach is treated with nickelic hydroxide form-
ing a precipitate of cobaltic hydroxide and nickelous hydroxide. These are
digested and converted to ammine complexes. Acidification precipitates nickel
as a double salt. The liquor is further purified by LIX. Autoclaving the
cobaltic pentammine at 360 F and 500 psig' in the presence of hydrogen produces
cobalt metal powder. The nicke,! sulfate solution is reduced, to the metal in
autoclaves similar to those used in the cobalt reduction; however, hydrogen
and ammonia are used, producing the metallic nickel and ammonium sulfate. The
ammonium sulfate is recovered and sold as fertilizer.
The process is described in detail in the article together with a schematic flow
diagram of the Port Nickel facility. During conversion of this plant for Amax's
use, "Amax made certain that every feasible ecological consideration was made to
avoid adversely affecting the environment of the area. So-lid wastes, largely
harmless iron oxides, are ponded to prevent entering area waterways. Discharge
management methods, however, were not described in this article.
REFERENCE: J. L. Blanco, Selling's Mining Review, 66 (43), October 22, 1977,
pp. 1, 6-9.
150
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USEPA TECHNOLOGY AWP TREWPS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 14.2.2
Page 1
Subject:
Materials From the Sea -
Inexhaustible Source of Magnesia and Magnesium
This article reviews the history of magnesium production from seawater
and the many industrial uses being found for the unique properties of
magnesium.
The new process described, complete with flow chart, is being used in a
Porsgrunn, Norway, plant, utilizing waste from the German potash industry to
produce magnesium chloride from 30 percent magnesium chloride brine. The
brine is purified, then carefully dried, before being converted into a solid
by spraying into a prilling tower. Dehydration is completed by circulating
hydrogen chloride gas through the system, producing a very hydroscopic anhy-
drous magnesium chloride, which is then electrolized, producing magnesium
metal and chlorine. The chlorine will be piped to another plant for poly-
vinyl chloride plastic production.
Because this process uses no chlorination furnaces, atmospheric pollu-
tion by chlorine will not be a problem.
Reference: R
__
. J. Dowsing, Metals and Materials, January 1978, pp. 20-26,
151
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USEPA TECHNOLOGY AND TRENDS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index 15.1.4
Page 1
Subject:
Environmental Impact of Deep Sea Mining
Late this year, NOAA will begin tests of the hydraulic mining system
for gathering manganese nodules from three sites along the floor of the cen-
tral Pacific Ocean.
These tests will not only explore the mining technique but the environ-
mental aspects of the operation as well. As the nodules are collected, most
waste material is rejected at depth, but some is discharged on the ocean
surface. It is this surface discharge that will be studied extensively as
to the rate of discharge, temperature, salinity, and solids concentration
to estimate impacts on the marine ecology.
In later tests, it is hoped to monitor the effects of the mining opera-
tion on the sea floor by the use of underwater cameras and water samples
taken along the path of the dredgehead.
Reference: Journal of Metals, 29_ (11), November, 1977, p. 6.
152
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USEPA TECHNOLOGY AMD TRENDS ABSTRACT index 1514
for the NONFERROUS METALS INDUSTRY ' page ^T
Subject: Seabed Mining - Background and
Current Outlook: Systems, Methods
This summary sketch of the legal and technological status of mining of
sea nodules is based upon papers presented at a 1977 British Royal Society
meeting on the subject of "Sea Floor Development - Moving into Deep Waters".
At present, a "mine site" has been hypothetically defined as one com-
prising an area of 30,000 sq km with 10 kg (dry weight) of nodules/sq m
grading not less than 2 percent combined nickel, copper, and cobalt. This
would necessarily support operations on the order 10 to 15 kmt/day for about
25 years to make operations of the scale presently envisioned economical.
Sampling to define such a "mine site" would require some 300 samples over a
grid of 10 km square elements to provide 90 percent confidence of merit.
Required sampling procedures and analyses are briefly discussed.
The major elements of a seabed mining operation are the collector, lift-
ing equipment, mining vessel, and transporters. The collector typically will
be a 10 to 15 meter wide drag-scoop which will accumulate the nodules and
exclude clay, fines, and "boulders". Location and navigation will have to
traverse the bed without overlap or coverage gaps. Based on the presently
available state of technology, first-generation mines will yield about 25
percent of these nodules and the second, about 40 percent, hopefully. Direct
mechanical bucket lifts, buoyant-lift units, and combined hydraulic-
mechanical lifts are possibilities. The mining vessel will typically be a
45,000-ton displacement unit designed for an on-site tour of, say, 4 years
and a transport fleet (three or four, 65,000-ton displacement vessels) for
crew, supplies, and product transportation. Probable power requirements
will be on the order of 40 to 50 megawatts, which suggests a shipboard
nuclear power plant.
The expenditure required for such operations mandates an international
legislative framework to provide long-term security of the investment.
Points of view of various national factions relative to the Law of the Sea
dealing with sea-mining ventures are recapped in the article.
Reference: World Mining, 30 (13), December, 1977, pp. 54-58, 80.
153
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USEPA TECHNOLOGY ANP TRENPS ABSTRACT Index 15.1.4
for the NONFERROUS METALS INDUSTRY Page 3
Subject: Optimization of Polymer FT peculation
of Heavy Metal Hydroxides
Acid mine water is the major heavy metal-laden aqueous discharge asso-
ciated with the nonferrous metals industry. Lime-and-settle methods are used
to reduce heavy metals to acceptable levels where these wastes are discharged,
The poor settling characteristics of metal hydroxides may be combatted by
flocculation with polymer additions. To improve the technical basis of poly-
mer flocculation, this laboratory research was conducted by McMaster
University, Hamilton, Ontario. The conclusions from the research were
• Mixing conditions are more important than polymer properties
in the flocculation of neutralized mine water.
• The degree of polymer hydrolysis had no effect on the floccu-
lation of iron-, zinc-, or copper-bearing mine water.
• Mixing time and speed vary indirectly and directly, respectively,
with mine water strength.
• At a metal: sulfate ratio of about 0.3, the optimum polymer
dosage is about 0.5 x 10~3 times the sulfate concentration.
Reference: P. M. Huck, K. L. Murphy, C. Reed, and B. P. LeClair, J. of Water
Pollution Control Federation, 49 (12), Dec. 1977, pp. 2411-2418.
154
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USEPA AWAR£NESS BULLETIN
INDEX 15.1.8
ECHNOLUGY $ 1 RENDS*
IN THE NONFERROUS METALS INDUSTRY RAGE
. Environmental Problems of Tailings Disposal
This is the second of three articles by the authors (see 15.1.8, page 1).
All mining operations need to eliminate some waste, thus creating major
environmental problems of tailings disposal. These problems involve safety
and stability, aesthetic nuisance, air and water pollution, and land reclama-
tion. The release of water from impoundments is probably the single, most
serious, and widespread problem associated with terrestrial disposal, and this
method of disposal is likely to be the predominant one used for many years to
come.
Terrestrial impoundment is discussed in depth in this article, with dia-
grams of pond construction and flow sheets of water used in various mining
operations, cost comparisons of stabilization methods, and landscaping and
reclamation details.
Lake, river, and marine disposal is examined with reference to use and
pollution in specific areas of the world. Underground disposal by deep-well
injection is mentioned briefly.
In the future, research and development will be concentrated on control
of water flow in impoundments, chemical treatment of effluents, and revege-
tating the most acidic, toxic tailings. Marine disposal will receive greater
attention because of the prospects of ocean mining.
REFERENCE: C. G. Down and J. Stocks, Mining Magazine, 137 (1), July, 1977,
pp. 25-33.
155
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USEPA AWARENESS BULLETIN INDEX 15-1.8
ECHMOLOGY $ 1RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE
SUBJECT• Positive Uses of Mill Tailings
This is the third of three articles by the authors (see 15.1.8, page 2>.
The most satisfactory solution to tailings disposal is to find economic
uses for them; however, the sheer quantity of these tailings presents the
largest obstacle to their utilization.
Recovery of additional values by reprocessing, use as a backfill mate-
rial, and use as a raw material to make higher value products are the three
major uses of tailing material. Each use, and problems encountered, is
examined in detail with typical examples taken from mining areas throughout
the world.
A considerable amount of research and development has been expended on
the use of tailings but almost none on the use of the tailings disposal area.
Almost all disposal areas that have been developed have been made into recrea-
tion areas or wildlife sanctuaries by revegetation. However, the long-term
viability of such schemes is questionable in view of the toxicity of many
deposits.
Because of the continued strength of the environmental lobby, pressures
will grow to ensure that tailings be utilized in bulkfill or upgraded
applications.
REFERENCE: C. G. Down and J. Stocks, Mining Magazine, 137 (3), September, 1977,
pp. 213-223.
156
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USEPA AWARENESS BULLETIN
, _ _ _
ECHNULUUY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY ^
INDEX 15.2.4
PAGE
SMR.iFrf.
Pollution Control at
Myra Falls Operation'
The Western Mines Limited is currently mining and milling some of the
most complex polymetallic ores in British Columbia .in Strathcona Park near
the center of Vancouver Island. The ore contains recoverable quantities
of copper, lead, zinc, gold, silver, and cadmium. This presents one of
the most complex milling problems requiring close control of grind, pulp
density, pH, and reagents. And, because the plant is located in a park,
stringent limitations are placed on the tailings discharge.
Tailings have been and are being dispersed by cyclone separation for mine
backfill ("o 50 percent) and, by deep discharge below, the thermocline in nearby
Buttle Lake. Daily assays of the tailing stream, and monitoring of the lake,
fish, and appurtenant waters, are conducted.
Commencing in 1973, the processing of a lead-rich ore body required
cyanidation for lead-copper separation. At that time, a basic chlorination
cyanide-breaking circuit was installed. The size of this circuit (^ 250,000 gpd)
required a much larger scale of operation than, for example, similar cyanide
destruction circuits associated with industrial metal -finishing operations.
Chlorination occurs in three large tanks arranged in series to allow the 1-1/2-
hour treatment time to destroy the copper cyanide complex at flows up to 10,000
g/hr. Lime is injected prior to chlorination to maintain the pH at 10.5 or
greater as required to precipitate the copper, drive the cyanide oxidation (to
cyanate) to completion, and to prevent the escape of toxic CNC1.
Chlorine is provided as tank gas. The use of 1500 Ib/day caused difficul-
ties with refrigeration and loss of Cl£ pressure, which was magnified at ambient
temperatures <50 F in the Canadian clime. Western Mines accordingly found it
necessary to install an evaporator to maintain adequate feed during chlorination.
The chlorine feed is controlled automatically by continuous monitoring of
the oxidation-reduction potential to ensure system stability on the hypochlorite
side. An ORP setting of -600 mv was found to allow this condition.
The installation and establishment of operations of the chlorination plant
has allowed Western Mines to maintain heavy metal and cyanide concentrations in
effluents of less than specified maxima in their most recent operating permit.
This report, however, alludes to analytical disagreement between laboratories.
Improvements in sampling practice, preservation of samples, and. standardization
of assay practice have improved interlaboratory agreement,- although cyanide
analyses remain as an area of concern that is yet to be resolved.
REFERENCE: A. G. Eccles, CIM Bulletin, 70_ (785), September, 1977, -pp. 141-147.
157
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USEPA AWARENESS BULLETIN INDEX 15.2.9
1ECHMOLOGY $ I RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE ]_
SUBJECT* Continuous Monitoring of Froth Level and
Pulp Density Helps Mineral Efficiency by
Computer Control
The Noranda Research Center has developed a froth level monitor and a pulp
density meter, the output of which can be used by a computer to control the
froth level and pulp density of a beneficiating process for a number of metallic
ores.
The froth level controller consists of a set of stainless steel electrodes
of decreasing length so that at least one is always immersed in the froth. An
electronic circuit senses the number of electrodes in contact with the froth
and produces a dc output signal which is an accurate linear function of the mean
froth level. ^This signal can be used as an input to a control system.
The pulp density meter consists of two pressure chambers which transmit
hydrostatic pressure to a differential pressure transducer where the pressure is
converted to an electric signal for readout on a calibrated scale or as input to
a control system.
The two instruments are proving to be of value to several Noranda group con-
centrators and to others where it has been installed, offering increased automa-
tion and improved metallurgical control.
Automation allowed by such instrumentation leads to lower process losses,
cleaner plant operations, and decreased pollution by spills and other fugitive
emissions.
REFERENCE-' F. Kitzinger, F. Rosenblum, and P. Spira, The Northern Miner, 63 (22),
August 11, 1977, pp. 12-13.
158
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USEPA TECHNOLOGV ANP TREWS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index
Page
15.3.2
1
Subject: Sulphide Mineral Electrolvsis
This review of processes for the direct electrolysis of metal sulfides
to metal and free sulfur admits to the ideological desirability of such pro-
cesses, particularly in light of present air pollution constraints in
developed countries. However, its main theme is that, in most cases, the
complexities of cell operation and electrolyte purification, even when tech-
nical feasibility can be shown in the laboratory, are such as to make direct
conversion processes uneconomic. An exception is the operation by
International Nickel Company, Ltd., of the Thompson, Manitoba, works for
nickel production.
Reference: T. Biegler, Chemistry in Australia, 44 (8), pp. 193-197.
159
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USEPA TECHNOLOGY ANP TREWPS ABSTRACT Index 15.3.2
for the NONFERROUS METALS INDUSTRY Page 2__
Subject: Impact of Environmental Control Expenditures
on Copper, Lead, and Zinc Producers
Recent past capital expenditures toward compliance with pollution abate-
ment regulations have added considerably to the burdens of primary copper,
lead, and zinc producers. This article summarizes an independent survey con-
ducted by National Economic Research Association, Inc., with the cooperation
of major nonferrous primary metal producers.
Since 1970, about 40 percent of the copper industries' capital expendi-
tures have been for environmental control equipment. For lead and zinc pro-
ducers, this figure approaches 30 percent. Similar or greater expenditures
will be required through 1985, according to expected EPA implementations, if
nonferrous metal producers are to maintain compliance. Considering world
competition, the return on investment will shrink from about 12 percent to
about 7 percent, which will hardly attract investment needed to even maintain
the current industry, let alone provide for the expansion of the domestic
industry to meet domestic demand.
As an example of current trends that bode ill for the domestic nonfer-
rous metals industry, the supply elasticity for domestic copper is estimated
at +0.6 (i.e., a 1 percent increase in price effects a 0.6 percent increase
in supply) versus +1.2 for the rest of the free world. In a free-trade
structure, the domestic copper industry is becoming less competitive with the
rest of the free world, due in major part to U.S. environmental compliance
requirements that are not extant in other major copper-producing countries.
It would seem that the domestic nonferrous metals industries, which have
been impacted more severely than other major domestic industries by EPA regu-
lations, are doomed to wither with the net result that the U.S. will become
more and more dependent upon foreign supply for these necessary materials.
Recent trends in the copper and zinc industries may be mere harbingers of
things yet to come.
Reference: Bt ^ MacDonald and M. Weiss, Mining Congress Journal, 64 (1),
Jan. 1978, pp. 45-50.
160
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USEPA TECHNOLOGY AND TRENDS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Subject: Hot, Dirty SO,, Handled in Mild
Steel
Index
Page
15.3.2
3
The processing of sulfidic ore by Inco at Copper Cliff (Sudbury),
Ontario, presents a problem of handling the hot sulfur dioxide that is pro-
duced. Two gas streams, one containing 12 percent and the other 80 percent
sulfur dioxide, must be cleaned and processed into sulfuric acid and liquid
sulfur dioxide.
Three units used in the operations are described in detail. With the
temperature of the sulfur dioxide reaching over 2000 F in some parts of the
equipment, corrosion was a major problem. Although a number of alloys were
tried, refractory lined carbon steel remains the most cost effective. Other
alloys tested were Inconel 601, 801, and 814 and 316 and 430 stainless.
Although such materials are more corrosion resistant, they are more expensivej
and lined carbon-steel equipment is preferred for economic reasons.
Reference:
^m^IBMi^MIII^1^••—»—••»•^^W^"*™™""""'""'"^™^^^•""""""""^^^
C. F. Baxter, Canadian Chemical Processing, 6J. (12),
December, 1977, pp. 30-32.
161
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USEPA AWARENESS BULLETIN INDEX 15.3.8
1ECHMOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 1
SUBJECT- Solvent Extraction in Hydrometallurgy
Solvent extraction is today one of the most important processes in hydro-
metallurgy for the separation, purification, and concentration of metal ions.
This process is being used commercially for the production of vanadium,
tantalum/niobium, zirconium/hafnium, uranium, zinc, beryllium, tungsten,
copper, nickel, cobalt, and the rare earths. Developments nearing commercial
application include metals of the platinum group, molybdenum, and rhenium.
This recent review presents a summary of solvent extraction information,
primarily devoted to copper, with a lesser amount concerning uranium and the
other metals. A list of solvent extraction reagents is given with their uses;
copper plants and nickel and cobalt plants throughout the world using solvent
extraction are given. Schematic flowsheets of processes of solvent extraction
for copper sea nodules and for uranium are included.
Future developments in solvent extraction are inevitable, and its future
in hydrometallurgy is assured.
The use of solvent extraction hydrometallurgy will do much toward elimi-
nation of sulfur dioxide emissions which are inherent in many older pyrometal-
lurgical techniques.
REFERENCE: D. S. Flett, Chemistry and Industry (17), September 3, 1977,
pp. 706-712.
162
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USEPA AWARENESS BULLETIN
INDEX 15.3.8 (Ger.)
ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY PAGE 1
SMR.IFPT. The San Telmo Process, a Hydrometallurgical
Route for the Recovery of Copper and Zinc from
Complex Sulfide Ores"
The frequently observed weathering of sulfide minerals under ambient con-
ditions has led to a systematic investigation of their leaching behaviour.
From these tests, a process has evolved which is characterized by a cyclic
heap leaching operation with a controlled oxidation of pyrites containing cop-
per and zinc. Both metals are recovered from a closed leach liquor circuit by
solvent extraction with liquid organic ion exchangers and subsequent
electrowinning.
REFERENCE: M. J. Meixner, Erzmetall, 30 (5), May, 1977, pp. 204-208.
163
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USEPA TECHNOLOGY ANP TRENPS ABSTRACT
for the NONFERROUS METALS INDUSTRY
Index
Page
15.3.8
Subject: Chloride Metallurgy Developments Enabling
Treatment of Complex Zinc-Lead Sulphides
Large, mixed zinc-lead-copper sulfide ores in New Brunswick and else-
where in Canada do not respond well to selective flotation. CANMET has con-
ceptualized a chloride hydrometallurgy flow sheet for such ores, and has done
small-scale bench tests to verify certain unit operations. In this process,
typical bulk ores (30% Zn, 20% Fe, 4% Pb, 0.7% Cu, and 40% S) are chlorinated,
with elemental sulphur or SCI as a byproduct. The metal chlorides are roasted
to oxidize the iron to Fe203 and recover some chlorine for recycle. Solids
are water-leached to dissolve zinc and copper chlorides, and after liquid-
solid separation, the residue is brine-leached to remove
Zinc- and copper-bearing liquor is passed through staged
from copper, and, after stripping, the respective metals
barren liquors recycled to leaching or stripping stages.
brine leaching are crystallized (and/or LIX-treated, according to purity
demands), and electrowon.
the lead chloride.
LIX to separate zinc
are electrowon, with
Lead values from
This is conceived as essentially a closed process with the major water
and gas streams contained and recycled. In addition to zinc, lead, and copper
as coproducts, iron oxide and sulfur are visualized as byproducts. The waste
tailings, largely silicates, would contain typically 0.1% zinc and sulphur,
and 0.2% copper and lead, and should be environmentally acceptable.
The selection of corrosion-resistant materials, continued study of unit
operations, design of special equipment, environmental controls and processes,
and cost evaluations are included in the list of priorities in continuing the
development of this process by CANMET in Ottawa.
Reference: H. VI. Parsons and G. M. Ritceg, The Northern Miner, 63_ (37)
November 24, 1977, ,pp. D20-21.
164
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USEPA AWARENESS BULLETIN
INDEX 15.3/7.9
ECHNOLOGY $ 1R£NDS
IN THE NONFERROUS METALS INDUSTRY **^-J
SUBJECT: Humboldt Wedag's Cvclone-Furnace Smelting
Recovers Nonferrous Metals
Designed by Humboldt Wedag of Germany and the Metal Research Institute
of U.S.S.R. , a cyclone-furnace smelting process has-, been developed which,
for low capital investment and low operating cost, will recover metal from
low-grade nonferrous ores, oxide or sulfide concentrates, and slags and
residues.
The process is based on a compact, continuous operating cyclone-furnace
smelter, which can use any fuel or atmosphere and reaches 1200-1600 C in tem-
perature. High-vapor-pressure metals are volatilized as elemental metal or
as metal compounds and are collected in a baghouse for refining. Those
metals that cannot be vaporized are upgraded to a matte.
Two plants using this process are located in Bolivia. The first is
used to recover antimony at a yield exceeding 96 percent. The second plant
will be used to upgrade low tin content concentrates when operations begin
in 1979. Lead-bearing furnace slags and residues from zinc leaching can be
processed, in addition to the tin.
Current maximum throughput in furnaces of the Humboldt Wedag design is
about 300 tons per day, but this can be increased several times by using
parallel cyclone furnaces with only one waste gas system and electric furnace.
Waste gases pass to a baghouse or electrostatic precipitator or both to
recover the metal oxide dusts. The molten products are collected in a heated
settling furnace.
(Operating specifics and ancillary facilities are not described.)
REFERENCE: Engineering and Mining Journal, 178 (10), October, 1977, pp. 45, 49.
165
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USEPA TECHNOLOGY AMD TREN0S ABSTRACT Index 15.4.2
for the NONFERROUS METALS INDUSTRY Page 1
Subject: Processes to Refine Ocean Nodules Assessed
Although the cost of mining ocean nodules is still debatable, it is
believed that the costs associated with onshore processing will be about
twice those for mining. Two methods of processing are being assessed and
the decision is still open.
The Kennecott process reduces the ground nodules with carbon monoxide
at low temperature and pressure. An ammoniacal leach solubilizes the copper,
nickel, and cobalt, while the tailings contain the manganese. Liquid ion
exchange removes the copper and nickel; sulfide precipitation removes the
cobalt.
International Nickel's pyrometallurgical process dries the nodules
(not ground) in a rotary drier, then prereduces them with coal in a rotary
kiln, before smelting in an electric furnace. Manganese is concentrated in
the slag, copper, nickel, and cobalt in the matte. The matte is given a
hydrometallurgical treatment with ion exchange and electrowinning similar to
the Kennecott process. Gas from the dryer in the pyrometallurgical process
is cleaned with an electrostatic precipitator. Any sulfur dioxide produced
in drying is absorbed by the nodules, and is of no environmental concern.
For a 5000-ton-per-day nodule input, the capital cost required of the
pyrometallurgical process would be $400-500 million, with yearly operating
costs of $100-150 million, while the hydrometallurgical plant would cost
$70-120 million to operate yearly after a capital investment of $250-350
million.
Reference: Chemical and Engineering News, 56_ (12), March 20, 1978, pp. 22-23,
166
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USEPA AWARENESS BULLETIN
i ___ _____^ INDEX 15-6-6
ECHNOLOGY $ 1 RENDS
IN THE NONFERROUS METALS INDUSTRY RAGE ]
SIIR.IFPT. Recovery of Nonferrous Metals Using
Fluid Techniques
Colloidal suspension of magnetic particles in a fluid allows applied
magnetic fields to impart fluid characteristics best described as "apparent
density". This has held promise for use0in the field of heavy-media separa-
tion. Magnetite (FeoO^) particles, 100 A in diameter, when coated with a
surfactant such as oleic acid form a colloid in water, kerosene, or other
suitable fluids.
Hitachi of Japan has developed and demonstrated a system utilizing mag-
netic fluid separation of metal values from scrap automobiles. After mag-
netic separation to remove iron and steel, shredded automotive waste was pro-
cessed to recover 84 percent of the aluminum value at a purity of 95 percent,
all of the lead, 81 percent of the copper at 98 percent purity, and 94 percent
of the zinc at 90 percent purity.
The processing of discarded consumer products and even municipal wastes
through such a unit would separate valuable resources to allow economical
recycling as well as significantly lower the land burden of solid waste
disposal.
REFERENCE: S. Nogita, T. Ikeguchi, K. Muramori, S. Kazama, and H. Sakai,
Hitachi Review, 26 (4), April, 1977, pp. 139-144.
167
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
. REPORT NO.
EPA-600/2-79-092
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Annual Summary of Technical Awareness in the Nonferrous
Metals Industry
5. REPORT DATE
April 1979 issuing date
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
E. S. Bartlett and B. G. Koehl
Battelle's Columbus Laboratories
8. PERFORMING ORGANIZATION REPORT NO
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Battelle Columbus Laboratories
Columbus, Ohio 43201
10. PROGRAM ELEMENT NO.
1BB610, 1AB604
11. CONTRACT/GRANT NO.
R-805095-01
12. SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Lab-Cincinnati
Office of Research and Development
U. S. Environmental Protection Agency
Cincinnati, Ohio 45268
13. TYPE OF REPORT AND PERIOD COVERED
Final. 5/1/77 to 4/30/78
14. SPONSORING AGENCY CODE
600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The goal of this project was to pilot and refine methods and procedures
for maintaining current awareness of technology and commercial trends in the
U.S. nonferrous metal mining and manufacturing industry. The principal effort
resulted in the publication of six bimonthly technical awareness bulletins
during the first year. Items culled from the technical and trade literature
were presented as news notes, brief patent and foreign technology abstracts,
and, where the article content warranted, brief analytical summaries of per-
tinent technology. Examples of the product are appended.
This report was submitted in fulfillment of Grant No. R-805095-01 by
Battelle's Columbus Laboratories under the sponsorship of the U. S. Environ-
mental Protection Agency. The report covers the period from May 1, 1977, to
April 30, 1978.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Group
Air Pollution
Nonferrous Metals Pro-
duction
Primary Metals
Secondary Metals
S02 Trace Metals Hydro-
metallurgy
Water Pollution Control
68A
68D
7 IN
8. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
UNCLASSIFIED
21. NO. OF PAGES
174
20, SECURITY CLASS (This page)
UNCLASSIFIED
22. PRICE
EPA Form 2220-1 (Rev. 4-77) PREVIOUS EDITION is OBSOLETE 168
U. S. GOVERNMENT PRINTING OFFICE: 1979 - 657-060/532?
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