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Fire Explosion Hazard SX-EW

Fire Explosion Hazard SX-EW

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UNITED STATES DEPARTMENT OF LABOR
Mine Safety and Health Administration
Investigative ReportMarch 1999
A Study of the Fire and Explosion HazardsAssociated with the Electrowinning of Copperin Arizona Surface Mine Plants
ByDerrick M. TjernlundFire Protection EngineerEngineering Support Branch
-Originating Office-
Approval and Certification Center
Steven J. Luzik, Chief
Engineering and Testing Division
David C. Chirdon, ChiefRR #1, Box 251Industrial Park RoadTriadelphia, West Virginia 26059(304) 547-0400
 
i
PART I. INTRODUCTION........................................................................................................................1
A. P
URPOSE OF
S
TUDY
.....................................................................................................................................1B. S
COPE
..........................................................................................................................................................1C. S
TUDY
M
ETHODOLOGY
...............................................................................................................................2
PART II. GENERAL MINE INFORMATION........................................................................................2
A. A
PPLICABILITY
.............................................................................................................................................2B. M
INE
L
IST AND LOCATION
M
AP
...................................................................................................................3C. MADSS D
ATABASE
S
EARCH
R
ESULTS
........................................................................................................3
PART III. SXEW PROCESS......................................................................................................................3
...................................................................................................................................................3
1. Description of process.............................................................................................................................32. Ore types.................................................................................................................................................53. Leaching..................................................................................................................................................5
................................................................................................................................................6
1. General....................................................................................................................................................6 2. Mixing and Separation............................................................................................................................6 3. Chemical Reactions.................................................................................................................................7 4. multi-stage extraction..............................................................................................................................95. multi-stage stripping ...............................................................................................................................96. wash stage.............................................................................................................................................10
.............................................................................................................................................10
1. General..................................................................................................................................................102. Cathodes................................................................................................................................................113. Anodes...................................................................................................................................................114. Tankhouse .............................................................................................................................................115. Cell operation........................................................................................................................................126. Normal electrochemical process...........................................................................................................127. Abnormal electrochemical process.......................................................................................................138. acid misting from electrowinning..........................................................................................................14
F
O
S
............................................................................................17
1. Fugitive organic....................................................................................................................................17 2. Economic benefit...................................................................................................................................13. Hazard reduction ..................................................................................................................................17 
PART IV. FIELD OBSERVATION.........................................................................................................18
A. F
IELD
S
URVEY PROCEDURES
.....................................................................................................................18B. F
IELD
S
URVEY FORMS
................................................................................................................................18C. SX.............................................................................................................................................................18D. EW............................................................................................................................................................20
PART V. HAZARDS ANALYSIS............................................................................................................23
A. I
NTRODUCTION
..........................................................................................................................................23B. L
ABORATORY
I
NVESTIGATION OF
H
AZARDS OF
F
UGITIVE
O
RGANIC
..........................................................23
1. Goal.......................................................................................................................................................232. Methodology..........................................................................................................................................243. Results...................................................................................................................................................25
C. L
ABORATORY
I
NVESTIGATION OF
H
AZARDS OF
C
ELL
D
EPLETION
..............................................................27
1. Goal.......................................................................................................................................................27 2. Methodology..........................................................................................................................................283. Results...................................................................................................................................................30
 
ii
PART VI. CONCLUSIONS AND RECOMMENDATIONS.................................................................32
A. T
ANKHOUSE
H
AZARD
M
ITIGATION
S
TRATEGIES
........................................................................................32
1. Fugitive Organic Hazards.....................................................................................................................322. Cell Depletion Hazards.........................................................................................................................36 
B. S
OLVENT
E
XTRACTION
H
AZARD
M
ITIGATION
S
TRATEGIES
.......................................................................39C. L
EACH
P
AD
H
AZARD
M
ITIGATION
S
TRATEGIES
.........................................................................................39
PART VII. ACKNOWLEDGMENTS.....................................................................................................40PART VIII. REFERENCES.....................................................................................................................40PART IX. LIST OF ATTACHMENTS...................................................................................................41
A. A
TTACHMENT
1: M
INES
S
ITES
V
ISIT
F
OR
S
TUDY
......................................................................................41B. A
TTACHMENT
2: M
INE
S
ITE
L
OCATION
M
AP
.............................................................................................41C. A
TTACHMENT
3: F
IELD
S
URVEY
F
ORM
......................................................................................................41D. A
TTACHMENT
4: T
ABLES
..........................................................................................................................41E. A
TTACHMENT
5: F
IGURES
..........................................................................................................................41

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