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By Ahmad Ghahremaninezhad, Denver H. Cowan

Much of today’s gold is locked within sulphide minerals. These sulphide minerals, including pyrite, need to be subjected to oxidative pre-treatment in order to leach the refractory-gold using traditional methods. Typically autoclaves employing high temperatures between 180?225 ºC, and extremely high pressures between 1,500?3,200 kPa, are used for the oxidative pre-treatment. However, the autoclaves themselves are very expensive, costly to operate and maintain, and produce excess sulphuric acid. This paper studies the atmospheric oxidation of pyrite in ferric sulphate solutions. In general, pyrite oxidation under atmospheric pressure can result in high elemental sulphur production, i.e. less acid generation. Activated carbon has displayed an ability to catalyze the process, achieving reasonable kinetics. The reaction kinetics were investigated by altering acidity of the leaching solution, temperature, catalyst ratio, sparged oxygen and agitation. A combination of X-ray diffraction, scanning electron microscopy, optical microscopy, X-ray fluorescence, inductively coupled plasma mass spectrometry (ICP-MS), and atomic absorption spectroscopy (AAS) were used to monitor the kinetics of the process and elemental sulphur yield. The purpose of this investigation was to determine optimal operating conditions that maximized kinetics of the atmospheric oxidation while maximizing elemental sulphur yield.

Jan 1, 2015

By A. V. Corlett

MR. C. S. Gibson: Mr. Chairman, I listened with much interest to Mr. Corlett's paper. Those of us who are directly engaged in mine ventilation and dust control are impressed by the improved atmospheric conditions to be derived from the use of methods of mining such as those in operation at Aldermac, which Mr. Corlett has just described, and those employed at Noranda. It is a well known fact that drilling-dust is one of the most potent factors in the production of silicosis in mines handling ores containing quartz, so that from that angle the use of diamond drills, instead of percussion drills, to drill ore for blasts in stopes is an important development. A second point which I think merits mention is blasting. Blasting, we all know, creates the most dust in a mine and the fact that you can drill ore for a large blast with diamond drills and fire it, say, on Saturday night, and then have all the next day to ventilate the workings, is a great advance in dust control. 1 have wondered if Mr. Corlett, or possibly those at Noranda, can en-vision the use of the diamond drill as a means of advancing cross-cuts and drifts, preparing stopes, etc. I believe it is a matter which is receiving considerable attention at the moment in some parts of the world and J thought it would be interesting to have Mr. Corlett's reaction on that point. MR. A. V. CORLETT: I am not quite so hopeful of using diamond drills as a means of drilling holes in the ordinary drift. Maybe some of the diamond drill men can give us some further information on that point. MR. R. D. LoNGYEAR: The diamond drill manufacturers are working on that problem, but until further work is done we have nothing definite to offer. Drilling holes with a diamond drill to compete with rock drills for advancing drifts and cross-cuts is a desirable objective, because of the elimination of drilling dust and the ability to cut a smooth bore of uniform diameter. To reach this objective, higher rates of penetration are required, which can only be achieved by discovering the optimum bit rotating speed, by reducing vibration, and by further improving the bits and machines. We are optimistic, but the problem is still largely in the research stage.

Jan 1, 1940

By Pura Alfonso, Teresa Escobet, Hernan Anticoi, Eduard Guasch, Josep Oliva, Sarbast A. Hamid

"The liberation modelling of mineral particles using mineral liberation analysis have been used in the past to model comminution and concentration processes. In this work this concept has been taken a little further, using comminution and concentration for applying the mineralogical characteristics of particles. This approach is shown using the image analysis, mineral liberation analysis and the distribution density functions for liberation modelling. The work focused on the effect of comminution on mineral liberation for liberation modelling. To model this, effect the mineral liberation of the particles using distribution density and the cumulative distribution was linked to the image analysis of the ore particles. These properties have been estimated by statistical measures such as the distribution density and liberation grade, which were extracted from MLA data and images analysis, using proper image analysis and techniques based on MATLAB software. A comparison of different tungsten ores of liberated particles, has been introduced and evaluated by estimated results and image analysis.INTRODUCTION The chief economic minerals of tungsten are wolframite [(Fe,Mn) WO4] and scheelite(CaWO4), and approximately two-thirds of the world tungsten reserves consist of scheelite deposits (Lassner and Schubert, 1999). Tungsten has unique properties and is widely used in various industrial high strength and high temperature applications. It occurs coarsely aggregated in low grade ores. Most of tungsten ores, particularly scheelite, wolframite and ferberite, occur in deposits with very low content of WO3 (0.1–2.5%) that is not economically viable to apply directly metallurgical methods to extract tungsten (Martins, 2014). Tungsten is considered as a critical metal by the European Union by the economic importance and also the high supply risk (European Commission, 2014; Chakhmouradian et al., 2015).Currently, scheelite is playing an increasingly important role in tungsten industry because the mineral reserve of wolframite is getting depleted after gradual exploitation and utilization (Min et al., 2016). In mineral processing, the liberation of valuable mineral from the gangue determines the efficiency of subsequent separation processes. The liberation characteristics of an ore are primarily dependent on its texture, the association of mineral in the host matrix of gangue minerals, and to some extent on the grinding process (Zhang and Subasinghe; 2013)."

Jan 1, 2017

By J. Worden, D. Hughes, S. Smart, H. Zughbi

The enterprise wide optimization (EWO) of steelmaking and manufacturing is a multi-level, hierarchical problem which spans higher level corporate planning and scheduling through to the lower level operations of processes that produce and manufacture steel. External and internal system dynamics combined with process unit co-ordination create complex changing circumstances for the enterprise. This paper presents a scoping study as a prelude to enterprise wide considerations at an integrated steelworks to help inform the choice of appropriate model types and optimization techniques. The hierarchical, multi-level structure of the enterprise and the important spatial-temporal scales to consider are defined. Insights into the system were gained by analyzing a large set of dynamic operational data. Over two years of data were subject to both univariate and multivariate analysis with the intent of understanding the complex interrelations of energy flows on site, the inherent system dynamics of the energy network, system operational modes, aspects of planning and scheduling and the coordination between major processing units. This analysis was further used to evaluate the performance of the system in regards to energy utilization and understand the potential economic benefits derived from improved operational decisions.

Jan 1, 2015

By R. B. Nourse, S. F. Gwynn-Jones, S. Nikolic, M. L. Bakker, I. McDougall, H. Joubert

"Tenova Pyromet’s core furnace knowhow and expertise has been built within the ferroalloy and nickel/platinum group metal (PGM) industries with the supply of electric furnaces for a number of nickel/PGM operators, including Eastplats, Lonmin, and Anglo-Platinum in South Africa, Mineraçào Serra Da Fortaleza in Brazil, and Norilsk Nickel in Russia. Tenova Pyromet has also supplied the electrode columns and associated electrode equipment – the heart of the electric furnace technology – for cobalt recovery in furnaces in Zambia and the Democratic Republic of the Congo. The quantity and size of projects undertaken by Tenova Pyromet has provided the opportunity to continuously improve furnace designs and the scope of supply, culminating in the most recent nickel/PGM project currently under construction at Northam Platinum. Through this innovative culture, the Tenova Pyromet Base Metals Initiative was formed in 2015 to develop the Novasmelt™ Furnace; a next generation optimised Top Submerged Lance (TSL) furnace design. The combination of Tenova Pyromet’s advanced Novasmelt™ product with our industry leading electric furnace technology are discussed with reference to applications for nickel and cobalt production. Flowsheet arrangements are compared summarising potential capital savings, operating requirements and achievement of downstream product quality.INTRODUCTION Tenova Pyromet is a leading player in the field of smelting technology development and equipment supply. Tenova Pyromet is the result of the union of three furnace suppliers under the Tenova banner: Techint Technologies (Tagliaferri), Core Furnace Systems Corp (Lectromelt) and Pyromet Technologies. The furnace experience of the combined groups dates back over a century with the earliest Lectromelt going into production in the early 1900s. Throughout the modern era, Tenova Pyromet has developed a reputation for providing dependable innovative smelting technology, high quality equipment and sound project execution to a worldwide client base with customer plants operating in Europe, Southern Africa, North America, South America, Russia, Kazakhstan, the Middle East, South Korea, and India. Tenova Pyromet’s core knowledge and expertise was developed in the South African ferroalloy, base metals, and platinum group metals (PGM) smelting industries. Tenova Pyromet has spent considerable effort on development and has contributed significantly to improve the state of the smelting industry. Tenova Pyromet’s electrode columns have become widely renowned and are now providing significant benefits, especially in increased furnace availability, to many smelting furnace operators. The electrode column is the heart of the furnace as it delivers a controlled amount of electrical energy, at an optimum depth in the burden/bath, to the smelting process. Every furnace is custom designed to the specific operating range and optimal operating point of that furnace and process"

Jan 1, 2017

By Rick Steen, Weldon Read, Morrism Tracy T.

Edging for starter sheet blanks used in conventional copper refineries has always been problematic for getting the edging to seal and adhere to the titanium material used for the blank so that copper is prevented from plating under the edging and cause undo problems in getting the copper sheets to separate from the blanks. A method was developed at the Amarillo Copper Refinery utilizing an injection molding process that better adheres the edging material to the titanium that makes the harvesting of starter sheets much easier to the point that robots are now used to strip with and which holds up very well to the unforgiving physical nature of the electroplating process. It is believed that this technology could be successfully utilized for permanent cathodes as well. INTRODUCTION ASARCO LLC (Asarco) was organized in 1899 as the American Smelting and Refining Company. Originally a consolidation of several lead-silver smelting companies, it evolved over the years into an integrated producer of primary non-ferrous metals, including copper, lead and zinc and associated co- products (Marcosson, 1949). Grupo México, S.A.B. de C.V acquired Asarco in 1999. Today, Asarco is a vertically integrated producer of primary refined copper and associated co-products such as gold, silver, molybdenum, selenium and tellurium. Asarco operates three open-pit mines and mills and two solvent extraction-electrowinning (SX-EW) plants all in Arizona plus a copper smelter in Arizona and a copper refinery in Texas. Figure 1 illustrates how the copper metal comes out of the ground at the mine and ends up as a refined product at the refinery. The copper refinery in Texas is known as the Amarillo Copper Refinery (ACR) and is located in Amarillo, Texas. It was built in 1975 to replace 3 other aging refineries and was designed to produce 550,000 tons (500,000 MT) of refined copper per year using conventional starter sheet technology. At the time it was commissioned it was the largest tankhouse in the world at just under 1/2 miles long under one roof.

Jan 1, 2019

By T. Johnson, K. Lambrych, D. Kelley

Materials for construction of equipment used in hydrometallurgical plants are selected based on a combination of their ability to perform as required in aggressive process environments as well as their cost. As a material of construction, fiber reinforced plastic (FRP) has been shown to provide equal if not improved durability relative to alternative materials such as corrosion resistant alloys at a considerably lower cost. This is particularly true in the case of equipment used in acid leaching processes for copper, cobalt, nickel and rare earth elements. The selection and extensive use of FRP over alloys in new hydromet plant construction in North and South America illustrates this advantage of FRP effectively. This paper will compare corrosion performance and cost of plant equipment fabricated with stainless steel alloys and FRP made with Epoxy Vinyl Ester thermoset resins. Real world case histories for FRP piping, storage tanks, extraction vessels, and electrowinning cells combined with laboratory based corrosion studies will be reviewed to demonstrate how FRP materials are selected for hydrometallurgical equipment.

Jan 1, 2015

By W. Curlook, L. M. Pidgeon

THE PURPOSE of this investigation was to study part of the ternary system Co-Fe-S. Jensen ( 1) established the solubility limits of sulphur in pyrrhotite. The compound with 61.7 per cent Fe, corresponding to a formula Fe12S13, was found to melt congruently at l,192°C. Hulsmann and Weibke(2) determined the Co-S phase diagram from O to 35.2 per cent S. The solubility limits of sulphur in the com-pound Co(l-x)S were not determined. The initial object of the present in-vestigation was to determine the composition at which the compound Coci-xiS melted congruently. Once this was ascertained, it was decided to investigate the ternary system Co-Fe-S from the region of 100 per cent Co(1-x) S to the region of 100 per cent Fe12S13.

Jan 1, 1953

By Nessetech Consulting, L. A. Cisternas, E. D. Galvez, S. H. Kuan, L. H. Saw

"In Malaysia, there were two rare earths processing plants namely Asian Rare Earth (ARE) and the Malaysian Rare Earth Corporation Plant (MAREC) in Perak, which were operated until 1992 and were subsequently closed due to problems pertaining to disposal of large amount of radioactive waste. Recently, Lynas Advanced Materials Plant (LAMP) has become one of the largest rare earths processing plant in the world producing rare earth elements (REE) in Gebeng, Pahang. The primary raw material is lanthanide concentrate (LC) which is imported from Mount Weld mine in Australia and shipped to Malaysia. LC is produced from lanthanide ore after mining and mineral processing. The ore has a lower impact than Bayan Obo, Mountain Pass and adsorbed clay deposits, given the small footprint of the mine itself and the remoteness of the location. The type of ore being mined (rare earth phosphates: carbonatite, monazite) may have higher thorium content than bastnasite ore from the Chinese or American mines but still far below radiation concerns. This paper was written to review the processing flowsheet at the Lynas Advanced Materials Plant (LAMP), the environmental impact associated with the processing of the said ores and the sustainability of the operation.INTRODUCTIONRare earth minerals are one of a set of 17 minerals or chemical elements which consists of yttrium and scandium, as well as the 15 lanthanide elements (lanthanum, cerium, praseodymium, neodymium, promethium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, and lutetium). Despite their importance, rare earth minerals rarely exist in economically viable concentrations and they are usually difficult to extract. Rare-earth minerals create strong magnets when added to magnetic elements such as iron, and are useful for the production of electronics systems as well as electric cars. They are also used extensively in automotive catalytic converters, fluid cracking catalysts in petroleum refining, wind turbines, phosphors in colour televisions and flat panel screens, displays for mobile phones and laptops, rechargeable batteries, and various medical devices. The elements are typically split into two subgroups: the cerium sub-group of ‘‘Light’’ rare earth elements (LREEs) which includes La to Eu and the yttrium sub-group of ‘‘Heavy’’ rare earth elements (HREEs) which include the remaining lanthanide elements, Gd to Lu, including yttrium (Gupta and Krishnamurthy, 1992; Jordens et al., 2013; Trifonov, 1963). Scandium, however, when it is classified as a rare earth element, is not included in either the LREE or HREE classifications (Gupta and Krishnamurthy, 1992; Jordens et al, 2013). Half of the world’s 110 million tons of reserves exist in China while other sizable deposits are found in Russia, United States, Brazil, India, Australia, Canada, and Greenland. The countries known to be actively mining REE are China, Russia, India, Brazil and Malaysia (Hao et al., 2015). Among these countries, China has the largest REE production, accounting for more than 93% of global supply (Yap, 2015). The critical metal report (Moss et al. 2011) listed 14 economically vital raw materials that are prone to supply disruption and concluded that supply disruption would threaten the goal for cleaner transport and sustainable energy since rare earth metals are used in products using green technology, such as hybrid/electric vehicles, carbon capture systems, wind power generation, low-energy lighting, and energy efficient flat-screen displays."

Jan 1, 2016

McArthur River Operation is the world?s largest high grade uranium deposit and is located in Northern Saskatchewan. McArthur River came into production in December 1999 with a number of innovative technologies to allow for mining of a high grade uranium deposit in challenging geotechnical and hydrological conditions. The raisebore mining method has been supplemented by the continued development of a boxhole mining technique to allow for mining of mineralization that cannot be accessed with a drill chamber from above. An innovative freeze wall re-design ? a cathedral freeze wall, was implemented in 2009 to allow for top access of a new orebody in the unconformity area of the Athabasca Sandstone. This paper highlights some of the ongoing improvements to the mining method and the innovative risk mitigation applied to manage the extraction of this challenging orebody.

May 1, 2011

By Bob Drew, Goran Vukovic, Bojan Zivanovic, Klaus Gamweger

Reaction bath temperature is a major factor in processing liquid metals and in many applications where a balance between process duration and temperature has to be found to run a procedure efficiently. Also extremes of temperature can decrease the output of a process if too cold or even make it impossible, conversely overheating can be detrimental to both the product and furnace integrity. With the help of the new online temperature measurement system very accurate monitoring of the process is possible in contrast to the current routine practice where the temperature is measured periodically with dip thermocouples. The system works with a digital, fiber optic pyrometer, which is embedded in a refractory housing. Installation in the lining is possible below liquid level as nitrogen is blown to keep the system open and to ensure continuous sight from the optical head of the pyrometer to the molten metal through the tuyere. This permanent temperature measurement gives optimal process control with the potential of taking appropriate actions at an early stage enabling proactive process control. Therefore energy savings and even process endpoint detections can be realized.

Jan 1, 2015

By Elma van der Lingen

Gold is considered the most inert of all metallic elements, but the metal can show catalytic activity when prepared by specific techniques. Preparation techniques being used to prepare gold catalysts systems mainly involve precipitation methods incorporating gold compounds or complexes. This paper introduces a totally different method for the preparation of gold-based heterogeneous catalysts that can be used for oxidation and reduction reactions, as well as electrocatalysts. The method involves alloying of gold with a less noble metal, such as aluminium, to form a gold-containing intermetallic precursor. AuAl2 was produced by melting gold and aluminium together in a vacuum arc furnace under a protective atmosphere. The aluminium is then dissolved from the AuAl2 precursor by means of NaOH to produce a highly porous gold structure. The paper also reports on a method of incorporating transition metal oxide(s) with the porous gold to form an active heterogeneous catalyst. Promoter elements can also be melted with AuAl2 to improve catalytic activity. Alloying has the advantage that the promoter element can be in contact on atomic level with the gold. In-situ xray photoelectron spectroscopy (XPS) studies have also been done on the porous gold catalysts to further clarify the CO oxidation mechanism on gold-based catalysts.

Oct 1, 2003

By Krishna Parameswaran

In this paper, we attempt to answer an often asked question, how can metal mining be compatible with the principles of sustainable development. Starting with the classic Brundtland Commission definition of sustainable development as "development that meets the needs of the present without compromising the ability of future generations to meet their own needs," we make the case that mining is or should be sustainable, using examples of sustainable practices at ASARCO LLC, an integrated U.S primary copper producer. These examples cover the entire mining cycle starting with exploration, mining, beneficiation, smelting, refining, closure and post-closure and post-mining land use. It is hoped that the presentation will challenge the mining industry to even greater innovation as future mineral development projects are planned.

Jan 1, 2015

By Veronique Falmagne

"In 1987 the only knowledge available of the Ansil orebody was that it was high grade, deep and relatively small . High stresses were also anticipated because there had been rockbursts during shaft sinking and destress blasting had been necessary (Fig. 1). From the design, through the development and now in the mining stage, rock mechanics and microseismic monitoring have been used to maximize recovery and safety and minimize dilution. Examples are given of the use of a microseismic monitoring system in the early stages o f mining. This paper also presents a review of the mine's in situ stress measurement campaign, cable bolting practice and backfill procedure.The Design PhaseAfter the initial mapping and classification work, preIiminary numerical modelling was performed using assumed stresses of ov = oH and oH = 3ov• The empirical Mathew's analysis was then used to optimize stope dimensions based on geomechanics data available at the time (Bawden et 01., 1988; Falmagne, 1987; Potvin et 01., 1988). Because of high stresses predicted by numerical modelling and a brittle, strong and relatively unfractured host rock which was believed to be rockburst prone, it was decided to mine without temporary or permanent pillars. However, in order to satisfy production rates, the orebody had to be broken up into two horiwns separated by a triangular pillar (Fig. 2). The final mining sequence is shown in Figure 3.The Development PhaseAt this point, based on work accomplished to date, including mapping and observations from drifting and modelling, the following problems were identified: (1) flat backs in the hangingwall andesite were thought to be highly stressed; (2) flat backs in weak massive sulphide ore would also be subjected to high stress and be difficult to support; (3) the felsic dyke was noted as a "" stress raiser"" , because activity increased as drifts approached it; and (4) chlorite coating of joints in the hangingwall was thought to be an important factor in reducing their stability."

Jan 1, 1991

By Sandeep Singh Sandhu, Karanvir Singh Ghuman, Manjit Singh

"Cobalt based super alloy stellite 6 was weld cladded on AISI 304 L stainless steel using SMAW process in order to improve the wear resistance for tyre crusher blades. Microstructure characterization and micro hardness testing was performed on stellite 6 cladding. The suitable parameters viz. 80 Amp current with arc weaving technique was selected by performing bead on plate experiment were further used for depositing multipass multilayer cladding to achieve full filler chemistry at the top surface. Further GTAW process was used for re-melting the top surface of the cladding. Comparative evaluation of the claddings showed that TIG re-melting resulted in increased microhardness and wear resistance in comparison to as cladded specimens even with lesser deposition of material. It was observed that TIG re-melting improved the hardness from 603 HV0.5 kg to 712 HV0.5 kg. Micro structures of stellite 6 contained cobalt solid solution matrix along with inter dendrite chromium carbides which resulted in the increased micro hardness values. Pin on disc abrasion tests were carried out at room temperature and the worn out surfaces were characterized using SEM and EDS.INTRODUCTIONThe crusher blades are used in many industries for crushing various types of material and its wider applications in tyre rubber crushing mills, metal-powder crushers industries etc. Most of the crusher blades are damaged by the wear and impact loading conditions. It is because of metal to metal abrasion and the temperature also plays a vital role in blunting the cutting edges of these blades. The wear is the major cause which leads to loss of material and thus the productivity that can never be recovered (Kotechi et al., 1992). The wear can be reduced by coating of various super alloys which could reduce the behavior of metal degradation even in aggressive environments. Cladding of cheaper low alloyed material with expensive superalloys to enhance the performance of components at low cost has been investigated by many scholars (Deng et al., 2010, Kennametal, 2007, Lolla et al., 2014, Singhet al., 2014, J.N et al., 2003, Ramkumar et al., 2012). Many researchers have reported that cladding is an application of build-up deposits of specialized alloys to resist abrasion, high temperature corrosion and impact loadings. Cladding is used for providing required mechanical strength properties as well as inhibition of oxidation and other corrosive degradation. Coatings are used to protect the heat affected areas like tubes of fluidized bed combustor etc. (Kirchbner et al., 2008, Wang et al., 1994, Hocking et al., 1993, Ananthapadmanabhan et al., 1991, Staia et al., 2001). Coating techniques are widely used for the protection of turbine engine and boiler tubes against high temperature corrosion attack, power generation equipment, chemical process equipment, aircraft engines, pulp and paper processing equipment, bridges, rollers and concrete reinforcements, orthopedics and dental, land-based and marine turbines, ships. Coatings of stellite 6 are widely used in steam turbine blades and boiler tubes for power generation because of an excellent combination of impact, wear and other properties. It can maintain its properties even at high temperature and in harsh environments (Kobayashiet al., 1999, Alam et al., 2009, Munehru et al., 2009). The loading and unloading conditions experienced by the material may induce the surface cracks which lead to its breakage and leaving large pits in the surface (Meng et al., 1995). Many researchers have reported that the properties of cladded layers can be increased by various techniques such as controlling the current variations, dilution, heat input, laser and other re-melting processes, addition of special alloying elements, speed of weldingetc(C.M Anaet al., 2002, Kumaret al., 1999, Luo et al., 2012, et al., Madadi et al., 2011, Shin et al., 2003, Kuzucu et al., 1997, Sudha et al., 2008, Sawant et al., 2017, Houdkova et al., 2016, Ciubo"

Jan 1, 2017

By M. Kim, M. Ha

"The effect of red mud on the melting behavior of ferronickel slag was investigated by a laboratory-scale horizontal tube furnace. Melting and softening of slag samples fluxed with different amount of red mud was examined by in-situ visualization technique at temperature range from 1400 to 1550°C. FactSageTM 7.0 was used for the thermodynamic calculation of multi component system of ferronickel slag and red mud. Liquid phase area was extended to lower temperature by adding red mud indicating its suitability as a flux material. X-ray diffraction analysis confirmed the dependency of the phase changes on the red mud content. Microscopic observation by scanning electron microscope (SEM / EDX) clarified the phase transformations from olivine to spinel along with red mud additions.INTRODUCTION Ferronickel smelting by submerged arc furnace (SAF) is an energy intensive process performed at high temperature range 1500–1600°C. During the smelting process of saprolitic nickel laterite ore with a nickel content of 2.2–2.3 pct, a large quantity of ferronickel slag is being produced that account for 97 pct of ore charged. To achieve ferronickel grade of 15–20 pct Ni, electrical energy of 80 to 85 MW is used for the melting and reduction of nickel oxide (NiO) and iron oxide (FeO) in the ore (Rodd et al., 2010). Unreduced components, mostly MgO, SiO2 and partly FeO are removed from the furnace in a liquid slag form by a tapping operation. Due to the high melting temperature, forsterite (Mg2SiO4) based slag containing approximately 10 pct FeO requires typical process temperature of 1600°C. Flux in metallurgical process is a medium that decreases melting and operating temperatures while it increases fluidity of the liquid slags. Calcite and fluorite are examples of flux materials used for the ironmaking, steel refining and continuous casting process. Oxide systems based on CaO - CaF2 - SiO2 - Al2O3 - MgO cover most of the slag composition in ferrous metallurgy accordingly. Crucial operating factors for ironmaking and steelmaking slags are basicity (typically CaO/SiO2 ratio), viscosity and impurity levels. These are extensively controlled by the fluxes. General metallurgical fluxes such as limestone, dolomite and calcium fluoride are abundant in nature and supplied to steel mills at low prices. Meanwhile, in copper flash smelting process, silica is supplied with copper concentrate to remove iron oxide (FeO) generated from sulfide oxidation. FeO - SiO2 binary system formulates eutectic area at 25–38 pct of silica that has low melting temperature below 1205°C. Fayalitic system (Fe2SiO4) that has low viscosity (0.1 Pa·s) (Park et al., 2011) facilitates easy separation of slags from molten sulfide mattes. Recently, copper plants actively utilize recycled raw materials as a flux. Various recycled glasses are ground and fed to copper smelting process as a partial replacement of silica ore. Applying industrial wastes to smelting processes is advantageous since the operators can reduce the production cost remarkably. Not to mention the consumption of recycled materials can ultimately minimize the environmental risks and the waste management costs. The authors, therefore, investigated the reasonable waste materials that can be effectively used for ferronickel smelting process. Prerequisites for potential fluxing materials are non-recyclable property, low transportation cost and excellent performance as a flux."

Jan 1, 2017

By J. M. Goris

"Researchers at the U.S. Bureau of Mines are conducting research on cable-type ground supports to assess their material and support properties and to provide design criteria for implementing cable supports as a workable roof control system under various underground mining conditions. Much of this work involves laboratory assessment of the material and support properties of cable supports using both conventional and birdcage steel cables. Included in this assessment are single and double cables, effects of changes in embedment length on support strengths, water-cement ratios, use of breather tubes, and pumpability and water-bleeding properties of grouts.IntroductionSince cable supports were introduced in the early 1970s, considerable research has been conducted in laboratories and at mine sites to understand their behaviour. The U.S. Bureau of Mines began a laboratory evaluation project in 1985 at the Spokane Research Center (SRC) to study the behaviour of cables supports under uniaxial loads so that the effects of various cable support components, such as grout and breather tubes, could be identified. Other objectives were to compare the behaviour of various types of cables and grouts and to collect meaningful data for numerical analyses. Pull tests were conducted to determine how cables supports reacted under uniaxial loads and how they failed when ultimate loads were exceeded. Such data are essential for the development of numerical models for analyzing rock mass behaviour when the rock is supported with cables.Test ProgramBecause each cable support can be composed of either single or double cables as well as a breather tube, pull tests were designed to include a variety of samples containing these components. A series of samples containing a single conventional cable, a neat cement grout having a water-cement ratio of 0.45, and no chemical additives was selected as a standard (Table I). Then one component in the system, such as the presence of a breather tube, was changed, and results of tests compared to results obtained for the standard samples to determine what influence that component might have on the behaviour of the support system. If significant changes in test data occurred, they could be attributed to that one component. To control the quality of the samples, the physical condition of the cables and tubes were monitored closely, and compressive and tensile strengths as well as flow properties were determined for the grout used in each test series."

Jan 1, 1991

By S. Nakamura, K. Fujiwara, S. Hirosawa, S. Tsukamoto, Y. Koshino, Y. Aruga

"In this study, hardness test, differential scanning calorimetry(DSC)and transmission electron micros copy were carried out to investigate the age-hardening behavior of Al-Mg-Si alloy with a Mg+Si concentration of 1.5mass%, and a Mg/Si ratio of 1.0. Pre-aging treatment was conducted for the solution-treated and then water-quenched specimen at 100, 80, 60, 40, 20 (natural aging), 0 and -20°C for 20min or 5h, followed by artificial aging at 170°C for 20min. It was found that when pre-aging time is prolonged from 20min to 5h, the bake-hardening response is deteriorated irrespective of the pre-aging temperature. In particular, the specimens subjected to pre-aging at 20-40°C for 5 h hardly increased the hardness with the subsequent artificial aging. From the results of DSC measurement, it was suggested that as pre-aging temperature is lowered, the amount of solute clusters formed during pre-aging, i.e. Mg-Si clusters and Si-rich clusters, is decreased, but the ratio of Si-rich clusters is increased, resulting in the deteriorated bake-hardening response.INTRODUCTIONIn recent years, Al-Mg-Si alloys have been widely used forautomotive body panels due to their excellent characteristics such as high strength-to-weight ratio and good formability. Their strength is increased not only by artificial aging during paint-bake treatment; i.e. “bake-hardening”, but also when kept at room temperature(RT);i.e. “natural aging”, in association with the suppressed bake-hardening response. Such a “negative effect of two-step aging” has been a serious problem because Al-Mg-Si alloy coils are unavoidably maintained at RT in the manufacturing process of body panels; e.g. shipping and storage. However, it was reported that pre-aging above 70°C before the two-step aging can restore the bake-hardening response, and such an improvement is related to the formation of solute clusters(Sato, 2006; Abidet al., 2010; Takaki et al., 2014; Zandbergen et al., 2015). From the comprehensive analysis by three-dimensional atom probe (Aruga et al., 2014 and 2015), it is believed that Mg-Si clusters formed during pre-aging transform into the strengtheningß"" phase, whereas Si-rich clusters formed during pre-aging act as a detrimental precursor of ß""phase. In this study, it was aimed to investigate the effect of pre-aging conditions, especially pre-aging temperature and time, on the formation of solute clusters during pre-aging, in order to elucidate the mechanism of the age-hardening behavior of an Al-Mg-Si alloy."

Jan 1, 2018

By Farzad Khodabakhshi, Adrian P. Gerlich

"Multi-pass friction stir processing (FSP) was performed to fabricate a new Al-Mg-Graphene nanocomposite. Microstructural developments and distribution of graphene were studied by using electron backscattering diffraction (EBSD) and transmission electron microscopy (TEM) analysis. In the stirred zone (SZ), grain structure was refined down to about 2 µm attributing to the operative dynamic restoration mechanisms and the locking effect of graphene phase. As a result, the yield strength of Al-Mg alloy was improved more than two times due to incorporation of graphene nano-sheets. Also, the indentation hardness resistance of nanocomposite was increased up to ~60%.INTRODUCTION Aluminum-matrix nanocomposites have garnered significant in recent years due to their superior performance and potential advantages for several industrial applications including the automotive and aerospace sectors. Among various reinforcing nano-materials, carbon-based structures featuring sp2 or sp3 hybridization bonds have been found to offer considerably improved physical and mechanical properties. Such carbon allotropes form at micro- and nano-scales including; graphite, carbon nano-tube (CNT), nano-fiber, and graphene. The potential of two-dimensional (2D) carbon materials was introduced in 2004, with the development of graphene as an alternate 2D allotropic form of the carbon structure with a honey-comb lattice at the atomic-scale. It has been shown that it is currently among the strongest materials ever tested with an intrinsic tensile strength of 130 GPa and Young’s modulus of 1000 GPa, and also offers unique thermal and electrical properties.To fabricate metal-matrix nanocomposites reinforced by graphene nano-sheets with typical metallurgical processing techniques, some attempts have been reported in the literature for various solid-state techniques including; hot rolling, mechanical alloying, and friction stir processing (FSP) of pre-cast plates or surface dispersed graphene oxides. The main challenge in those methods was to facilitate the considerable high temperature and pressure for attaining a uniform dispersion of the nano-sheets during the consolidation process. In most cases, significant difficulties have been reported in obtaining a uniform dispersion of graphene within the metal matrix. Among various techniques for production of metal-matrix nanocomposites, FSP has attracted significant attention as a method of surface modification since it was first reported by Mishra et al. In this process, a non-consumable rotating tool is plunged into the surface of material for the aim of microstructure modification. Extreme material plasticity is induced without melting as a result of friction between the tool and workpiece. Frictional heating and severe plastic deformation induced by the FSP process enables metal matrix nanocomposite fabrication by softening the base material and mechanical stirring to disperse the reinforcing nano-materials into the matrix."

Jan 1, 2017

By Ian Sherrell, Michael Pirie, Riddhika Jain

"Conventionally, direct reduced iron (DRI) mixed with char from rotary furnace discharge is cooled down before separating the char via magnetic separator. The DRI must then be reheated for further downstream processing (i.e. smelting). Outotec has developed the PyroMagTM specifically to conserve thermal energy during this separation process. DRI is cleaned by feeding hot particles directly after reduction onto a rotating surface just above a stationary magnet assembly. This allows hot feeding of the clean DRI to the downstream equipment which renders the entire process more energy efficient.Continuous testing of the PyroMagTM was performed to verify design and separation. Because the use of DRI/char was not practical for test use, the pilot plant testing was conducted using a magnetite/sand mixture heated up to and beyond the Curie temperature of magnetite. The separation was efficient for both cold and hot processing with recoveries varying from 98.6% to 99.74%. As expected, the recoveries decreased to as low as 83.99% as the temperature was increased beyond the curie temperature of magnetite (585°C). Long term separation was thermally efficient and sustainable.INTRODUCTIONMagnetic drum separators are widely used in the mineral processing industry. These low to high intensity magnetic separators are used to concentrate various magnetic material, such as iron ore, and less magnetic materials, such as ilmenite and garnet from silica and other contaminantsThere are multiple classes of magnetism based on the effect that each material displays while in and out of a magnetic field. In a simplified fashion, which is more appropriate for mineral processing, the magnetic susceptibility of a mineral is used to define it as being ferromagnetic, paramagnetic or nonmagnetic. In this respect, minerals with varying degree of magnetic susceptibility can be selectively separated with different types of magnetic separation equipment in different stages of a process flow sheet. The lower strength magnets are employed early in the process to remove highly magnetic fractions. Later stages utilize greater magnetic fields for capture of less magnetically susceptible material."

Jan 1, 2016