In this study the data taken from Outokumpu type Flash smelter of Eti-Bakir Plant (Samsun, Turkey) was used to write a computer program in Visual Basic with interface to Excel. Flash smelting is the pyrometallurgical process for smelting metal sulfide concentrates, used in Eti-Bakir plant. In this plant, copper flash smelting consists of blowing fine, dried copper sulfide concentrate mixtures, silica flux, lignite with air into the furnace and natural gas as main fuel. The molten matte is the principal product of the furnace and slag contains 0.5-2% Cu. It is sent to a slag treatment (flotation) process for Cu recovery. This flash furnace off-gas contains from 8-12 volume % SO2 which is fixed as H2SO4. Written program was used to optimize the consumption of oxygen enriched air, fuel and lignite in this Flash Smelter by making material and heat balance of the plant.

HudBay Minerals (formerly the Hudson Bay Mining and Smelting Co., Limited) has operated a Zn and Cu processing facility in Flin Flon, MB since the 1930’s. Located in the Boreal Shield, the area surrounding the mine complex has been severely impacted by both natural (forest fires) and the anthropogenic disturbance, which has adversely affected recovery of the local forest ecosystem. Zinc is one of the most prevalent smelter-derived metals in the soils and has been identified as a key factor limiting natural revegetation of the landscape. Because metal toxicity is related more to speciation than to total concentration, Zn speciation in soils from the impacted landscape was characterized using X-ray absorption fine structure, X-ray fluorescence mapping and µ-X-ray absorption near edge structure. Beginning with speciation at a micro-scale and transitioning to bulk speciation was able to determine Zn speciation and link it to two distinct landform characteristics: (1) soils stabilized by metal tolerant grass species—in which secondary adsorption species of Zn (i.e., sorbed to Mn and Si oxides, and as outer-sphere adsorbed Zn) were found to be more abundant; and (2) eroded, sparsely vegetated soils in mid to upper slope positions that were dominated almost entirely by smelter derived Zn minerals, specifically Franklinite (ZnFe2O4). The long-term effect of liming on pH and Zn speciation was examined using field sites limed by a community led organization over a ten year period. Upon liming to a pH of 4 to 4.5, the eroded, sparsely vegetated soils where found to form a Zn-Al-Hydroxy Interlayer Material (HIM) co-precipitate, reducing the phytotoxicity of both Zn and Al and allowed for boreal forest vegetation to recovery quickly in these areas. The grass stabilized soils experienced a steady pH increase, as compared to a sporadic pH increase in the heavily eroded soils, as the buffering capacity was overcome allowing for a transition between multiple adsorption species based upon the point of zero charge of reactive soil elements. Ultimately reaching a near neutral pH after ten years, this allowed for the formation of stable Zn-Al-layered double hydroxide (LDH) soil precipitates and significantly reduced concentrations of plant available Zn.

Thesis (MAppSc(Env&RecMgt))--University of South Australia, 1999

Western Mining Corporation produces nickel matte at the Kalgoorlie Nickel Smelter(KNS)from nickel sulphide concentrates within an integrated flash smelter.

La contamination en éléments traces métalliques (ETM) des sols constitue un problème environnemental majeur qui réside principalement dans le risque de leur transfert vers les eaux superficielles et souterraines et/ou vers la chaîne alimentaire. L’objectif principal de ce travail était de comprendre le comportement des ETM dans des sols impactés par une usine de recyclage de batteries au plomb localisée dans les Ardennes. Sur une zone de 17 ha environnant l’usine, la répartition spatiale des teneurs en ETM étudiée par fluorescence X portable a révélé que les sols étaient majoritairement impactés par Pb et dans une moindre mesure par Cd, Cu, Ni, Sb, Sn et Zn. Une méthode géostatistique a permis d’identifier l’origine industrielle ou lithogénique de la plupart des ETM précédemment cités. A partir de cette cartographie, de la nature des sols et du mode d’occupation, le comportement des ETM a été étudié le long de six profils pédologiques. Le calcul des coefficients de distribution a permis de mettre en évidence une mobilité importante des ETM liée au caractère acide des sols (pH 4-5). Quel que soit le profil étudié, Cd présentait la mobilité la plus élevée, suivi de Zn, Ni, Pb et Cu. Le couplage de méthode expérimentale (soil-column Donnan membrane technique) et de modélisation géochimique a permis de préciser que Cd, Ni et Zn étaient totalement sous forme libre, Pb majoritairement sous forme libre mais également associé aux acides fulviques et Cu principalement associé aux acides fulviques dans la solution du sol. La répartition de Pb dans la phase solide des horizons de surface a également été déterminée en combinant des méthodes chimiques (extractions séquentielles), des méthodes physiques (MEB-EDS, microspectrométrie Raman) et de la modélisation. Le plomb était majoritairement associé à la matière organique et, dans une moindre mesure, aux oxydes de manganèse. Aucune des phases cristallines riches en plomb potentiellement émises par ce type d’industrie n’a été identifiée, ce qui suggère que Pb a été redistribué dans les sols à partir de ces phases. Ce travail insiste sur l’importance de l’étude conjointe des sols et de leur solution pour mieux comprendre le comportement des ETM, évaluer les risques et proposer d’éventuelles solutions de remédiation. / The soil contamination by trace elements (TE) is a major environmental issue which mainly lies in their potential transfers from soils to surface and ground waters and/or to food chain.The main objective of this study was to understand the behaviour of TE in impacted soils located in the vicinity of a lead-acid battery recycling plant (Ardennes, France). In a 17 ha surrounding area, the spatial distribution of TE was performed using portable X-ray fluorescence. It indicated that the soils were mainly contaminated by Pb and, to a lesser degree, by Cd, Cu, Ni, Sb, Sn and Zn. A geostatistical approach enabled to discriminate the natural or anthropogenic sources of most of these TE.Based on the TE mapping, the soil type and the land cover, the behaviour of the TE was studied along six soil profiles. The calculated partition coefficients highlighted a high mobility of the TE which is related to the acidic soil conditions (pH 4-5). Regardless of the studied soil profile, Cd exhibited the highest mobility, followed by Zn, Ni, Pb and Cu. A combined experimental (soil-column Donnan membrane technique) and modelling approach helped to specify that Cd, Ni and Zn occurred as free ions, Pb mainly occurred as free ion and associated to fulvic acids and Cu was mainly associated to fulvic acids in the soil solutions. The distribution of Pb among the soil components of upper soil horizons was also determined using chemical methods (sequential extraction), physical methods (SEM-EDS, Raman microspectroscopy) and modelling. Lead was mainly associated with soil organic matter and to a lesser extent with manganese oxides. None of the Pb-bearing phases potentially emitted by the recycling plant were identified, suggesting a remobilization of Pb in the studied soils after smelter particles deposition. This work emphasizes the importance of studying the soil and its solution to better understand the behaviour of TE, to assess the environmental risks and to suggest remediation strategies.

The Kalplats platinum group metal deposit is located in the Northwestern Province of South Africa, 80 km southwest of Mafikeng, in the Stella Layered Intrusion. The Stella Layered Intrusion intruded into the Kraaipan Greenstone Belt and is dated at 3.03 billion years. The Kraaipan Greenstone Belt is host to the 80 000 ounce per annum Kalgold Gold Mine. Platinum Group Element mineralized layers in the Stella Layered Intrusion are interpreted to occur in the overturned western limb of folds, formed by an eastward vergent compressional event. Three major reefs have been identified, namely the Lower Grade (LG) reef, the Mid Reef and the Main Reef. High grade reefs occur within these three. The average Pt:Pd ratio of the Main Reef is 1:1. Highest total precious metals content is concentrated in the Upper Main and Lower Main Reefs and the average grade for these two reefs is 4g/t. Open pit mining is suggested. The total inferred precious metals resource equates to 84Mt at an average grade of 1.4 g/t Pt+Pd+Au, for 3.9million ounces. Platinum, palladium and gold occur as fine grains. Maximum recoveries of approximately 72% are possible, from sulphide ore, using a twostage mill-float circuit. The estimated reserve (non-JORC compliant) is 26 Mt at an average grade of 2.01g/t Pt+Pd+Au, for 1.68 million ounces. A financial evaluation was done on the viability of the Kalplats deposit, using a discounted cash flow model. Future projections used were a R/$ exchange rate of R6-50 to the dollar and long-term metals prices of US$ 800/oz Pt, US$ 200/oz Pd and US$ 400/oz Au. The result of the discounted cash flow model was negative and indicated no return on capital and a negative Nett Present Value (NPV) of –R206 million at a discount of 13%. Factors impacting negatively on the viability of the project, include grade, metallurgical recovery, smelter fees, government royalties, metals prices and the Rand-US$ exchange rate. / Dissertation (MSc (Geology))--University of Pretoria, 2008. / Geology / unrestricted

Thesis (MScEng) –Stellenbosch University, 2010 / ENGLISH ABSTRACT: More mining houses are turning their attention to the processing of ore mined from the UG2 reef. This is mainly due to the depletion of the Merensky reef or the low availability of ore from the Platreef. With the higher UG2 ore concentration in the process feed, companies experience more problems with the processing of the ore due to its high chrome content. Although there are various possible solutions to the problems experienced in the processing of UG2 ore, very little of thise solutions are actually implemented in the industry. When smelting chrome-bearing ore, the chrome can go to any of three phases: matte phase, spinel phase or glass phase. If it reports to the furnace matte phase it can lead to problems in the down stream processing. When chrome forms part of the spinel phase it forms a solid, refractory-like material which, to an extent, is an unwanted material inside the furnace. Lastly the chrome can report to the glass phase (liquid phase) which is the more desireable phase to which chrome should report to since it will have little or no impact on downstream processing. There were four main objectives for this research project namely to conduct a literature review to understand the problem of chrome in the smelting process, to do an experimental simulation of a matte and slag phase in one crucible, to interpret the experimental results and compare the experimental results to thermodynamic predictions obtained using FactSageTM. From literature the following aspects were found to be important: Silica structures Research has shown that silica incorporates different metal ions into its structures. When the metal ions are incorporated into the silica structures they are seen as part of the glass phase. By incorporating cations such as chromium into the silica structure the structure is able to maintain its neutral electrical charge. Basicity of slag Oxides once melted will either donate or accept oxide ions. The group of oxides that are in excess will determine whether that specific slag is acidic or non acidic. This is important to our study since the basicity can determine the stability of the spinel phase. Partial pressures The partial pressure of the system is important since it forms part of the equilibrium constant calculations - meaning that partial pressures determine the stability of certain species. Currently different arguments exist as to how the sulphur pressure inside a molten bath is maintained. What is important, however, is that for the system in this research project a log oxygen partial pressure of -8 and a log sulphur partial pressure of -3.5 was chosen. These values were based on previous research done on PGM and copper smelting processes. Chrome deportment Previous research on chrome deportment shows a relationship between temperature and the amount of chromium dissolving into the glass phase as well as an increased chromium(II)oxide solubility (when compared to chromium(III)oxide) in a silicate melt. Regarding slag chemistry and chrome deportment very little work has been published for the system found in the PGM industry but it is mentioned that by adjusting certain slag additives (alumina, lime and silica) the chrome deportment can be manipulated. The scope of this project was to investigate the effect of chromium, lime and silica on chrome deportment. More specifically, the effect of lime. The reason being that lime was originally added as 10%wt of the feed stream in the processing of Merensky ore to act as a fluxing agent. With the new furnace design and higher power densities the slag are maintained at 200oC to 350oC higher than when Merensky ore was smelted. With these higher slag temperatures fluxing agents will play a smaller role meaning that lime additions become less important. Literature studies also showed that additional lime in a slag system can stabilize the spinel structure (which is an unwanted phase). Removing lime would be advantageous out of a chrome presepective as well as an economic point of view. The research was conducted in three sections namely the determination of the time required for this particular system to reach equilibrium, the investigation of different additives on chrome deportment using a controlled atmosphere and synthetic slags and, lastly, a comparison of the experimental results obtained to thermodynamic predictions. For the equilibration studies reaction time periods of 4,7,11 and 16 hours were used. From the results it was found that the alumina crucible dissolved into the glass phase continually. This indicated that equilibrium was not reached. However, a reaction time, rather than an equilibrium time, was chosen where the species and phases had enough time to react. This was based on literature, on observations of species diffusing between the matte and slag phase as well as on two-point analysis (diffusion gradients). A reaction time of nine hours was chosen With the reaction time fixed, the effect of different slag additives on chrome deportment was investigated. For the addition of chrome it was seen that an 1.5%wt increase in the starting material increased the chrome content of the slag phase by 0.025%wt. For the same increase in chromium in the starting materials the chrome content of the spinel phase increased by 2.1% indicating that chromium has a tendency to report to the spinel phase. The increase in chromium had a minor effect on the chrome content of the matte phase, however, since the chrome content only increased from 0.025%wt to 0.028%wt. Plotting the results showed that increasing the lime in the starting material decreases the chromium content in the glass phase. For the 39%wt silica system the chromium content in the glass phase decreased from 0.75%wt to 0.46%wt for an increase in the lime content from 1.7%wt to 7.3%wt. The same trend was seen for the 33%wt silica system. For the spinel phase an increase of 1.27%wt was seen when the lime content of the starting materials was increased from 1.7%wt to 10.1%wt for a 33%wt silica system. The same increase in lime increased the chrome content of the matte phase from 0.03%wt to 0.06%wt for a 33%wt silica system. Silica also proved to affect chrome deportment. Increasing the silica content of the starting materials from 25%wt to 39%wt increased the amount of chromium in the glass phase from 0%wt to 0.46%wt for a 10%wt lime system. The same effect is seen for a lower lime content except that more chromium were incorporated into the silica structure. A silica increase from 32.4%wt to 39%wt resulted in a chromium decrease from 5.2%wt to 0% in the spinel phase for a 10%wt lime system. The same trend was seen for the 1.5%wt lime system. An increase in the silica levels lead to an increase in the chrome level of the matte phase. When silica is increased from 32%wt to 39%wt the chrome content of the matte phase increased from 0.06%wt to 0.07%wt. The last part of the research project entailed the comparison of the trends observed with the experimental results to trends obtained from thermodynamic predictions. FactSageTM is a program that uses model equations to predict the Gibbs free energies for different phases. The program is therefore also able to predict the amount of different phases present at equilibrium. This is called thermodynamic ”optimization”. In section 6 trends that were observed from FactSageTM results are compared to the trends found in the experimental results. It is important to note that it is only trends that are evaluated and not actual values since FactSageTM calculations are for a system that is at equilibrium and (as explained above) this system is not at complete equilibrium. The comparison however was good. Several trends found in the experimental results were confirmed by the results from FactSageTM. These included the relationships of chromium fed versus chromium spinel, lime fed versus chromium spinel, lime fed versus chromium in glass, silica fed versus chromium in glass, silica fed versus chromium in spinel and silica fed versus chromium in matte. To conclude, slag additions can be used to manipulate chrome deportment to an extent. Secondly, FactSageTM can be used for thermodynamic predictions but a proper understanding as well as some form of validation of the specific system investigated is still needed. Due to time constraints and the difficulty of experimentally simulating this multi-phase system in the lab, only a few parameters were investigated. In order to obtain a more complete understanding of the system the effect of partial pressures and temperature should also be investigated.

Thesis (M.Sc (Physiology)) --University of Limpopo, 2015 / Objective This study assesses whether noise levels above legal limits of 85 dB(A) that can result in noise-induced hearing loss are present in areas where employees are supposed to work and to verify that such areas are demarcated as noise zones at the Polokwane Platinum Smelter. Background and motivation Excessive noise is a global health hazard with considerable social and physiological impact, including the development of noise-induced hearing loss (NIHL). Noise is a major hazard in many workplaces. It is estimated that more than 30 million workers (almost 1 in 10) are exposed to unsafe noise in their work places. NIHL is the second most self-reported occupational illness or injury in the United States. Amongst miners, more than 90% of the population reports hearing problems by the age of 55 years. Noise exposure is prevalent in construction, foundries, agriculture, transport, industry and mining-related activities. The prevalence of NIHL has not changed much in the past two decades. Therefore, a hearing conservation programme is an important issue in the smelter as certain areas are denoted as noise areas. Study design A cross-sectional study design with a group of utility workers at the Polokwane Platinum Smelter, as the experimental group, and a group of undergraduate Bachelor of Science students at the University of Limpopo (Turfloop Campus) served as a control group. Method A sound level meter was used to measure the noise levels where the utility group performs their technical work. Data were analysed using the Statistical Package for the Social Sciences (SPSS) computer program. Results The average noise measured in various locations of the Polokwane Platinum Smelter was between 62.6 dB(A) and 105.1 dB(A). The results indicated that workers at the Polokwane Platinum Smelter are over exposed to noise in certain work areas if they work eight hours in the area. Areas where the average noise level was above noise rating limit of 85 dB(A) were demarcated as noise zones as an additional protective measure. Employees also use hearing protective devices, when they are working in noise zones, to control personal noise exposure. This is in accordance with the Occupational Health and Safety Act No. 85 of 1993 as amended eleventh edition (OHS Act 85/93). Conclusion In the present study, noise levels in certain areas exceeded the noise rating limit of 85 dB(A). However such areas are clearly demarcated as noise areas and employees accessing those area must wear earmuffs or earplugs. Possibilities of employees developing hearing loss overtime exist, if employees work for eight hours or longer in demarcated areas and do not adhere to the existing Hearing Conservation Program (HCP) implemented at the Polokwane Platinum Smelter. Noise levels at the Polokwane Platinum Smelter should be monitored regularly. / University of Limpopo

The boreal forest area around Flin Flon, MB, and Creighton, SK, has been the site of a metal mining and smelting complex since the 1930s. Smelter emissions, coupled with forest logging, forest fires, and subsequent soil erosion, have led to severe vegetation dieback and the development of soils containing a mixture of metals in varying concentrations. In affected areas, existing vegetation typically is stunted. Limestone applications to affected soils have served to increase pH and, in some instances, the vegetation has responded positively; however, in some areas limestone application has failed to restore vegetation, leading to an interest in examining the suitability of other soil amendments to affect revegetation in these areas. Typically revegetation programs focus on aboveground vegetation responses; however, healthy plant growth often is dependent on the presence of an equally healthy soil microbial community. Thus, this study attempted to link revegetation success with responses of the soil microbial community structure to various soil amendments. Two studies were conducted to determine the influence of soil amendments (biochar, municipal and manure compost, glauconite, and an arbuscular mycorrhizal/ectomycorrhizal inoculant) on plant growth and microbial community structure in two soils from the Flin Flon area, classified as containing high and low metal concentrations. The two studies evaluated the growth of boreal forest understory species American vetch (Vicia americana) and tufted hairgrass (Deschampsia caespitosa) and overstory species jack pine (Pinus banksiana) and trembling aspen (Populus tremuloides) after addition of soil amendments, and the subsequent effects on microbial community structure. Greenhouse experiments evaluated plant growth for a period of 8 weeks (understory species) or 19 weeks (overstory species), after which plants were analyzed for changes in biomass and metal accumulation in plant tissue. Soils were analyzed for available metal concentrations, as well as microbial biomass carbon and nitrogen, and phospholipid fatty acid concentration, which is a measure of microbial community structure. Significant effects were seen on plant growth and microbial community structure due to the metal concentrations in the soil, but no one amendment consistently impacted plant growth or metal uptake, or any measured microbial parameter. The results of this study indicate the variability of plant growth and microbial functioning in soils from the study site, as well as the inherent challenges associated with revegetating heavy metal affected soils, and underline the need for further research on plant growth and microbial community structure at this site.

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