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By Han Xing, Cui Jianzhong, Qin Ke, Shao Bo, Zhang Haitao

In this paper, a new approach that uses hot-top DC casting process to producing multi-alloy ingots is present. The different type and size of composite and coated ingots (4045/3004/4045 three-layer composite ingots with section 630mm by 1500mm and 4045/3003 coasted ingot with F140mm/F110mm in diameter) are cast by this approach. The macro-morphologies and microstructures of the composite ingots, the temperature distribution and the element distribution in the interface zone were investigated, also and the interface bonding strength was measured. Results show that the solid supporting layer formed on the cooling plates plays a key role in the casting process of composite ingots. The solid supporting layer can prevent the blending of two melts by resisting the impact of alloy melt, which ensures the stable casting process and casting high quality composite ingots, because the contact height is increased using hot-top DC casting. In addition, fabrication and properties of 4045/3004/4045 three-layer composite ingots with section 630mm by 1500mm are reported in detail.

Jan 1, 2015

By H. Tsuruta, A. Fujibayashi, I. Sumi, A. Murao, R. Murai

Injection of biomass into blast furnace as alternative reducing agent is so effective for the purpose of mitigation of carbon dioxide emissions from steel industries, because biomass is considered to be carbon neutral raw materials. Certain amount of Palm Kernel Shell (PKS) is abandoned after Palm oil extraction process. To use as a reducing agent of blast furnace, PKS was carbonized and classified by 100 mesh sieve. To examine the gasification behavior of PKS carbide under the blast furnace conditions, several combustion experiments were conducted using hot model experimental furnace. The experimental results showed that the gasification efficiency of PKS carbide increased as the quantity of volatile matter increased. This tendency is the almost the same for the pulverized coal, so carbide of PKS can be used at blast furnace at appropriate amount of volatile matter that can be controlled by carbonization condition. In addition, the pressure drop of the furnace tends to decrease because the amount of ash in PKS carbide may be smaller than that of pulverized coal. PKS carbide is a suitable reducing agent in that respect.

Jan 1, 2015

By K. Chattopadhyay

Fluid flows in metallurgical reactors play a vital role on liquid metal cleanliness for both ferrous and non-ferrous metallurgy. Thus, it is absolutely critical to understand different fluid flow mechanisms, and the use of computational methods to model the complex non-isothermal, turbulent, single- and multiphase-flows, has to be appreciated. The present case study emphasizes on controlling the flow of liquid steel in a tundish and enhancing liquid metal cleanliness. CFD modeling was used to build a robust mathematical model, and effects of flow control furniture and non-isothermal conditions were analyzed. The mathematical model was validated against water model experiments. Parameters that were conducive for inclusion removal were identified and implemented in the plant. Some flow control devices could increase inclusion removal to a great extent compared to the existing configurations. In cases, where a hot ladle was poured into a relatively cooler tundish, inclusion removal was better, whereas results were catastrophic in cases where colder liquid was poured from ladle to the tundish. Similar techniques can be applied for other liquid metals including light metals and non-ferrous metals.

Jan 1, 2015

By G. W. Norval, V. G. Papangelakis, G. A. Moldoveanu

Smelting has been the primary method of treatment for refractory copper sulfide concentrates such as enargite (Cu3AsS4), but the pyrometallurgical processing generates elevated levels of volatile arsenic. The present research investigates a novel hydrometallurgical process of oxidative dissolution of enargite at ambient conditions in the presence of chlorine dioxide (ClO2), a very powerful oxidant generated in solution by the reaction between a strong acid (HCl or H2SO4) and sodium chlorite (NaClO2). The effects of initial oxidant concentration, particle size, agitation speed and temperature on dissolution kinetics and copper extraction were investigated. It was found that a stoichiometric ratio of ClO2:Cu3AsS4 = 9:1 were needed to completely and congruently dissolve the mineral with fast kinetics (<15 minutes) under ambient temperature. The dissolution extent (metal extraction) increases with increasing ClO2 concentration and decreasing particle size of solids, but is not influenced by temperature or agitation speed.

Jan 1, 2014

By C. Riveros, H. Henein

Bulk Metallic Glasses have a high potential as advanced engineering materials due to their various properties including strength and corrosion resistance, to name a few. This paper investigates amorphous phase formation and rapid solidification characteristics of impulse atomized Co-based alloys in order to understand and control the application properties of the final products. Amorphous fraction and kinetic crystallization properties of the atomized Co-based alloy powders were quantified by means of Differential Scanning Calorimetry. In addition, different but complementary characterization tools were used to analyze microstructures of the powders. These include optical microscopy, X-ray diffraction and micro-hardness tests. While the amorphous fraction within the powders is promoted by high cooling rate and smaller powder size as expected, hardness is found to decrease with the fraction of amorphous phase.

Jan 1, 2015

By L H. Warren

The types of equipment available for generating a plasma have been reviewed. The efficiency and potential of the plasma generating equipment used in performing extractive metallurgical reactions have been determined. A general classification of the reactions that might be per-formed in a plasma has been proposed. Experimental work done on extractive metallurgical plasma reactions, heat transfer between the plasma and solids, and the quench of the products of plasma reaction has been summarized. From the preliminary results it appears that the high-intensity are or the transpiration-cooled anode plasma torch offer the most promising areas for further research. C ONSIDERABLE world-wide research effort is currently being devoted to the development of processing technologies which employ the new high-temperature generating devices that have appeared over the past few years. The plasma flames produced by these devices offer the potential for subjecting materials to any single gas or mixture of gases at temperatures up to 20,000°K. With these conditions available, many reactions in extractive metallurgy,

Jan 1, 1965

By John J. Jonas, Hong Qin

Cylindrical samples of pure titanium were subjected to uniaxial compression at room temperature, leading to the formation of three generations of twins. Many primary contraction twins were observed as the initial texture was favourable for their formation. Numerous secondary extension twins formed within the primary contraction twins and some tertiary contraction twins within the secondary extension twins. The orientations of these three generations of twins were determined by electron backscatter diffraction techniques and their associated Schmid factors (SFs) were calculated. The formation of the twin variants selected in each generation and the absence of certain potential variants are accounted for by rotating the twinning displacement gradient tensor expressed in the twin system reference frame into the crystallographic reference frame of the relevant neighbouring grain. The presence of the observed primary, secondary and tertiary twins is explained in terms of the ease of imposing the required accommodation strains on the neighbouring grains. By contrast, certain first, second and third generation potential high SF twins were absent because their formation would have required accommodation by the most difficult deformation mode: pyramidal glide.

Jan 1, 2015

By P. S. Arthur, G. R. F. Alvear

Development of a new smelting process is risky. Many novel processes in the metals industry failed to fulfil the initial expectations of their inventors. Large sums of capital have been invested in technologies that either didn&apos;t provide a satisfactory return on investment, or didn&apos;t perform at all, and had to be replaced. One of the keys to success in process development is incremental scale up of the technology, with potential problems being identified and rectified as early as possible. In this way the cost of any rectification that is required can be minimized. The ISASMELTTM process was developed to maturity by Mount Isa Mines through the 1980&apos;s and 1990&apos;s using incremental scale up. Commercialization only occurred once the process had been proven on laboratory, pilot and demonstration scale over many years. As a result ISASMELTTM technology now operates successfully at numerous plants around the world. The methodical approach to development of the technology has allowed owners to modernise their existing operations or create new businesses with significantly reduced technical risk.

Jan 1, 2011

By Hajime Miki, Gde Pandhe Wisnu Suyantara, Tsuyoshi Hirajima, A. M. Elmahdy, Keiko Sasaki

"Seawater has been reported to depress molybdenite in a copper-molybdenum (Cu-Mo) flotation process at high pH due to the precipitation of Mg(OH)2. Meanwhile, to improve mineral recoveries, collectors are usually added into the flotation cells, thus adding the complexity to the mechanism of bubble-particle interactions involved in Cu-Mo flotation. Therefore, understanding the interaction mechanism in seawater flotation and in the presence of collectors is important to explain the minerals depression. The present work investigated the effect of kerosene on the bubble collision and attachment to pure chalcopyrite and molybdenite surfaces in MgCl2 solution as one of the seawater major components at pH 6 and 11. Mineral surfaces were characterized using atomic force microscopy (AFM). In addition, minerals floatability in the same system were tested in a column flotation. The study of bubble-particle interactions shows that following several collisions, bubble could displace the intervening liquid layer on the mineral surfaces, forming a three-phase contact (TPC). A TPC formed more rapidly in the presence of emulsified kerosene in a 0.01 M MgCl2 solution at pH 6 for both minerals. The reason is kerosene increased the surfaces hydrophobicity and destabilized the intervening liquid layer on the surfaces. Moreover, the average time required to form a TPC was shorter on molybdenite surface. This can be attributed to the effect of adsorbed kerosene on molybdenite surface and molybdenite surface roughness.INTRODUCTIONIn froth flotation, bubbles are used to separate hydrophobic mineral particles from hydrophilic particles. In this process, bubble-particle interactions (i.e., collisions, attachment, and detachment) are crucial with regard to mineral recoveries. The effectiveness of froth flotation depends on the formation of stable aggregates between the hydrophobic particles and the bubbles, allowing the bubble to carry the particles to the froth layer. To form such aggregates, the bubbles and particles must collide, and the intervening liquid layer must be drained below the liquid layer critical thickness, forming a stable threephase contact (TPC) (Ralston & Dukhin, 1999). Particles detachment may take place if the particles still have sufficient kinetic energy and the TPC is not formed. Previous studies of bubble-particle interaction in electrolyte solutions have been conducted using atomic force microscopy (AFM) (Assemi, Nguyen, & Miller, 2008), and by approaching the bubble using mica plate (Pushkarova & Horn, 2008), however, these studies did not focus on the bubble-particle collisions. Bubble collisions and attachment to hydrophobic (Teflon) and hydrophilic (glass) surfaces in a a-terpineol solution have been investigated by Krasowka et al. (2003)."

Jan 1, 2016

By A. V. Corlett

THE use of the diamond-drill hole as a means of breaking clown ore and waste is not new. Years ago, the method was adopted in mines in northern Ontario and in the western United States to reach out to bad pillars, or to remnants of ore left on walls, the winning of which by any other method might be dangerous or too expensive. The practice is still in vogue and has generally proved a success. Of the known mineral deposits in Canada and elsewhere, many are of very low grade. Some are marginal and not even worthy of being classed as &apos;ore&apos; until some means is found and proved of exploiting them economically. Other conditions being favourable, if a mining method could be found that would give a large &apos;bulk break&apos; with a sufficiently low cost of development and a low cast of mining per ton, mineral deposits of this latter type might be brought into the classification of ore. We know that any block-craving system whereby the ore may be undercut and allowed to crush and cave will give a very high breakage and low costs. In some cases, however, the physical characteristics of the ore do not lend themselves to this method. In such ore-bodies, the alternative system of &apos;bulk-breaking&apos; might be aided by long diamond-drill blast holes. We could obtain this &apos;bulk breaking&apos; by the use of long diamond-drill holes in conjunction with a sub-level system using extremely thick benches, or possibly by the adaption of modified open-pit methods to underground mining. ln fact, if conditions are favourable, the idea would be simply ta open up a slot or free face and break into it on a larger scale with longer holes. The use of deeper benches-that is, using each level as a sub-level and thereby eliminating much development footage, slashing, setting up, and mucking time-would naturally be expected to lead to cheaper mining.

Jan 1, 1940

By B. K. Choi, S. H. Kang, G. E. Kim, K. B. Kim, S. Noh, T. K. Kim, H. J. Jin

Oxide dispersion strengthened (ODS) steel is being considered as an in-core structural material of future nuclear reactor systems because of its excellent creep and irradiation resistance on the basis of uniformly distributed nano-oxide particles with a high density, which is extremely stable at high temperature in a ferritic/martensitic matrix. Up to now, ODS steels have been intensively studied and developed to apply these materials to the in-core structural component of future nuclear systems. The primary activity is to develop high strength advanced ODS steel, fabrication technology for the structural components and key joining technology for the component fabrication. As a result, a Fe-10Cr-1Mo alloy with a superior creep resistance at high temperatures has been developed. An optimized fabrication process of this alloy system has been established through various process conditions in mechanical alloying, hot/cold working, and heat treatment processes. Joining technology for the ODS steel components is also being developed using solid-state welding such as magnetic pulse welding, friction stir welding and diffusion boding. These R&D activities will contribute to the realization of ODS materials for future nuclear reactor system applications.

Jan 1, 2015

By W. T. Robson

LAKE Shore Mines, Limited, with property at Kirkland. Lake, Ontario, was incorporated m 1914 and commenced product10n m March, 1918, with an initial capacity of about 60 tons per day. Since that time a gradual expansion has taken place until a present capacity of approximately 2,300 tons per day has been reached, giving a total annual gold production valued at approximately $16,000,000. At the time of incorporation of the Company, the Lake Shore property consisted of four mineral claims and four fractions, totalling 171.05 acres. In 1934, four claims belonging to the Minaker Kirkland Gold Mines, Limited, were acquired and a controlling interest purchased in the Kirkland Hudson Bay Gold Mines, Limited. Both these properties adjoin the Lake Shore claims on the south. From the accompanying compilation of the world&apos;s largest gold mines for 1934 (1), it will be seen that, while Lake Shore holds sixth position in respect to the number of ounces produced, there are twenty-five gold mines which treat a greater tonnage of ore. This is an indication of probably the most unusual feature of the Kirkland Lake deposits, namely, the high aver-age tenor of the ores. coupled with the comparatively large tonnages available.

Jan 1, 1936

By J. Grignon, C. Fleming

It is possible to reproduce the performance of an operating CIP or CIL plant in the laboratory, in small scale batch kinetic tests, coupled with mathematical models that translate kinetic data into predicted steady state gold profiles across multi-stage adsorption circuits. Once the performance of the commercial plant has been mimicked by the model, the plant operating parameters can be varied systematically in the model, and the likely response of the plant to the step wise change can be determined. In this way it is possible to inexpensively optimize the operating conditions of an existing plant, with no disruption to plant operations and no economic risk to the mining company. This approach had been adopted by IAMGOLD to optimize the performance of their Rosebel CIL plant following several major expansions in mill capacity since 2004.

Jan 1, 2011

By L O. Montpetit

The economics of the asbestos mining industry of Canada, and the physical and chemical characteristics of asbestos fibre, as well as exploration, mining, milling and quality control methods, have been described by several authors in the past few years. The scope of this presentation is to survey the application of asbestos fibres in the major product groups of the construction industry in North America. Principal categories considered include flooring materials, asbestos-cement pipes and building products, high-temperature insulation, textiles, saturated asbestos felts and asphalt com pounds. During 1962, the asbestos mining industry of Canada produced an estimated 1.3 million tons of chrysotile fibre grades, and production capacity is expanding. The market demand for chrysotile fibre, on this continent, has been in the order of 50 per cent of the production volume. The asbestos industry is dependent for growth on the construction industry. Product research is active in finding new uses for asbestos fibre; some of the new developments are presented, including the use of short-fibre asbestos grades for extending the life of asphalt pavement.

Jan 1, 1963

By Henrik Saxén, Mikko Helle, Hamid Ghanbari

In this study, a process integration approach in a primary steelmaking is investigated to evaluate future operation concepts of a steelmaking site considering sustainability issues. Mathematical programming is used to study the integration of the steel plant with chemical units for utilization of available off-gases in the system, and carbon capturing and sequestration unit. Different industrial carbon utilization options are considered to find the best route of development. A multi-period optimization model is developed based on site-wide mass and energy balances by considering the availability of the fuels and by-product gases and their consumption in the production system and a conceptual polygeneration system. The objective is to reach maximum economic profit while environmental aspects of integrated system are considered for different fuel systems, alternative blast furnace reductants and implementation of new process technologies. The model can provide useful information concerning techno-environmental and economic aspects for decision-making and can estimate optimal operational condition of current and future primary steelmaking under alternative scenarios. The results of the work illustrate the potential to develop steelmaking towards more sustainable operation in the future.

Jan 1, 2015

By S. C. Ellis

THE bituminous sand of northern Alberta has already an extensive literature, and most of the reports dealing with the subject are still available (see Selected Bibliography at end of paper). A phenomenon so striking and, as regards its extent, so unique, as the deposit in the vicinity of McMurray settlement could not fail to attract the notice of the early explorers, and we find references to it as far back as the latter part of the eighteenth century. However, scarcely a thought had been bestowed upon the possible economic value of minerals in the the remote northern parts of Canada before the second decade of the present century, and practically no detailed mapping had been done north of the town of Athabaska. The late Wm. Ogilvie made a track survey of Athabaska river in 1884, and surveys of certain lines-including the 23rd base line-had been completed by 1911. Between this base line and lake Athabaska, nothing had been attempted. Actually, no definite information at all was available regarding the character and extent of the bituminous sand when, in the earl y summer of 1913, a reconnaissance party set out from Athabaska for McMurray. At that period, the journey was made in summer by scow or canoe. No telegraph line had been laid, and a casual mail service by canoe or dog team once in three months formed the only means of communication with the outside world. The investigation has begun by the Mines Branch was continued during several subsequent years. The sand deposits were studied and sampled, the bi rumen was extracted from the sand and studied chemically and physically, and the economic significance of the deposit was given exhaustive study.

Jan 1, 1937

By Abu Syed H. Kabir, Mehdi Sanjari, Steve Yue, Jing Su, In-ho Jung

AZ31 magnesium alloy sheets were produced by high speed rolling (HSR) at 1000 m/min at a low temperature of 100 ?. A high reduction of 72% can be achieved in single pass. At the reduction of 30%, the microstructure was covered by shear bands and twins. When the reduction was increased to 49%, dynamic recrystallization (DRX) was clearly observed in the vicinity of shear bands and twins and the full recrystallization was seen at a reduction of 72%. In order to study the static recrystallization (SRX) behavior on the heavily twinned structure, annealing was then carried out at 200 ? on the as-rolled specimens at the reduction of 30% for different times. Static recrystallized grains were also firstly observed on shear bands and twins after 45 s and the microstructure was mostly fully recrystallized after 1 h annealing with a few retained large elongated un-recrystallized grains. Texture weakening was found during annealing on the heavily twinned specimens by SRX, but not during high speed rolling by DRX. In the present study, effect of DRX and SRX on microstructure and texture evolutions during rolling and annealing were compared.

Jan 1, 2015

By J. G. Debanne

MOST company-employed petroleum engineers have in their accounting departments punch-card computers that can perform engineering calculations thirty to three hundred times faster than desk calculators, or they can rent such machines from Computing Service centres. These machines not only eliminate the drudgery of desk calculation but also the risks of human errors. The I.B.M. t 604 punch-card computer of Texaco&apos;s accounting department in Calgary has been used for oil and gas property evaluations, curve fitting by least squares, statistical core analysis studies, unsteady-state water in-flux studies, phase equilibrium performance prediction of oil reservoirs, gravity segregation calculations, etc.

Jan 1, 1958

By D. C. Treilhard

After a brief history of the mining and smelting operations of Kilembe Mines Limited, this paper outlines the smelter layout and describes . the. daily operations at the Jinja plant. Particular attention 1s paid to the details of the furnace and converter operation. A subsequent section of the paper deals with the significant developments in plant metallurgical practice, covering both smelting and converting.

Jan 1, 1966

By D. G. Klaren, E. F. de Boer

Self-cleaning fluidized bed heat exchangers have demonstrated unparalleled performance internationally for the implementation of indirect heat transfer in severely fouling fluid environments. The ingenious configuration of recirculated cleaning particles through the tubes of vertical shell and tube heat exchangers provides the ability to solve any problems that arise as a consequence of tube-side fouling during indirect heat transfer to process fluids or slurries. In most cases, the cleaning particles consist of chopped metal wire, however other process-specific materials have been used. In addition to the mitigation of fouling effects, a number of other significant benefits for slurry heating are afforded by the mode of operation of the self-cleaning fluidized bed heat exchangers. Increased turbulence at the slurry/tube interface is imparted by the action of the fluidised particles, resulting in very high heat transfers at relatively low liquid velocities. Furthermore, given the thixotropic nature of most process slurries, the action of the fluidised particles imparts additional shear to the process slurry, resulting in shear thinning effects with a consequent reduction in pressure drop and enhancement of heat transfer across the heat exchanger. The benefits provided by the self-cleaning fluidized bed heat exchanger make it the ideal option for the indirect heating of laterite nickel slurry for High-Pressure-Acid-Leach (HPAL) plants. This article explains the principle and application of the self-cleaning fluidized bed heat exchanger technology for the processing of laterite nickel and cobalt slurries in HPAL plants. It also presents an elegant method to revamp existing direct heated laterite nickel and cobalt processing plants into an indirect heated configuration employing self-cleaning fluidized bed heat exchangers.

Jan 1, 2004