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By J. Day, Matthew X. Yao, Lijue Xue

Hardfacing overlays are commonly applied on the shroud Z-section of turbine blades for enhanced wear resistance. Among various processes that are used to apply the hardfacing overlays, the plasma transferred arc (PTA) welding process offers several advantages including lower heat input, less base material dilution, rapid process time, and reduced operating cost associated with the capability to apply materials in the powder form. The development of a robust PTA process is crucial for overlay performance and repeatability, particularly in the aerospace industry where a quality intensive manufacturing environment prevails. For this reason, the Taguchi method of experimental design was selected to develop a test plan. A 4-factor 3-level (L9) orthogonal array (OA) was used in the experiment. The L9 OA allows for a more detailed (3 level) investigation of critical process parameters, namely plasma gas flow rate, traverse speed, powder feed rate, and arc current. Two hardfacing materials, Stellite 694 and Tribaloy T-800, both Co-based wear resistant alloys, were investigated by deposition onto a cast IN738 Ni-based superalloy substrate. Performance measurements of the hardfacing deposits included deposit hardness, substrate hardness, deposit density (porosity), degree of cracking/inclusions, and a quantified visual inspection. The procedure resulted in optimized PTA hardfacing parameters for both Stellite 694 and Tribaloy T-800 on IN738 turbine blade material.

Jan 1, 2004

By W. G. Miller, J. D. Scott, D. C. Sego

ABSTRACT: As part of an overall study of properties and processes influencing consolidation of oil sands fine tailings resulting from different extraction processes, self-weight consolidation tests were per-formed. Fourteen 2 m and 1 m high standpipe tests were instrumented to monitor the rate and magnitude of consolidation of seven fine tailings materials. Tests provided valuable information about the variation of consolidation related to differences in fine tailings material properties that result from a change in bitu-men extraction process (caustic versus non-caustic). In addition, the effect of adding a coagulant to caustic fine tailings was measured. Test results are presented and discussed in terms of consolidation rate long-term volume decrease, compressibility, and downward drainage. Non-caustic fine tailings had fasterinitial consolidation, which is important in tailings ponds for reducing storage capacity and returning decant water at a faster rate to the extraction plant. Similar results were obtained for caustic fine tailings with a coagulant addition. However, long-term settlement of the different fine tailings appears to con-verge to a similar value over time because it is then governed by effective stress.

Jan 1, 2011

By K. Bunney, R. Pleysier

The deportment of a suite of elements through representative gold ore processing unit operations in cyanidation has been investigated. Chromium and lead are not soluble in alkaline cyanide solutions. Arsenic, antimony, cobalt, molybdenum, selenium, tellurium and vanadium are soluble, but typically do not adsorb onto activated carbon to any appreciable extent. Silver, copper, cadmium, mercury, nickel and zinc to varying extents report along with the gold to the carbon eluate. Cadmium, mercury and zinc can report to the carbon regeneration kiln off-gases. Strontium is soluble and adsorbs on carbon where it remgins.

Jan 1, 2011

By Jianglan Duan, Steve L. Cockcroft, Andre B. Phillion, Carl Reilly, Daan M. Maijer

"In the aluminum alloy wheel casting process, careful design of the cooling system in the die and its operation (cooling channel timing) are critical to achieve quality and productivity goals. The problem is challenging owing to the cyclic nature of the process and the relatively large thermal mass of the die in comparison to the wheel. For a given die geometry, a set of constraints have been defined to ensure directional solidification and an objective function, based on cooling rate during solidification, has been defined to reach a target secondary dendrite arm spacing. The methodology presented in this study employs the commercial finite element package, ABAQUSTM, and an optimization module based on the open source library, Scipy. The developed methodology has been applied to a series of geometries and cooling system configurations, including a 2-D axisymmetric wheel and die assembly generated from a prototype die. Preliminary testing has shown that careful selection of the objective and constraint functions have made it possible to reach desired solidification pattern.TM- Dassault Systèmes Corp."

Jan 1, 2014

By Z. Gostynski

The paper is a historical cross-section through a 28-year period of operation of the direct-to-blister Flash Smelting Furnace in the KGHM Glogów Copper Plant. It presents the origin of the furnace as well as the path of numerous changes and modifications both in technology and process introduced in the furnace in response to the production and cost-reduction challenges. The authors provide justification of the statement that continuous improvement of the "Polish" Flash Smelting Furnace has ranked it among the most modem smelting units in the world.

Jan 1, 2007

By J. Doucet, C. Price

In an industrial setting, operational changes are continually introduced, driven by new technologies or changing economics. Because of day-to-day variability, quantifying the impact of these changes based on metallurgical performance requires long trial periods to achieve statistically significant results. Tools and techniques developed by the mineral processing group at McGill University have allowed for direct measurement of process variables (e.g., bubble size, gas and solid holdup). Two case studies are described where direct measurement techniques were used to evaluate: a) a new rotor stator mechanism; and b ), the introduction of a new frother type. Application of these methods has accelerated the evaluation of process changes and improved confidence in results.

Jan 1, 2009

By Robert E. Wood

Engineers have known for some time that the efficiency of filtering iron ore concentrate slurry can be significantly improved by pre-heating the slurry ahead of the filters. However, heating such large quantities of dense slurry by conventional means has proven to be inefficient and high-maintenance. Recently though, submerged combustion was considered by Altos Hornos de Mexico SA (AHMSA), an integrated steel producer in the state of Coahuila, Mexico, as a means of pre-heating their iron ore concentrate. The company toured many iron ore facilities in Brasil and Labrador, reviewing their heating processes, and concluded that submerged combustion could provide a competitive advantage through operational efficiency and lower capital cost than steam boilers. Inproheat was retained by the company to design and manufacture a SubCom slurry heating system to heat 403 m3/h of iron ore concentrate slurry from 25°C to 60°C. The 60GJ/h SubCom system consists of five natural gas combustion chambers mounted in an iron ore concentrate storage tank. The system features a heat recovery unit whereby the exhaust gases are used to preheat the incoming slurry stream, giving the system an overall thermal efficiency of 95%. As a result, the steel company expects to realise significant improvements in filtering efficiency which will enable them to increase the capacity of their pelletising plant without installing additional filters.

May 1, 2010

By J. G. Kim, B. G. Chae, D. S. Cheon, E. S. Park

The underground structures such as high-level radioactive waste disposal thermal energy storage should be designed and constructed considering thermal-mechanical characterization because of long term and/or cyclic thermal stress. High temperature changes in these structures can extend the existing cracks and generate new cracks in surrounding rock mass. In case of long term and/or cyclic thermal stress conditions, it is possible to lose the function of structures caused by the significant cracks and fracture growth in the rock mass. In this study, the critical thermal crack temperature of the granite, limestone and thermal Kaiser effect were evaluated. Experiments were carried out with the heating speed of 1.5?/min. To avoid thermal shock and target temperatures were set at 150? and 250?. In order to verify the thermal Kaiser effect, the samples were heated by 150 ? after 2-3 repetition to 250?. The generation and growth of cracks were observed through an acoustic emission measuring system. The variation of the physical rock properties was measured before and after thermal experiments. After compared with the thermal experiments using PFC2D, numerical simulations were carried out at higher temperatures (400?). The experiments showed that the initial thermal crack temperature of granite and limestone is about 35?, 32? and the critical thermal crack temperature were about 69? , and 49? , respectively. The experiments confirmed the thermal Kaiser effect of experimented granite and limestone due to thermal cyclic loading. From the numerical analysis, the critical crack temperature showed the same tendency as the thermal experiments. The P and S wave velocity of the sample after the experiment were reduced. Therefore, when heat is applied in long-term and repetitive conditions, these cracks may affect the function and stability of the underground structure. Therefore, further studies of thermal stress effects should be performed.

Jan 1, 2015

By Dan Zou, Ji Chen, Deqian Li

"Bayan Obo mixed RE concentrate is the largest RE source in the world. RE elements occur dominantly in bastnaesite and monazite. This paper describes a clean and green technique for processing Bayan Obo mixed rare earth (RE) concentrate. A two-step oxidation method can lead to the effective recovery of REs, thorium (Th), fluorine (F) and phosphorus (P). Ce has a property of valency change, enabling the separation of it from other RE(III) elements. Making use of the interactions of cerium (IV) (Ce(IV)), F and P, a new extraction system was created to separate Ce(IV) effectively from other RE(III) while recovering F, P and Th by complexing F and P following the oxidation of Ce(III) to Ce(IV). The method includes two parts. Firstly, bastnaesite is oxidized by air roasting and sulfuric acid leaching. And then a first leach liquor containing Ce(IV), F and P is obtained. Secondly, monazite was converted into REhydroxide through alkaline attack and then Ce(III) in the RE-hydroxide was oxidized into Ce(IV) by wetair oxidation. After sulfuric acid leaching the oxidized RE-hydroxide, a second leach liquor is obtained. The two parts of leach liquor containing Ce(IV), F and P are then extracted by Cyanex923 to obtain CeO2, CeF3 and CePO4 based on the complex of Ce(IV) with F and P. The raffinate was further extracted by the primary amine N1923, and Th-product was recovered as ThO2. The RE elements recovery yield during the whole process is greater than 92%. The new technique not only provides a new way for Bayan Obo RE ore utilization, but also avoids resource waste and environment pollution.INTRODUCTIONRare Earths (REs) refer to lanthanides, including scandium and yttrium. Owing to the similar structure and property of RE(III), it is difficult to separate them from each other, especially for the adjacent elements. According to the United States Geological Survey, in 2010, the whole world has about 142 million tonnes of rare earth reserves. In that, China ranks the second with 22% following Brazil which ranks first with 32% (Cheng, 2011). There are three main RE ore types in China with about 80% mixed ores in Bayan Obo, 10% bastnaesite ores in SiChuan and ShanDong province and 2.9% ion adsorption ores in Southern China. Bayan Obo mixed RE concentrate consists of bastnaesite and monazite. The concentrate contains CeO2/_REO of 50% and there are 7–8% F, 4-6% P and 0.2–0.3% Th."

Jan 1, 2016

By Xiaozhu Chen, Qi Ping, Pu Yuan, Qinyong Ma

"In order to investigate the fractal feature of coalmine deep rock fragments under impact loads, variable cross-section split Hopkinson pressure bar apparatus, 50 mm in diameter, was adopted to conduct impact compressive test for rock specimens from -962m deep coalmine. Various impact pressures, such as 0.3, 0.6, 0.9 and 1.2MPa, were selected to implement different loading rates. Sieving statistical analyses were conducted for rock fragments after being impacted, and the particle size distribution of broken rock in various loading rates were calculated with the fractal method and then the corresponding fractal dimension was obtained. Test results shows that there is a good self-similarity and fractal feature in fragments distribution of deep coalmine sandstone under impact loads. The fractal dimension of fragments is between 1.9 and 2.7. The research also indicates that there is an approximate power relationship between dynamic compressive strength and fractal dimension, and a strength power relationship between fractal dimension and average strain rate. Moreover, there is a linear relationship between fractal dimension and specimen absorbed energy. The rock fractured process can be quantitatively described through fractal dimension, which can reflect the deep rock broken degree and is an ideal index to evaluate the distribution of rock fragments.INTRODUCTIONBroken rock is one of the most basic processes in mining operations, rock fragmentation has always been an important index to evaluate rock breaking effect (Xu & Yu, 1984). Macroscopic fragmentation of rock material is the final results of continuous development, expansion, gathering and cutthrough of internal micro-cracks. This process, developing from microscopic damage to macroscopic fragmentation, is an energy dissipation process and shows fractal characteristics (Xie, 1993). Turcotte (1986) has conducted statistical analyses of fragmentation for different kinds of geological materials under various broken conditions, and arrived at the conclusion that fragmentation distribution is a fractal."

Jan 1, 2015

By E. Goris Cervantes

"A theoretical framework based on a detailed analysis of mine operations data from an oil sands mine in northern Alberta and the static simulation of truck cycle times are developed, verified, and validated in this paper. Implementation of this framework provides better results than existing tools that rely solely on manufacturer data. This, therefore, aids in efficient equipment planning for the life of the mine. The use of this framework to modify existing productivity curve estimation methods currently in use at the mine site is also proposed. This method replaces “loaded flat haul” with “loaded effective flat haul” in the productivity estimation. Validation of the model results in a 4% overestimation of productivity, versus an underestimation of more than 10% when using the existing in-house method. ¦ KEYWORDS Equipment planning, Life-of-mine (LOM) planning, Oil sands, Productivity, Truck cycle times RÉSUMÉ Un cadre théorique fondé sur une analyse détaillée des données relatives aux activités minières d’une exploitation de sables bitumineux dans le nord de l’Alberta et la simulation statique des temps de cycle des camions sont développés, vérifiés et validés dans cet article. La mise en oeuvre de ce cadre offre de meilleurs résultats que ce que proposent les outils existants, lesquels se basent uniquement sur des données des constructeurs. Ceci contribue donc à une planification efficace de l’équipement pour des projets relatifs à la durée de vie de la mine. On propose également de se servir de ce cadre pour modifier les méthodes d’estimation de la courbe de productivité actuellement utilisées sur le site minier. Cette méthode remplace le concept de loaded flat haul (la distance parcourue par des camions avec un chargement du point de collecte jusqu’au point de déchargement des résidus miniers) par celui d’effective loaded flat haul (la distance relative parcourue par des camions avec un chargement du point de collecte jusqu’au point de déchargement des résidus miniers) dans l’estimation de la production. La validation du modèle résulte en une surestimation de 4 % de la productivité, par rapport à une sous-estimation de plus de 10 % avec la méthode actuellement utilisée en interne. ¦ MOTS CLÉS planification de la durée de vie de la mine, planification de l’équipement, productivité, sables bitumineux, temps de cycle d’un camionINTRODUCTION One aspect that differentiates oil sands mines in northern Alberta from conventional hard-rock mining is the environment in which they operate. Due to ground characteristics, producers in the region experience roads with very high rolling resistance (RR) that, in turn, negatively affect haul-truck performance and greatly increase fuel consumption and emissions. Oil sands mining companies use some of the largest haul trucks in the world. In addition, oil sands mines cover more extensive areas than hard-rock pits, resulting in longer haul distances on roads made of comparatively more viscous material."

Jan 1, 2019

By D. Djokic

One of the most attractive features of electron beam curing as a process for manufacturing composite structures is the potential for attaining very low levels of residual stress as compared to thermal curing. This residual stress reduction is important both for the potential to reduce composite failure strains at low operating temperatures and the associated reduction in process-induced deformation. Previous work has demonstrated that it is possible in some cases to significantly reduce residual stress development during irradiation and also avoid development of additional residual stress during post cure. In this paper, simple L-shaped composite laminates were used to study the development of residual stress and deformation during thermal post-cure of specimens that were already partially cured using different radiation doses. Following post-cure, these specimens were also subjected to high-temperature loads to study creep behaviour under service conditions. Aerospace

Jan 1, 2006

By Franz Simon

Conventional fine gold electrolytes for barrel applications working electrolytically actually permit significant precious metal savings by corresponding optimizations but the most gold is still deposited on areas of the components where it is not absolutely essential for the desired bonding and soldering applications, i.e. in high current density areas. Therefore an electrolyte working electrolessly has been developed which inevitably leads to a much more uniform thickness distribution since in an electroless process there are no areas favoured by metal deposition and current distribution. The new electrolyte will be presented and its performance will be compared with conventional electrolytes as regards thickness distribution. The potential gold savings will be discussed.

Oct 1, 2003

By Christian Bourcier

La méthode d?exploitation traditionnelle de la mine est le chantier chambre-magasin. Cependant, lors de l?exploitation d?un chantier, nous avons été confrontés à un problème de soutirage. Le minerai abattu est resté accroché à l?intérieur du chantier ce qui nous obligea à soutirer environ 200 wagons, représentant 700 tonnes. Suite à l?ampleur de la situation, nous avons décidé de finir l?exploitation du chantier par la méthode sous-niveau long trou retraité. Cette première expérience de récupération de piliers ayant été réalisée avec succès, nous avons décidé de continuer avec deux autres récupérations de piliers afin de pouvoir augmenter notre expertise autant au niveau technique qu?au niveau économique.

Oct 1, 2001

By W. G. Worcester

THE chief object in presenting this paper on bentonite is to attract general attention to one of the least known and most neglected industrial minerals of Canada, a mineral of extensive commercial possibilities, as evidenced by its development and exploitation in other countries, principally in the United States and Germany; countries upon which some of our most important Canadian industries are dependent for their supply of special clays, such as Fuller's earth and activated bentonite. It was in view of these conditions and the knowledge of the presence of large quantities of bentonite in the Canadian West that the work here reported on was under-taken. While the investigational studies have not been completed, the results indicate that among the many samples tested there are some of real merit and industrial importance. While it has been the author's privilege to examine deposits and samples of bentonite from all of the Western provinces, his chief activities in the field and in research studies have naturally been confined largely to Saskatchewan materials. Notwithstanding this, however, this paper is presented in the hope that it may stimulate a more general interest in, and study of, Canadian bentonites as a whole, a matter of such importance that provincial boundary lines should be overlooked. GENERAL CHARACTERISTICS OF BENTONITE According to Schurecht and Donda (1), bentonite is commonly composed of the mineral montmorillonite, (Mg,Ca)O.Al203 5SiO2 .nH2O, though some are known to consist of beidellite, Al2O3 3SiO2.nH2O: where n is approximately 4, and in certain cases the Al2O3 may in part be replaced by Fe2O3. For present purposes, however, it may be sufficient to state that, in general, bentonite is a "soapy' clay-like mineral or group of minerals composed largely of hydrous aluminium silicate, but frequently carrying small percentages of the alkalies, alkaline earths, and free silica, as well as silicates, gypsum, and other admixed detritus such that purification is usually necessary.

Jan 1, 1937

By C. Larsen, R. A. Walker, A. Voth, C. Daoust

"The 3000 t/d mill at Hernia Gold Mines Inc. was commissioned in March, 1985. By Canadian standards the concentrator is highly automated, however, unlike the retrofit systems in many other plants, the Hernia process control system was installed during plant construction. This paper describes the Hernia control system beginning with system development (justification, architecture, start up, etc.), proceeding to current applications (crushing, grinding, leaching, etc.) and finally discusses some of the short term objectives for system improvement.INTRODUCTIONThe Hernia Gold Mines Inc. operation is located in the Marathon area of Northwestern Ontario. Controlled by Noranda Minerals Inc. (50.1 %), the cost of bringing the mine into production was nearly $300 million. A unique feature of the mine development was the extraordinarily short elapsed time of three years from Noranda's initial involvement to the start of milling operations. Additional background information on this project can be found in the trade literature (e.g. Tinter (1986). Scales (1987).)The Hernia concentrator is designed to process 3000 tpd of ore and commenced operation in March, 1985. Figure 1 provides a general plant flowsheet indicating the major circuits. Typical annual production statistics are included on the figure and these have been extrapolated from the available 1987 year-to-date data. Larsen and Tessier (1986) have previously described the operational aspects of the mill.In a metaphorical sense, the Hernia concentrator is like the traditional bride, ""wearing something old (e.g. the cyanide leach process), something new (e.g. a plant wide digital control system installed during construction), something borrowed (e.g. crushers from Gaspe) and something blue (e.g. the cladding on the surface buildings). While the prospect of fully undressing this bride is of considerable interest, here we choose to focus on something new. In particular, we choose to examine the process control system in some detail since Hernia is one of Canada's more highly autcmated gold mills. The control system is of interest because it has received suostantial credit for maximizing metal production and minimizing operating costs. With reference to the latter, it is worthy of note that Hem lo reports recent operating costs of less than $100 U.S./oz."

Jan 1, 1988

By D. Vanin

"Conventional single heading track drifting in the hard rock mining industry has not shown any significant improvements in advance rates, despite the advent of modern track jumbos and igh speed muck handling systems .This paper presents Kiena 's experience in using a 7 ft 2 in. diameter larva Mark 6 Tunnel-Boring Machine (TBM) for driving 6000ft of drift.IntroductionKiena Gold Mines is located about 5 miles west of the town of Val d'Or, Quebec, approximately 300 miles north of Montreal. The mine commenced production in October 1981 and has gone through various expansions of ore production with 287 916 metric tonnes in 1982 to reach 453 800 metric tonnes in 1986.Due to the majority of claims being covered by a lake, a grassroots exploration drive of remote areas of the property was required to allow diamond drilling on a yearly basis. High speed sequential excavation methods (SEM) of single heading drifting in the mining industry has not progressed much in the past 20 years despite the advent of electric-hydraulic jumbos, Haggloader and Hagglund type cars. Certain examples of record SEM drifting advances have been performed in the past but only under very specific ground and cost conditions."

Jan 1, 1987

By B. N. Church, J. J. Barakso, A. F. Bowman

"An evaluation of mineralization in the Goosly- Owen Lake area of central British Columbia is the result of a comprehensive geochemical study of rock samples obtained from a regional geological survey. The dispersion of metals in country rocks about a line of Tertiary intrusions suggests that these igneous bodies may be genetically related to known sulphide replacements, disseminations and vein deposits. The geochemical investigation is based on the determination of 12 elements from samples gathered from more than 800 scattered field stations. To assist processing and interpretation, the data are subjected to a variety of statistical procedures, including correlation of the elements, factor analysis, clustm• analysis and computer contouring of the elements. Some practical applications of rock geochemistry in regional exploration are indicated."

Jan 1, 1976

By O. Hall

DISCUSSION AT QUEBEC MEETING MR. A. V. CORLETT: With drill holes radiating from a common point, is loading carried to the collars, and do you undertake to distribute the powder evenly? MR. R. V. PORRITT: When the collars of the holes, particularly the diamond-drill holes, are close together, two out of three holes are loaded only to within six or seven feet of the collars, and the intervening holes are loaded close to the collars. When the collars are farther apart, the holes are loaded close to the collars. No spacers are used, and the holes are filled solid with powder, this applying particularly to the diamond-drill holes, except, of course, where the collars are close together and some holes are not loaded close to the collars. MR. J. G. L. McCREA: I would like to enquire in respect to the various efforts made to reduce the cost of diamond drilling to the lowest point, what is. the relative cost of the solid bit to the standard bit? It would seem that the solid bit has the higher cost. MR. PORRITT: The non-coring or solid bit gives a slightly lower diamond cost than the coring bit. With the coring bit, the greatest diamond loss is on the inside stones, apparently due partly to vibration, but mainly to the core blocking against these stones. This condition, of course, does not apply with the non-coring bit. Our experience is that the non-coring bit, which drills out a much greater area, has a diamond consumption slightly less than the coring bit. The non-coring bit is sturdier, and is far less liable to damage in starting holes and in drilling through cracked or broken ground.

Jan 1, 1939

By D. J. Robertson

"THE copper smelting operation of the Hudson Bay Mining and Smelting Company, Limited, at Flin Flon, Manitoba, generates a gas flow of 350,000 c.f.m. at n.t.p. This gas stream passes to atmosphere through a 20-foot diameter by 250-foot brick stack, carrying with it an appreciable dust burden in the form of metallic oxide fumes. The flow constituents during the period 1952 and 1953 and •before gas filtration was included in the treatment scheme are shown in Table I. This paper describes the gas filtration treatment which was installed in 1957, using glass cloth media to recover this dust burden, and discusses the associated problem as its treatment for recovery of zinc and cadmium.The metallurgical details associated with the problem are illustrated by a description of the material flow sequence of the Company's hydrometallurgical zinc plant and copper smelter. In this ore processing complex, the zinc plant and copper smelter form an integrated unit within which intermediate zincrich products of each operation enter the treatment circuit of the other."

Jan 1, 1960