Lakshmanan / Roy / Ramachandran Innovative Process Development in Metallurgical Industry

Concept to Commission
1. Auflage 2016
ISBN: 978-3-319-21599-0
Verlag: Springer Nature Switzerland
Format: PDF
Kopierschutz: 1 - PDF Watermark

E-Book, Englisch, 447 Seiten

This book describes the phases for innovative metallurgical process development, from concept to commercialization. Key features of the book include:• Need for process innovation• Selection and optimization of process steps• Determination of the commercial feasibility of a process including engineering and equipment selection• Determination of the environmental footprint of a process• Case-study examples of innovative process development 

Dr. V.I. Lakshmanan is an internationally renowned teacher, scientist and innovator in the area of sustainable development. He has more than 40 years of hands-on experience in technology commercialization and skills development initiatives with both private and public sectors including the United Nations. He has successfully guided process technologies from concept through development and demonstration to commercialization for resource, energy and chemical industries. Dr. Lakshmanan is an Adjunct Professor within the Department of Materials Science and Engineering at the University of Toronto and is a member of several private and public sector advisory committees on natural resources, recycling technologies and waste management.
Dr. V. 'Ram' Ramachandran has over 39 years of experience in non-ferrous metal industry with emphasis on process development and process improvements including water conservation and treatment. He received Milton. E. Wadsworth Hydrometallurgy Award in 2001 and Distinguished Services Award in 2008.
Dr. Raja Roy has over 18 years of experience in minerals processing and metallurgical engineering with emphasis on process flowsheet development. He received Light Metals Recycling Award in 1998. He is currently Senior Project Manager at Process Research Ortech Inc. based in Mississauga, Ontario, Canada.

Autoren/Hrsg.

Lakshmanan, Vaikuntam Iyer

Roy, Raja

Ramachandran, V.

Inhaltsverzeichnis

1;Dedication;6
2;Foreword;8
3;Preface;10
4;Contents;12
5;About the Editors;16
6;About the Authors;18
7;1: The Need for Process Innovation;23
7.1;References;27
8;Part I: Separation Processes and Process Selection;28
8.1;2: Physical Processing: Innovations in Mineral Processing;29
8.1.1;2.1 Introduction;29
8.1.2;2.2 The Hard Truth About Mining and Processing;30
8.1.3;2.3 The Big Opportunities;31
8.1.4;2.4 Innovations in Mineral Processing;32
8.1.4.1;2.5.1 Quantitative Mineralogy;33
8.1.4.2;2.5.2 Quantitative Gold Deportment;33
8.1.4.3;2.5.3 Future of Process Mineralogy;34
8.1.4.4;2.5.4 Geometallurgy;34
8.1.5;2.6 Pre-concentration;35
8.1.5.1;2.6.1 Size Classification;35
8.1.5.2;2.6.2 Ore Sorting;35
8.1.5.3;2.6.3 Dense Media Separation;36
8.1.5.4;2.6.4 Coarse Particle Flotation;37
8.1.6;2.7 Comminution and Classification;38
8.1.6.1;2.7.1 The Bond Work Index;38
8.1.6.2;2.7.2 Selection and Design of Comminution Circuits;38
8.1.6.3;2.7.4.1 Gyratory Crushers;40
8.1.6.4;2.7.4.2 Cone Crushers;40
8.1.6.5;2.7.4.3 SELFRAG Technology;40
8.1.6.6;2.7.4.4 IMP Super Fine Crusher Technology;41
8.1.6.7;2.7.4.5 High Pressure Grinding Rolls;41
8.1.6.8;2.7.5.1 Autogenous Milling;42
8.1.6.9;2.7.5.2 Semi-Autogenous Milling;42
8.1.6.10;2.7.5.3 Comparison of SAG and HPGR;43
8.1.6.11;2.7.6.1 IsaMills™;44
8.1.6.12;2.7.6.2 Stirred Mills (VertiMills® and Detritors);44
8.1.6.13;2.7.8.1 Derrick Stack Sizer®;46
8.1.6.14;2.7.8.2 Cavex Recyclone®;46
8.1.7;2.8 Froth Flotation;47
8.1.7.1;2.8.1.1 Flash Flotation;48
8.1.7.2;2.8.1.2 Operation of Large Mechanical Flotation Cells;48
8.1.7.3;2.8.2.1 Column Cells;50
8.1.7.4;2.8.2.2 Microcel™;50
8.1.7.5;2.8.2.3 CavTube™;51
8.1.7.6;2.8.2.4 Imhoflot™;51
8.1.7.7;2.8.2.5 Jameson Cell;52
8.1.7.8;2.8.2.6 The Woodgrove Staged Flotation Reactor;52
8.1.8;2.9 Physical Separation;56
8.1.8.1;2.9.1.1 Pulsed Devices;57
8.1.8.2;2.9.1.2 Flowing Film Separators;57
8.1.8.3;2.9.1.3 Fluidized Bed Separators;57
8.1.8.4;2.9.1.4 Enhanced Gravity Separators;58
8.1.8.5;2.9.1.5 Pneumatic Density Based Separations;60
8.1.8.6;2.9.3 Electrostatic Separation;61
8.1.9;2.10 Dewatering and Thickening;62
8.1.9.1;2.10.1 Flocculants;62
8.1.9.2;2.10.2 High Capacity Thickeners;62
8.1.9.3;2.10.3 High Density and Deep Cone Thickeners;63
8.1.9.4;2.10.4 Thickener Feed Dilution;63
8.1.9.5;2.10.5 Thickener Drives;63
8.1.9.6;2.10.6 Filter Media;64
8.1.10;2.11 Tailings Retreatment and Water Quality;64
8.1.10.1;2.11.1 Seawater Processing;65
8.1.11;2.12 Automation, Control, and Integration;66
8.1.11.1;2.12.2.1 On-Stream Analysis;67
8.1.11.2;2.12.2.2 Split Online Fragmentation Analysis;67
8.1.11.3;2.12.2.3 Slurry Flow Meters and Density Gauges;68
8.1.11.4;2.12.2.4 Online Monitoring of Mineralogy and Assays;68
8.1.11.5;2.12.5 4D-BIM (Building Information Model);73
8.1.12;2.13 Shifting Paradigm in Mining and Processing;75
8.1.13;References;78
8.2;3: Thermal Processing: Pyrometallurgy—Non-ferrous;86
8.2.1;3.1 Epilogue;93
8.2.2;References;94
8.3;4: Thermal Processing: Pyrometallurgy—Ferrous;96
8.3.1;4.1 Introduction;96
8.3.2;4.2 The Early Years;96
8.3.3;4.3 Steelmaking with the Oxygen Top Blown Converter;97
8.3.3.1;4.3.1 Evolution of Oxygen Top Blown LD Converter Steelmaking;97
8.3.3.2;4.3.2 Transfer of the LD Steelmaking Process to Japan;97
8.3.3.3;4.3.3 Development of the LD Steelmaking Process Within Japan;98
8.3.3.4;4.3.4 Maturation of the LD Process for High Productivity;99
8.3.4;4.4 Steelmaking with Bottom Blown and Mixed Blown Converters;100
8.3.4.1;4.4.1 Birth of the Bottom Blown Converter, OBM/Q-BOP;100
8.3.4.2;4.4.2 Blowing Characteristics of the Q-BOP;101
8.3.4.3;4.4.3 Development of Mixed Blowing Converters;104
8.3.4.4;4.4.4 Development of LDs with Bottom Injection of Inert Gases;105
8.3.4.5;4.4.5 Utilization of Mixed Blowing BOFs for Scrap Melting and Smelting Reduction;106
8.3.5;4.5 Future of Technological Innovation in the Steel Industry;107
8.3.6;4.6 Concluding Comments;107
8.3.7;References;108
8.4;5: Chemical Processing: Hydrometallurgy;110
8.4.1;5.1 Introduction;110
8.4.2;5.2 Leaching;111
8.4.2.1;5.2.1 Atmospheric Leaching;111
8.4.2.2;5.2.2 Pressure Leaching;111
8.4.2.3;5.2.3 Heap Leaching;112
8.4.3;5.3 Separation Processes;113
8.4.3.1;5.3.1 Solvent Extraction;113
8.4.3.1.1;5.3.1.1 Cobalt and Nickel Separation;113
8.4.3.1.2;5.3.1.2 Copper Separation;115
8.4.3.1.3;5.3.1.3 Zinc Separation;116
8.4.3.1.4;5.3.1.4 Titanium, Niobium, and Tantalum Separation;116
8.4.3.1.5;5.3.1.5 Rare-Earths Separation;117
8.4.3.1.6;5.3.1.6 Palladium and Platinum Separation;117
8.4.3.2;5.3.2 Ion Exchange Technology;118
8.4.4;5.4 Metal Recovery;119
8.4.4.1;5.4.1 Precipitation;119
8.4.4.2;5.4.2 Electrowinning;120
8.4.5;5.5 Summary;121
8.4.6;References;126
8.5;6: Biological Processing: Biological Processing of Sulfidic Ores and Concentrates—Integrating Innovations;128
8.5.1;6.1 Introduction;128
8.5.2;6.2 The Microbiology and Chemistry of Biological Processing;129
8.5.2.1;6.2.1 Microbiology;129
8.5.2.2;6.2.2 Chemistry of Biological Processing;133
8.5.2.2.1;6.2.2.1 Oxidation of Sulfide Minerals by Microbially Produced Ferric Iron;133
8.5.2.2.2;6.2.2.2 Microbial Attachment of Mineral and Biofilm Formation;135
8.5.3;6.3 Evolutionary and Revolutionary Developments in Commercial-Scale Biological Processing of Sulfide Ores and Concentrates;135
8.5.3.1;6.3.1 Early Practices and Developments in Dump (Stockpile) Bioleaching of ROM Copper Ores;135
8.5.3.2;6.3.2 Innovations in Heap Bioleaching/Biooxidation of Coarsely Crushed Sulfide Ores;137
8.5.3.2.1;6.3.2.1 Copper Sulfide Heap Bioleaching;137
8.5.3.2.2;6.3.2.2 ROM and Crushed Ore Heap Bioleaching of Low-Grade Primary Copper Ores—An Imperative Emerging Technology;140
8.5.3.2.3;6.3.2.3 Heap Bioleaching of Other Metal Sulfides;143
8.5.3.2.4;6.3.2.4 Heap Biooxidation Pretreatment of Sulfide-­Refractory Gold Ores;143
8.5.3.3;6.3.3 Biological Processing of Sulfidic Ores in Vats;144
8.5.3.4;6.3.4 Stirred-Tank Biological Processing of Sulfide Concentrates;144
8.5.4;6.4 Reductive Mineral Dissolution by Biological Processing—An Emerging Process?;147
8.5.5;6.5 Motivations for Commercial Use of Biological Processes and Closing Considerations;148
8.5.6;References;150
8.6;7: Process Compression;155
8.6.1;7.1 Introduction;155
8.6.2;7.2 Carbon-in-Pulp (CIP) Process;155
8.6.3;7.3 Resin-in-Pulp (RIP) Process;155
8.6.4;7.4 Heap Leaching;157
8.6.5;7.5 In-Situ Leaching;159
8.6.6;7.6 Mixer-Settler Equipment;160
8.6.7;References;162
8.7;8: Process Selection;163
8.7.1;8.1 Introduction;163
8.7.2;8.2 Methodology;164
8.7.3;8.3 Methodology Application;164
8.7.3.1;8.3.1 Methodology Application: Flyash and Its Utilization;164
8.7.4;8.4 Vanadium Recovery from Flyash: Process Options;165
8.7.4.1;8.4.1 Description of Process Options;166
8.7.4.1.1;8.4.1.1 Process Option #1: Concentrated Sulfuric Acid Leaching;166
8.7.4.1.2;8.4.1.2 Process Option #2: Concentrated Caustic Soda Leaching;166
8.7.4.1.3;8.4.1.3 Process Option #3: Salt Roasting Followed by Dilute Alkali or Water Leaching;170
8.7.4.1.4;8.4.1.4 Process Option #4: Preconditioning Followed by Carbon Removal and Pressure Leaching with Dilute NaOH;171
8.7.4.1.5;8.4.1.5 Process Option #5: Pyrometallurgical Process for Vanadium Recovery as Fe-V Alloy from Flyash;171
8.7.5;8.5 Process Option Analysis;172
8.7.5.1;8.5.1 Assumptions and Scoring Scale for Performance Aspects;172
8.7.5.1.1;8.5.1.1 PA1: Technical;172
8.7.5.1.1.1;PA1.1: Functionality/Reliability;172
8.7.5.1.1.2;PA1.2: Technology Maturity;174
8.7.5.1.1.3;PA1.3: Design Life;174
8.7.5.1.1.4;PA1.4: Operational;174
8.7.5.1.2;8.5.1.2 PA2: Financial;174
8.7.5.1.2.1;PA2.1: Payout Period;174
8.7.5.1.2.2;PA2.2: Life-Cycle Cost;174
8.7.5.1.3;8.5.1.3 PA3: Regulator/Health and Safety;175
8.7.5.1.3.1;PA3.1: Regulator Acceptance;175
8.7.5.1.4;8.5.1.4 PA4: Timelines;176
8.7.5.2;8.5.2 Overall Analysis: Ranking of Process Option;176
8.7.6;8.6 Path Forward: Next Stage 2 Process Selection Analysis and Implementation;177
8.7.7;8.7 Summary;178
8.7.8;References;178
8.8;9: Metallurgical Processing Innovations: Intellectual Property Perspectives and Management;180
8.8.1;9.1 Introduction;180
8.8.2;9.2 Importance of Innovation to Metallurgical Processing;181
8.8.2.1;9.2.1 The Innovation Imperative;181
8.8.3;9.3 Sources of Innovation in Metallurgical Processing, R&D/Technology/Innovation Continuum and the Role of Intellectual Property;183
8.8.3.1;9.3.1 Sources of Innovation;183
8.8.3.2;9.3.2 R&D, Technology, and Innovation in Metallurgical Processing;183
8.8.3.3;9.3.3 Intellectual Property in Metallurgical Processing;185
8.8.3.4;9.3.4 Competitive Advantages of Innovation and Intellectual Property;185
8.8.4;9.4 Overcoming Barriers to Intellectual Property Development and Technology Implementation in Metallurgical Processing;186
8.8.4.1;9.4.1 Barriers to Metallurgical Processing Innovation and Intellectual Property Development;186
8.8.4.2;9.4.2 Overcoming Intellectual Property and Innovation Roadblocks in Metallurgical Processing;188
8.8.5;9.5 The Future of Metallurgical Processing: Innovation and Intellectual Property;190
8.8.6;References;192
9;Part II: Process Development;194
9.1;10: Conceptual Idea, Test Work, Design, Commissioning, and Troubleshooting;195
9.1.1;10.1 Conceptual Idea and Experiments;195
9.1.1.1;10.1.1 Objectives and Examples;195
9.1.1.1.1;10.1.1.1 Enhancing Safety and Health of Operating or Maintenance Personnel;195
9.1.1.1.2;10.1.1.2 Reducing Environmental Impact;195
9.1.1.1.3;10.1.1.3 Improving Extraction Efficiencies;195
9.1.1.1.4;10.1.1.4 Reducing Capital and Operating Costs;196
9.1.1.1.5;10.1.1.5 Generating a New Product;196
9.1.1.1.6;10.1.1.6 Recovering a New By-Product;196
9.1.1.1.7;10.1.1.7 Enhancing Product Purity;196
9.1.1.2;10.1.2 Literature and Patent Search and Assessment;196
9.1.1.2.1;10.1.2.1 Determine Whether or Not the Idea Has Been Previously Proposed;196
9.1.1.2.2;10.1.2.2 Locate and Assess Any Previous Patents or Patent Applications;197
9.1.1.2.3;10.1.2.3 Evaluate the Results of Any Previous Published Test Work;197
9.1.1.2.4;10.1.2.4 Evaluate Strengths, Weaknesses, Opportunities, and Threats for the Proposed Idea;197
9.1.2;10.2 Scoping and Laboratory Scale Test Work;197
9.1.2.1;10.2.1 Scoping Test Work and Desk Top Study;197
9.1.2.1.1;10.2.1.1 Case History: Development of Selective Copper SX Extractants (Kordoski 2002);197
9.1.2.2;10.2.2 Laboratory Scale Test Work;198
9.1.2.2.1;10.2.2.1 Steps in Process Development;199
9.1.2.2.2;10.2.2.2 Laboratory Scale Test Work;199
9.1.2.2.3;10.2.2.3 Technical and Economic Study of a New Process;199
9.1.2.2.4;10.2.2.4 Batch Tests;201
9.1.2.2.5;10.2.2.5 Continuous Leach Tests;201
9.1.2.2.6;10.2.2.6 Batch and Continuous Laboratory Purification Tests;202
9.1.2.2.7;10.2.2.7 Process Simulation Model;203
9.1.2.2.8;10.2.2.8 Data for Patent Application;203
9.1.3;10.3 Pilot Scale Test Work;203
9.1.3.1;10.3.1 Pilot Plant Testing: Continuous Leach and Purification: (Ramachandran and Cardenas 1983);204
9.1.3.2;10.3.2 Results of Continuous Pilot Plant Leach Tests;204
9.1.3.3;10.3.3 Additional Leach Operating Data;205
9.1.3.4;10.3.4 Neutral Leach Slurry Thickener Data;205
9.1.3.5;10.3.5 Settling and Filtration of Washed Leach Residue;205
9.1.3.6;10.3.6 Results of Continuous Purification Pilot Plant Tests;205
9.1.3.7;10.3.7 Chemical Analytical Support for Pilot Plant Operations;206
9.1.4;10.4 Data Collection for Design of Full-Scale Plant;206
9.1.4.1;10.4.1 Specification of Test Program;206
9.1.4.2;10.4.2 Design of Pilot Plant;207
9.1.4.3;10.4.3 Collection and Monitoring of the In-Process Conditions;207
9.1.4.4;10.4.4 Sampling and Analyses of Process Streams;207
9.1.4.5;10.4.5 Process Model;207
9.1.4.6;10.4.6 Identification and Assessment of Environmental Impact;208
9.1.4.7;10.4.7 Corrosion and Erosion Studies for Selection of Materials of Construction;208
9.1.4.8;10.4.8 Additional Data Collection for Design of a Full-Scale Plant;209
9.1.4.9;10.4.9 Variables for the Continuous Leach Tests;209
9.1.4.10;10.4.10 Variables for the Continuous Purification Tests;209
9.1.4.11;10.4.11 Summary;209
9.1.5;10.5 Commissioning and Trouble Shooting;211
9.1.5.1;10.5.1 Start-Up Organization (Harmsen 2013);211
9.1.5.2;10.5.2 Start-Up Preparation;211
9.1.5.2.1;10.5.2.1 Commissioning;212
9.1.5.2.1.1;Commissioning Team;213
9.1.5.2.1.2;Completion and Hand-Over;213
9.1.5.2.2;10.5.2.2 Trouble Shooting;213
9.1.5.3;10.5.3 Post Start-up Report;213
9.1.5.4;10.5.4 Commissioning and Trouble Shooting of Modernization of an Existing Electrolytic Zinc Plant;214
9.1.5.5;10.5.5 Summary;215
9.1.6;References;215
10;Part III: Process Optimization;216
10.1;11: An Integrated Mining and Metallurgical Enterprise Enabling Continuous Process Optimization;217
10.1.1;11.1 Introduction;217
10.1.1.1;11.1.1 Challenges;217
10.1.1.2;11.1.2 Opportunities;218
10.1.1.2.1;11.1.2.1 Informed and Timely Decision Making;218
10.1.1.2.2;11.1.2.2 Cost Optimization;218
10.1.1.2.3;11.1.2.3 Asset Optimization;218
10.1.1.2.4;11.1.2.4 Energy Savings;218
10.1.1.3;11.1.3 The Way Forward;219
10.1.2;11.2 The Integrated Metallurgical Enterprise;220
10.1.2.1;11.2.1 Optimization Goals;220
10.1.2.2;11.2.2 Optimization Philosophy: Optimization of the Parts vs. Optimization of the Whole;221
10.1.2.3;11.2.3 Five-Layer Architecture for an Integrated Mining Enterprise;221
10.1.2.3.1;11.2.3.1 Logical Layer 1: Raw Data Collection and Smart Monitoring (Examples);223
10.1.2.3.1.1;Using Radio and Smart Tags for Ore Tracking;223
10.1.2.3.1.2;Fragmentation Analysis;223
10.1.2.3.1.3;Using Piezo Electric Sensor Array for Slurry Flow Meters and Density Gauges;224
10.1.2.3.1.4;Using Light and Chemometrics for Online Monitoring of Mineralogy and Assays;224
10.1.2.3.2;11.2.3.2 Logical Layer 2: Improved Control and Data Analysis;224
10.1.2.3.2.1;Supervisory Control Hierarchy;224
10.1.2.3.2.2;Kiln Alternative Fuels Optimization: Case Study;227
10.1.2.3.2.3;Process Historian;227
10.1.2.3.3;11.2.3.3 Logical Layer 3: Integrated Information;227
10.1.2.3.3.1;Mining Example: Mine-to-Mill Integration: Optimization of Blasting Costs vs. Milling Costs;227
10.1.2.3.3.2;Integrated Operations Support and Quality Production Reporting;228
10.1.2.3.4;11.2.3.4 Layer 4: Automated Workflows;229
10.1.2.3.4.1;Plant to Enterprise Integrated Workflows;229
10.1.2.3.5;11.2.3.5 Logical Layer 5: Collaboration Layer;234
10.1.2.3.5.1;Collaboration: Cement Industry Case Study;234
10.1.2.3.5.2;Proactive Collaboration: Asset Performance Management Example;235
10.1.2.3.5.3;Active Criticality Analysis for Assessment of Future Risks;237
10.1.2.3.5.4;Metrics Hierarchy;237
10.1.2.3.5.5;Optimization of Reactive and Proactive Interventions;238
10.1.3;11.3 Technology Enablers;241
10.1.3.1;11.3.1 Introduction;241
10.1.3.2;11.3.2 Unified Object Model;241
10.1.3.3;11.3.3 Field Device Configuration Technologies;242
10.1.3.3.1;11.3.3.1 FDT/DTM;242
10.1.3.3.2;11.3.3.2 EDDL;243
10.1.3.3.3;11.3.3.3 FDI;243
10.1.3.4;11.3.4 Field Device Networks;243
10.1.3.4.1;11.3.4.1 Fieldbus;243
10.1.3.4.1.1;FOUNDATION Fieldbus;243
10.1.3.4.1.2;HART;243
10.1.3.4.2;11.3.4.2 PROFIBUS;244
10.1.3.5;11.3.5 Field Data Access Standard: OPC;244
10.1.3.5.1;11.3.5.1 OPC DA;244
10.1.3.5.2;11.3.5.2 OPC AE;245
10.1.3.5.3;11.3.5.3 OPC HDA;245
10.1.3.5.4;11.3.5.4 OPC UA;245
10.1.3.6;11.3.6 Interoperability Standard—XML;246
10.1.3.7;11.3.7 Web and Next Generation Internet Technologies;246
10.1.3.7.1;11.3.7.1 HTML/HTTP;246
10.1.3.7.2;11.3.7.2 Web Services;247
10.1.3.7.3;11.3.7.3 The Industrial Internet of Things;247
10.1.3.7.4;11.3.7.4 Control Networks and ISO/IEC 14908-Based Systems;248
10.1.4;11.4 Implementing an Integrated Enterprise Strategy;249
10.1.4.1;11.4.1 Five Key Steps to Integrated Operations;249
10.1.4.1.1;11.4.1.1 Step 1: Identify Key Value Drivers and KPIs;249
10.1.4.1.2;11.4.1.2 Step 2: Measure the Key Value Drivers;250
10.1.4.1.3;11.4.1.3 Step 3: Monitoring of the Value Drivers;250
10.1.4.1.4;11.4.1.4 Step 4: Control;251
10.1.4.1.5;11.4.1.5 Step 5: Optimization;252
10.1.5;11.5 Concluding Remarks;252
10.1.6;References;252
10.1.6.1;11.5.1 Further Reading;253
11;Part IV: Equipment;257
11.1;12: Equipment Development, Design, and Optimization;258
11.1.1;12.1 Challenging the Status Quo;258
11.1.2;12.2 Staying Ahead;258
11.1.3;12.3 Degrees of Innovation;258
11.1.4;12.4 Developmental Steps;259
11.1.5;12.5 Sources of Innovation;260
11.1.6;12.6 Relax;260
11.1.7;12.7 Persistence;260
11.1.8;12.8 Optimization;261
11.1.9;12.9 Intellectual Property (IP);261
11.1.10;12.10 Recognize Individuals;261
11.1.10.1;12.11 Case Studies in Equipment Design and Development;261
11.1.10.2;12.11.1 Mineral Processing;261
11.1.10.3;12.11.2 Hydrometallurgy;263
11.1.11;12.12 Conclusion;267
11.1.12;References;267
12;Part V: Sustainable Development and Environmental Management;268
12.1;13: Sustainability Considerations in Innovative Process Development;269
12.1.1;13.1 Introduction;269
12.1.1.1;13.1.1 Is Mining Sustainable and What Are Sustainable Mining Practices?;270
12.1.1.2;13.1.2 Importance of Environmental Management and Environmental Management Systems;272
12.1.1.3;13.1.3 Regulatory Context: Applicable Environmental Laws and Regulations;272
12.1.1.3.1;13.1.3.1 Clean Air Act of 1970 and 1990 Amendments;272
12.1.1.3.2;13.1.3.2 The Federal Water Pollution Act of 1972 (aka the Clean Water Act);273
12.1.1.3.3;13.1.3.3 The Resource Conservation and Recovery Act;274
12.1.1.4;13.1.4 Regulatory Context: Applicable Health and Safety Regulations;275
12.1.1.5;13.1.5 Implication for Process Development;276
12.1.2;13.2 Opportunities for Resource Conservation;276
12.1.3;13.3 Opportunities for Energy Conservation;277
12.1.3.1;13.3.1 Energy Use in Copper Smelting Processes;278
12.1.3.2;13.3.2 Challenges and Opportunities Associated with Waste Heat Recovery from Copper Smelting Processes;279
12.1.3.3;13.3.3 Opportunities for Cogeneration;282
12.1.3.4;13.3.4 Opportunities for Utilization of Renewable Energy;282
12.1.4;13.4 Opportunities for Water Conservation;283
12.1.5;13.5 Effluent Management;285
12.1.6;13.6 Solid and Hazardous Waste Management;286
12.1.7;13.7 Control of Gaseous and Particulate Emissions;287
12.1.8;13.8 Industrial Hygiene and Safety;288
12.1.8.1;13.9 Case Study: Kennecott-­Outotec Flash Converting;288
12.1.9;13.10 Checklists;289
12.1.9.1;13.10.1 Conceptual Stage;289
12.1.9.2;13.10.2 Bench-Scale Testing;289
12.1.9.3;13.10.3 Pilot Plant Testing;289
12.1.9.4;13.10.4 Commercial Demonstration;290
12.1.9.5;13.10.5 Commercial Operation;290
12.1.9.6;13.10.6 Impact on Upstream Operations;290
12.1.9.7;13.10.7 Impact on Downstream Operations;290
12.1.9.8;13.10.8 Use;290
12.1.9.9;13.10.9 Ultimate Disposal;290
12.1.10;References;291
13;Part VI: Steps to Commercialization;293
13.1;14: Process Development, Execution, Owner’s Responsibility, and Examples of Innovative Developments;294
13.1.1;14.1 Process Development;294
13.1.1.1;14.1.1 Flowsheet Development;294
13.1.1.1.1;14.1.1.1 Initial Conceptualization;295
13.1.1.1.2;14.1.1.2 Bench-Scale Test Work;296
13.1.1.1.2.1;Scoping Study;296
13.1.1.1.2.2;Detailed Bench-Scale Test Work;297
13.1.1.1.3;14.1.1.3 Pilot Plant Test Work;297
13.1.1.1.4;14.1.1.4 Demonstration Plant;298
13.1.1.2;14.1.2 Technical Evaluation;299
13.1.1.2.1;14.1.2.1 Conceptual/Scoping Study;299
13.1.1.2.2;14.1.2.2 Prefeasibility Study;300
13.1.1.2.3;14.1.2.3 Definitive Feasibility Study;302
13.1.1.3;14.1.3 Capital and Operating Cost Estimation;304
13.1.1.3.1;14.1.3.1 Estimating methods:;305
13.1.1.3.2;14.1.3.2 Updating Estimates;305
13.1.1.3.3;14.1.3.3 Sources of Cost Information;306
13.1.1.3.3.1;Order of Magnitude Cost Estimate;306
13.1.1.3.3.2;Estimate of Operating Cost;307
13.1.2;14.2 Project Execution;308
13.1.2.1;14.2.1 Basic Engineering (Feasibility Engineering);308
13.1.2.2;14.2.2 Detailed Engineering and Procurement;309
13.1.2.3;14.2.3 Construction;309
13.1.2.4;14.2.4 Commissioning and Start-up;310
13.1.3;14.3 Owner’s Responsibilities;310
13.1.3.1;14.3.1 Owner’s Team;310
13.1.3.2;14.3.2 Staffing of Operating and Maintenance Personnel;310
13.1.3.3;14.3.3 Training of Operating and Maintenance Personnel;310
13.1.3.4;14.3.4 Ramp-up;311
13.1.4;14.4 Examples of Innovative Developments;311
13.1.4.1;14.4.1 Copper Solvent Extraction;311
13.1.4.2;14.4.2 Alternatives to Solid–Liquid Separation;311
13.1.5;14.5 Summary;312
13.1.6;Reference;313
14;Part VII: Financing;314
14.1;15: Investing, Financing and Harvesting Innovation and Technology;315
14.1.1;15.1 Self-Financing/Friends and Family;315
14.1.2;15.2 University/State Research Facilities/State Research Grants and Funding;316
14.1.3;15.3 Corporate-Funded Private Research: Internal/External;316
14.1.4;15.4 Public and Private Company Financings;316
14.1.4.1;15.4.1 Equity Financing;316
14.1.4.1.1;15.4.1.1 Sources of Equity Financing;317
14.1.4.2;15.4.2 Debt Financing;317
14.1.4.3;15.4.3 Debentures;317
14.1.4.3.1;15.4.3.1 Convertible Debenture;317
14.1.4.3.2;15.4.3.2 Nonconvertible Debentures;317
14.1.4.4;15.4.4 Bonds;318
14.1.5;15.5 Strategic Partnerships (Joint Venture);318
14.1.6;15.6 Crowdfunding;318
14.1.6.1;15.6.1 Donation;318
14.1.6.2;15.6.2 Lending;318
14.1.6.2.1;15.6.2.1 Presales;318
14.1.6.2.2;15.6.2.2 Traditional Loan;318
14.1.6.2.3;15.6.2.3 Forgivable Loan;318
14.1.6.3;15.6.3 Investment;319
14.1.7;15.7 Streaming Financing;319
14.1.8;15.8 Royalty Financing;319
14.1.9;15.9 Licensing Fee Financing;319
14.1.9.1;15.9.1 Types of Licensing Fee Agreements;319
14.1.9.2;15.9.2 Exclusive and Nonexclusive Licensing Fee Agreements;319
15;Part VIII: Case Study Examples;321
15.1;16: Innovative Case Study Processes in Extractive Metallurgy;322
15.1.1;16.1 Copper: (Partelpog 2014);322
15.1.1.1;16.1.1 Pyrometallurgy;322
15.1.1.2;16.1.2 Flash Smelting;323
15.1.2;16.2 Converting of Copper Matte;325
15.1.3;16.3 Copper;327
15.1.3.1;16.3.1 Hydrometallurgy and Electrometallurgy: (Hiskey 2014);327
15.1.3.1.1;16.3.1.1 Heap and Stockpile Leaching;327
15.1.4; Ore Stacking;327
15.1.5; Acid Cure and Agglomeration;328
15.1.6; Drip Irrigation;328
15.1.7;16.3.2 Copper Electrowinning and Electrorefining;328
15.1.8;16.3.3 Hydrometallurgy of Copper Concentrates;328
15.1.9;16.4 Process Metallurgy of Lead: Pyro, Hydro, and Electrometallurgy;329
15.1.9.1;16.4.1 Pyrometallurgy;329
15.1.10;16.4.2 Hydrometallurgy;329
15.1.11;16.4.3 Electrometallurgy;329
15.1.12;16.5 Process Metallurgy of Zinc: Pyro, Hydro, and Electrometallurgy: (Robinson and Anderson 2014);330
15.1.12.1;16.5.1 Pyrometallurgy;330
15.1.13;16.5.2 Hydrometallurgy;330
15.1.14;16.5.3 Electrorefining;331
15.1.15;16.6 Innovations in the Process Metallurgy of Other Metals;331
15.1.16;16.7 Chloride-Based Chemistry;331
15.1.17;16.8 Ammonia Leaching;332
15.1.18;16.9 Process “Intensification” in Process Metallurgy;332
15.1.19;16.10 Innovative Ideas for Solution of Environmental Issues;332
15.1.20;16.11 Summary;333
15.1.21;References;333
15.2;17: Development of a New Technology for Converting Iron-Bearing Materials to Nodular Reduced Iron for Use in Various Steelmaking Operations;335
15.2.1;17.1 Introduction;335
15.2.2;17.2 Background;336
15.2.2.1;17.2.1 The Scientific and Technical Merit of the Technology;336
15.2.2.2;17.2.2 Innovation, Originality, and Feasibility of the Technology;338
15.2.2.2.1;17.2.2.1 Linear Hearth Furnace Design Considerations;338
15.2.2.2.2;17.2.2.2 Oxygen-Fuel Combustion Systems;339
15.2.2.2.3;17.2.2.3 Oxygen-Biomass Combustion;339
15.2.2.3;17.2.3 Potential Energy, Carbon Emissions Reduction, and Environmental Benefits;339
15.2.2.4;17.2.4 Previous Laboratory Development;340
15.2.2.4.1;17.2.4.1 Laboratory Tube Furnace Tests;340
15.2.2.4.2;17.2.4.2 Laboratory Box Furnace Tests;341
15.2.2.4.3;17.2.4.3 Findings from  Laboratory Tests;343
15.2.2.5;17.2.5 Linear Hearth Furnace;343
15.2.2.5.1;17.2.5.1 Description;343
15.2.3;17.3 Use of Alternative Fuels to Produce Nodular Reduced Iron Products;346
15.2.3.1;17.3.1 Development of an Alternative Biobased Reductant Through Torrefaction;346
15.2.3.2;17.3.2 Calciner/Torrefier Apparatus and Testing Conditions;347
15.2.3.3;17.3.3 LHF Application and Testing Conditions;347
15.2.4;17.4 Comparison of Operating Results with Different Fuels and Reductants;349
15.2.4.1;17.4.1 LHF Operation with Alternative Solid Fuel Combustion;349
15.2.4.2;17.4.2 Atmosphere Control Using Late Stage Bio-char Addition;351
15.2.4.3;17.4.3 Bio-char as a Reductant;353
15.2.4.3.1;17.4.3.1 100 % Bio-char Reductant;353
15.2.4.3.2;17.4.3.2 Bio-char and Coal Reductant Blends;354
15.2.4.3.3;17.4.3.3 Micro-Nodule Generation;355
15.2.5;17.5 Mass Balances on LHF Furnace Tests;356
15.2.6;17.6 Commercialization and Market Acceptance of Nodular Reduced Iron (NRI);361
15.2.6.1;17.6.1 Value in Use;361
15.2.6.2;17.6.2 Economic Analysis;361
15.2.6.3;17.6.3 Market Share;361
15.2.6.4;17.6.4 Barriers to Commercialization;362
15.2.7;17.7 Conclusions;362
15.2.8;17.8 Recommendations;362
15.2.9;17.9 Intellectual Property and Patents Relating to NRI Development;363
15.2.10;17.10 Glossary;364
15.2.10.1;17.10.1 Abbreviated Notation of Lime and Fluorspar in Slag;364
15.2.10.2;17.10.2 Atmosphere Control;364
15.2.10.3;17.10.3 Basicity;364
15.2.10.4;17.10.4 Bimodal Super Stoichiometry;364
15.2.10.5;17.10.5 Bio-char;364
15.2.10.6;17.10.6 Fusion Time;364
15.2.10.7;17.10.7 Micro-NRI;365
15.2.10.8;17.10.8 Stoichiometric Amount;365
15.2.10.9;17.10.9 Torrefaction;365
15.2.11;References;365
15.3;18: Innovative Process for the Production of Titanium Dioxide;367
15.3.1;18.1 Introduction;367
15.3.2;18.2 Raw Materials for Titanium Dioxide Production;368
15.3.3;18.3 Beneficiation and Upgrading of Ore;369
15.3.3.1;18.3.1 Beneficiation and Upgrading of Ilmenite Ore;369
15.3.3.2;18.3.2 Beneficiation and Upgrading of Natural Rutile;372
15.3.4;18.4 Current Processes for the Production of Titanium Dioxide;372
15.3.4.1;18.4.1 Overview;372
15.3.4.2;18.4.2 The Sulfate Process;373
15.3.4.2.1;18.4.2.1 Acid Digestion and Clarification;374
15.3.4.2.2;18.4.2.2 Crystallization;375
15.3.4.2.3;18.4.2.3 Precipitation and Purification;375
15.3.4.2.4;18.4.2.4 Doping, Calcination, and Grinding;375
15.3.4.3;18.4.3 The Chloride Process;375
15.3.4.3.1;18.4.3.1 Chlorination;375
15.3.4.3.2;18.4.3.2 Condensation of Gas and Purification of TiCl4;376
15.3.4.3.3;18.4.3.3 Oxidation of TiCl4 and Recovery of Titanium Dioxide;377
15.3.4.4;18.4.4 The CTL Process;377
15.3.4.4.1;18.4.4.1 Chloride Metallurgy;378
15.3.4.4.2;18.4.4.2 Leaching;378
15.3.4.4.3;18.4.4.3 Iron Solvent Extraction;379
15.3.4.4.4;18.4.4.4 Titanium Solvent Extraction;380
15.3.4.4.5;18.4.4.5 Precipitation;383
15.3.4.4.6;18.4.4.6 Calcination;383
15.3.4.4.7;18.4.4.7 Finishing;383
15.3.4.4.8;18.4.4.8 Product Quality;383
15.3.4.4.9;18.4.4.9 Bench-Scale Test Work;386
15.3.4.4.10;18.4.4.10 Pilot Scale Testwork;388
15.3.4.4.11;18.4.4.11 Scale-up of CTL Technology;389
15.3.5;18.5 Comparison of Titanium Dioxide Production Processes;389
15.3.6;18.6 Conclusion;389
15.3.7;References;389
15.4;19: Innovative Processes in Electrometallurgy;392
15.4.1;19.1 Introduction;392
15.4.2;19.2 Copper Electrorefining and Electrowinning;392
15.4.3;19.3 Electrolytic Lead Refining;394
15.4.4;19.4 Nickel Electrorefining and Electrowinning;395
15.4.5;19.5 Zinc Electrowinning;396
15.4.6;19.6 Zinc SXEW Process;398
15.4.7;19.7 Conclusions;399
15.4.8;References;399
15.5;20: Innovations in Gold and Silver Processing;400
15.5.1;20.1 Introduction;400
15.5.2;20.2 Ore Body Knowledge;402
15.5.2.1;20.2.1 Geometallurgy;402
15.5.2.2;20.2.2 Quantitative Gold Deportment for Complex Ore Bodies;402
15.5.3;20.3 Comminution and Classification;403
15.5.3.1;20.3.1 Crushing;404
15.5.3.2;20.3.2 HPGR;405
15.5.3.3;20.3.3 Mine to Mill;406
15.5.3.4;20.3.4 Selfrag;406
15.5.3.5;20.3.5 IMP Superfine Crusher Technology;407
15.5.3.6;20.3.6 Classification;407
15.5.3.6.1;20.3.6.1 Derrick Stack Sizer™;407
15.5.3.6.2;20.3.6.2 Cavex Recyclone™;407
15.5.4;20.4 Pre-concentration and Ore Beneficiation;407
15.5.4.1;20.4.1 Pre-concentration;407
15.5.4.1.1;20.4.1.1 Size Classification;408
15.5.4.1.2;20.4.1.2 Ore Sorting;408
15.5.4.1.3;20.4.1.3 Dense Media Separation;409
15.5.4.1.4;20.4.1.4 Coarse Particle Flotation;409
15.5.4.2;20.4.2 Gravity Separation;409
15.5.4.3;20.4.3 Flotation;411
15.5.4.4;20.4.4 Magnetic Separation;412
15.5.4.5;20.4.5 Electrostatic Separation;412
15.5.5;20.5 Cyanidation;413
15.5.5.1;20.5.1 Cyanide Leaching;413
15.5.5.2;20.5.2 Cyanide Detoxification;415
15.5.5.3;20.5.3 Cyanide Recovery;415
15.5.5.4;20.5.4 Cyanidation Treatment of Copper-Gold Ores;416
15.5.6;20.6 Oxidation Pretreatment;416
15.5.6.1;20.6.1 Roasting;417
15.5.6.1.1;20.6.1.1 Rotary Kiln and Multiple Hearths;417
15.5.6.1.2;20.6.1.2 Fluidized Bed;417
15.5.6.1.3;20.6.1.3 Circulating Fluidized Bed;417
15.5.6.1.4;20.6.1.4 Oxygenated Fluidized Bed;418
15.5.6.2;20.6.2 Pressure Oxidation;418
15.5.6.3;20.6.3 Bio-oxidation;422
15.5.6.4;20.6.4 Ultrafine Grinding;423
15.5.7;20.7 Heap Leaching;423
15.5.8;20.8 Barrick’s Thiosulfate Technology;425
15.5.9;20.9 Concluding Remarks;426
15.5.10;References;429
15.6;21: Innovative Processes for By-product Recovery and Its Applications;436
15.6.1;21.1 Vanadium from Fly Ash;437
15.6.2;21.2 Ammonium Sulfate By-product from Uranium Processing;437
15.6.3;21.3 Production of By-product Metals;437
15.6.4;21.4 Metals and Materials Used in Photovoltaic Energy Industry;439
15.6.5;21.5 Materials Used in Solar Industry (http://en.wikipedia.org/wiki/Solar_cell);439
15.6.6;21.6 Metals and Materials Used in Fuel Cell Industry;441
15.6.7;21.7 Use of By-product Metal Compounds in Polymer Industry;442
15.6.8;21.8 Summary;442
15.6.9;References;443
15.6.9.1;General Reference;443
15.7;22: Conclusion;444
15.7.1;Reference;445
16;Index;446