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By R. Shiva Kumar, G. E. Sreedhar, Rajan Kumar, K. Suresh, A. K. Aketi Veera, M. Narasimha, P. S. Jodan

"In most of the coal washeries, Dense Medium Cyclone’s (DMC) are deployed to treat coarse coal fraction in the range of 50-0.5 mm. DMC’s are very popular due to its ability of high tonnage, ease of operation and effective separation at high near-gravity material (NGM) in feed coal. The ease or difficulty of washing is merely depending on the NGM fraction present in run of mine coal. However, the quantitative effect of NGM on DMC performance was not explored in the literature. Hence, in this investigation, the influence of NGM on DMC performance is focused. With the help of synthetically prepared coal mixture, the effect of NGM mass fraction on separation efficiency is studied in three different approaches. Firstly, by increasing the NGM coal fraction systematically from low to as high as possible; second by varying the distribution of NGM coal; and third by varying distribution of particles lying just above and below the near-gravity zone. Washability studies are also carried out to establish the theoretical yield for the prepared synthetic mixtures. Pilot-plant experiments are carried out in a 4-inch DMC with 1.4 operating separation density treating coal in the size range of 4 - 0.5 mm. From results, the partition curves are constructed by both density and size wise distributions. It is observed that at higher NGM coal fraction i.e above 60%, the performance of DMC is very poor with significant coal particles misplacement. In second approach with increased distribution at higher density fractions, the separation efficiency reduces. In third series the distribution of fraction in near-gravity zone doesn’t much effect the separation except the shift in separation density. It is observed that smaller size (-0.5 mm) coal particle having high NGM content seems have a profound effect on DMC performance leading to significant fines misplacement to wrong products."

Jan 1, 2018

By M. Rafieazad, P. Fathi, X. Duan, M. Mohammadi, A. M. Nasiri

"Direct metal laser sintering (DMLS) is a metal additive manufacturing technology that creates highly complex components by fusing metal powder into a solid part. In this study, the impact of surface roughness on corrosion resistivity of AlSi10Mg_200C alloy manufactured through DMLS was investigated. The as-printed DMLS-AlSi10Mg _200C alloy was subjected to various surface finishing processes including grinding and sandblasting. The corrosion performance of the surfaces was then evaluated using potentiodynamic polarization testing and electrochemical impedance spectroscopy (EIS) in a 3.5 wt.% NaCl solution to mimic seawater environment. Surface characterization and corrosion morphology of the samples were assessed by Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) spectroscopy. The results of this study show that the surface finishing process and the resultant surface roughness has a significant impact on the corrosion resistivity of the DMLS-AlSi10Mg_200C alloy in the seawater environment.INTRODUCTION Direct Metal Laser Sintering (DMLS), also known as Selective Laser Melting (SLM) (Sames, List, Pannala, Dehoff, & Babu, 2016), Laser Beam Melting (LBM), or Laser Metal Fusion (LMF) (Herzog, Seyda, Wycisk, & Emmelmann, 2016), is an additive manufacturing process that utilizes a precise, high-power laser to micro-join powdered metals and alloys layer by layer to form almost fully dense and functional components in three dimensions from the 3D computer-aided design (CAD) data. Complex geometries not possible with conventional manufacturing processes can be readily manufactured with high accuracy using the DMLS process with no need to time-consuming tooling."

Jan 1, 2018

By Jia Ma, Zhi-Chao Liu, Kang Liu, Chun-Feng Li, Bao-Bin Tang

"The geological environment of the certain uranium-molybdenum deposit is very complicated. While the study of process mineralogy is relatively few, which restricting the processing and leaching effect of ores. According to reaserch on process mineralogy of this mine, the basis of ore processing can be provided. The main contents of research are the uranium occurrence state and the influence of H2O2 in acid leaching. By various methods and experiments, the process of uranium mineralogical characteristics in this deposit are systematically studied. The results show that the uranium is mainly in the form of independent uranium minerals. The structures of these uranium minerals are venous and disseminated in mineral fissures, or microgranular inclusions in quartz and feldspar. It is not appropriate to concentrate the uranium minerals by flotation beneficiation because that the loss rate of target metals via water leaching process is very high. The ores are suitable for being acid leaching directly with 6% – 8% of H2O2, and the maximum leaching rate of uranium can be 96.88%. INTRODUCTION The uranium ores with associated elements have a large proportion in uranium resources (Lei, et al., 2014, Xing, et al., 2006; Ritchy and Wong, 1985). The uranium and molybdenum are easy to be paragenesis in nature enviroment because of their similar chemical properties. Therefor the uranium-molybdenum associated deposits are widely existing, such as the sedimentary sandstone uranium deposit in American with vanadium and molybdenum, the sedimentary sandstone uranium deposits in French with vanadium (Chen, et al., 2014; Lounis, 1997). A certain epithermal porphyry uranium-molybdenum deposit in China is mainly controlled by the subrhyolite- porphyry and the fault zone (Lv, 2012; Rui, 2010; Liu, et al., 2010). The ore properties of this deposit are complex, which include the high alteration degree, and the fine grain size of the target minerals (Ma, et al., 2013). The ore properties and occurrence state are quite different during each mining stage. As a consequence, the consumption of reagent increased and the leaching rate declined as long as the continuously mining. The author explored the best leaching rate of target elements According to the basic research on process mineralogy of present ores, experimental study of water leaching and oxidizing acid leaching on different particle sizes."

Jan 1, 2018

By A. L. Ling, A. K. Janzen

"Design of effective mine water treatment plants depends on the ability to reliably predict treatment outcomes, but systems with multiple chemical and physical treatment processes and recycle loops can be difficult to model. GoldPHREEQC is a modeling framework that integrates mass and flow routing capabilities of GoldSim software and water quality calculations provided by PHREEQC, and is well-suited to modeling parameters of interest in the mining industry, especially metals and sulfate. Physical processes such as membrane separation and greensand filtration are modeled by defining mass rejections for each parameter and flow routing based on vendor projections and bench- or pilot-scale equipment testing. GoldPHREEQC models chemical precipitation processes such as HDS metals removal and gypsum precipitation by (1) performing surface-aging and solubility calculations in PHREEQC and (2) using the GoldSim framework to direct supernatant and precipitate to subsequent process steps. Users can apply this modeling framework to predict effluent water quality, chemical requirements, sludge production, and required equipment capacity to support design, troubleshooting, and cost estimating. INTRODUCTION Design of effective mine water treatment plants depends on the ability to reliably predict treatment outcomes, but systems with multiple chemical and physical treatment processes and recycle loops can be difficult to model. GoldPHREEQC is a modeling framework that integrates mass and flow routing capabilities of GoldSim software (1) and water quality calculations provided by PHREEQC (2), and is well-suited to modeling treatment of parameters of interest in the mining industry, especially metals and sulfate. GoldPHREEQC can also be applied to other water treatment scenarios using inorganic reactions and processes. The GoldPHREEQC model framework moves water and mass between specified model nodes and calculates specified reaction and water quality outcomes. It can be organized to provide flow, load, and concentration information for each location, including effluent and byproduct streams, and outputs can be adapted to include power and chemical costs."

Jan 1, 2018

By Yi Ran Zhang, Nawoong Yoon, Brent Hilscher, Maria Holuszko

"Ore sorting technology has been rapidly advancing in recent years. Improving expected mill feed grade has a significant benefit to project returns, and can no longer be ignored. When there is an increase in the mill feed grade while maintaining the same throughput, the mine will be able to process much more metal and improve the floatation recovery. There are many more factors that contribute toward the economics of the project by implementing sensor-based sorting technologies covered in this paper. This paper reviews the economic impact on an underground copper-silver deposit with references to the concept of ""profit recovery,"" which is the measurement of recovery based on rock profitability rather than just metal content. The economic impact of sensor-based sorting is discussed in detail throughout the paper. The preliminary economic evaluation of the project compares the mine's base case design versus a design incorporating sensor-based sorting. The paper's primary focus is on economic impacts rather than the explanation of the sensor based sorting results. The sorting data is presented on a scoping level and using a sensor-based sorting study where the best possible results are used for obtaining the grade recovery curves. Also, the breakdown and analysis of the project economics are based on the operating cost available from the particular operation. Any assumptions taken into consideration are also outlined and discussed. INTRODUCTION The mining industry has been adopting Sensor-based ore sorting technology fairly rapidly in the recent years. The ability to increase mill feed grade by rejecting waste grade rocks early in the processing stage is proving to be revolutionary for some operations. These potential outcomes should not be overlooked by both producing operations and prospective projects, thus leading to a wide range of studies on ore sorting. The answer to this is the creation of a new term and concept - Profit Recovery™."

Jan 1, 2018

By M. D. Vilarinho, W. Xuan, F. Vasconcelos Guimarães

"This article summarises the efforts to reduce the energy consumption in grinding in a magnetite ore beneficiation plant. ArcelorMittal Kryvyi Rih ore beneficiation plant produces magnetite concentrate at 65% Fe and 8% SiO2, of which the D80 is approximately 44µm after three stages of grinding with ball mills and magnetic separation. Characterisation and laboratory scale bench tests performed on samples from the beneficiation plant indicate that the industrial flowsheet could be simplified. After the first stage of grinding and magnetic separation, a significant size fraction of the intermediate concentrate is already well liberated. Therefore, it can be directly concentrated in a second stage magnetic separation without further grinding. If a screen of 150µm size can be implemented after the first stage of grinding-magnetic separation, only the oversize of screening, representing 35% of the material, requires secondary and tertiary grinding and magnetic separation. The combined concentrate from the two fractions already meets the industrial specifications. This new route can provide the same final product, with fewer mills; it saves around 30% in energy consumption only in the grinding step without changing the main structures of the processing plant.INTRODUCTION Comminution, including crushing and grinding, is responsible for at least 40% of total energy usage in mining and mineral processing. This paper shows an example to reduce grinding cost, by changing the flow sheet design strategy in ArcelorMittal Kryvyi Rih (AMKR).AMKR is one of the most important mining and steel complexes in Krivoy Rog basin in Ukraine, which has been studied over 100 years because of mining of iron ores. The iron ores are associated to Banded Iron Formation of the Saksagan suite, with an average iron grade of around 36 percent Fe. The total thickness of the Krivoy Rog Supergroup reaches 5-6 km, whereas that of the iron-ore Saksagan Group comprises up to 1400 m. High-grade iron ore extends to more than 2,000 m below present surface"

Jan 1, 2018

By Yuexin Han, Wenbo Li, Yan Shan, Yanjun Li, Shumin Zhang

"With the accelerating pace of resource extraction, the quality of resources is decreasing, and the old tailing dams which have served for several decades have become the focus of attention. The secondary recovery of valuable metals in the tailings is an important aspect of the comprehensive utilization of tailings. The average iron content of iron tailing is 8%-12% in China. The research aimed at exploring the low-cost and efficient technical route to recycle eastern tailings of Anshan iron mining area. The purpose of the research is to scientifically find the rational conditions of magnetizing roasting and to provide an increase in recovery and quality of concentrates. The eastern tailings of Anshan mining area belong to high silicon bearing iron tailings, iron mainly exists in form of hematite-limonite with an iron grade of 10.60%, the main component of gangue is SiO2 with a grade of 76.22%. In order to reduce the influence of the tailings on the environment, fluidized magnetizing roasting and low intensity magnetic separation for the eastern tailings of Anshan mining area were carried out to improve the utilization of the tailings. The results indicated that an iron concentrate with an iron grade of 65.30% and a recovery of 85.85% could be obtained under the conditions of gas flow rate 8 m3/h, H2 concentration 50%, fluidized magnetizing roasting temperature at 600? for 20s. Phase analysis, magnetism analysis and XRD analysis on roasted materials indicated that hematite-limonite could be transformed to magnetite during the fluidized roasting, then the effective separation of iron and gangues could be made easily by the weak magnetic separation. INTRODUCTION It is universally acknowledged that the grade of iron ore in China is low, the output rate of iron ore tailings is high, usually more than 60%. At present, the comprehensive utilization rate of iron ore tailings is low in China. Generally, the iron ore tailings are stockpiled in the tailings dam. The tailing dams not only occupy a lot of land, but also takes a lot of money to construct and maintain. In addition, the noxious substances in the tailings, such as residual flotation agents and heavy metals, have a severe impact on the ecological environment. There is little doubt that tailing dams have a visual impact on the environment due to their regular geometric shape. Iron tailings can be treated as compound mineral, which is an important component of comprehensive utilization of mineral resources, and is an has been widely concerned. Lots of scholars have done a large amount of research work on a large number of iron ore tailings. Since the iron mineral crystal grain size is fine and the iron grade is low, the iron tailings have failed to achieve good selection criteria."

Jan 1, 2018

By B. Dyck, L. Verhelst

"Colloidal silica in Key Lake’s Solvent Extraction (SX) feed solutions has presented an operational problem for the mill throughout its history. The colloidal silica stabilizes aqueous continuous emulsions, resulting in elevated solvent losses and operational downtime. Through the years, many attempts have been made to solve this problem, but no viable solutions were found. By revisiting an idea dating back to the 1979 feasibility study and re-evaluating it under current operating conditions, a practical solution was achieved. This paper discusses Key Lake’s history around colloidal silica removal, starting with coagulation using a polyethylene oxide polymer (PEO), and ending with coagulation using a polyethylene glycol (PEG) polymer. The results of a mill trial using POLYSIL® RM1250 introduced at doses up to 300 ppm into the counter current decantation (CCD) circuit to clarify SX feed solutions are discussed with a focus on the benefits to SX.INTRODUCTION Colloidal silica has historically been a significant operational problem in the Key Lake mill. Silica originates from clays in the ore as well as concrete backfill intermixed with the ore resulting from the mining method used at Key Lake’s ore source, the McArthur River mine. The silica is dissolved as silicic acid into solution in the mill’s sulphuric acid leaching circuit. Once in solution, silicic acid polymerizes (Hearn, Smethurst, & Boskovic, 2016) forming a fine suspension of stable colloidal particles. These silica colloids are unaffected by flocculants and sand filtration reporting to the pregnant leach solution (PLS) as a fine turbidity in solution. Silica concentrations typically ranged from 700 to 1200 mg/L Si in the PLS fed to SX. Throughout Key Lake’s history, silica interactions in the Solvent Extraction (SX) process have made SX a mill bottleneck and a source of significant reagent costs."

Jan 1, 2018

By T. Avilez, D. Salari

"The economics of developing gold deposits containing elevated levels of cyanide soluble base metals is often challenged by high cyanide consumption and increased operating costs. SART is a chemical process that enables cyanide consumed by base metals to be recovered and recycled for gold leaching. The process also provides concurrent recovery of the base metal to generate incremental revenue from the sale of high-grade base metal sulphide concentrates. Although SART was developed and successfully piloted by Lakefield Research and Teck Corporation in the late 90’s and is now a public domain technology, the adoption of SART has been relatively slow due to concerns about implementation costs and the reliability of metallurgical performance. Through extensive experience in selective metal sulphide precipitation applied to mining wastewater since 2007, BQE Water has provided process know-how, design along with operations and maintenance experience to a number of projects involving the integration of SART into various metallurgical flowsheets on an industrial scale. This paper presents the commissioning experience and operating data from a SART plant treating up to 500 m3/hr of leach solution at a heap leach operation in Mexico. INTRODUCTION One of the current trends in the gold industry globally is the increasing importance of complex polymetallic gold deposits as discoveries of large Carlin type gold deposits become increasingly rare (Sceresini, 2005). The presence of cyanide soluble copper and zinc in complex gold deposits necessitates changes to the traditional gold extraction metallurgical flowsheet. A tool available to the industry to help manage the interference of cyanide-soluble base metals in gold extraction is the SART (sulphidization-acidification-recycling-thickening) process. SART breaks the weak acid dissociable (WAD) base metal-cyanide complexes, precipitates the metals as high-grade sulphide concentrates and makes the freed cyanide available for recycle."

Jan 1, 2018

By Sanchita Chakravarty, Sumantra Bhattacharya, Divya Jyoti, A. K. Mukherjee, Soni Jaiswal

"Release analysis is independent of collector and frother dosage and type, but it is primarily influenced by the degree of liberation or “state of release of the sample”. The shape of release curve is an indication of the degree of liberation. This paper briefs about the effect of reagent combination, particle size and surface characteristics on the release analysis of difficult-to-clean LVC coal.Release analysis of three LVC coal fines obtained from two different coalfields of India was carried out at three different size levels such as -0.5mm, (-0.5+0.1) mm, and -0.1mm. The collectors used were n-dodecane and commercial diesel oil. Incomplete liberation of coal fines even at a size of -100µm, corroborated by photomicrographs of ROM and clean coal macerals, in a great measure reduced the flotation-based cleaning potential of the fines. FESEM images of fines reveals that the adherence of ultrafine onto the surface of relatively coarser particles reduced the clean coal recovery. The results obtained also appear to be coal, reagent combination and, particle size and particle surface specific. Only one coal indicated the liberation as is usually expected for -0.1mm particles with a reasonable yield of 65% at 18% ash. INTRODUCTION Froth flotation has a long history of being used to treat coal fines. Coal flotation is considered to be difficult, if the percentage of Near Gravity Material (NGM), i.e. essentially locked particles, in flotation feed is >10% [Aplan, 1993], which is usually the case with all the coking coal fines in India. The fines are rich in vitrinite, so valuable for coking coal. Unfortunately, there appears to be no standard procedures to determine the separation efficiency of froth floatation. Release analysis proposed by C.C. Dell in 1953 [Dell, 1953], aimed to determine the ultimate floatability of coal. Several other techniques had been proposed but release analysis technique has been considered to be a vast improvement over the batch flotation process [Forrest et al. 1994]."

Jan 1, 2018

By A. V. Rasskazova

"The oxidized and mixed ores are processed by heap leaching. Primary ores with high gold content are floated. In recent years mining of primary ores with the low gold content (up to 4 ppm) has increased. Extraction of gold from these ores by floatation is technologically ineffective. Gravity concentration is ineffective for fine gold particles because of their floatability. The research objective was assessment of the viability of processing gold-bearing ore with combined gravitational and hydrometallurgical methods and testing of recovery of metals from a gold-copper oxidized ore chloride-hypochlorite leaching solution. The advantage of chloride-hypochlorite lixiviant is the low cost of reagents which is produced by the electrochemical synthesis of NaCl solution with the addition of HCl. The adsorption of chlorine compounds by a mineral matrix and its ability to oxidize the refractory ore components and allows for the application of chloride-hypochlorite systems for gold recovery for both oxidized and primary ores. The complexity and problem in using a gold–chloride system is the strong adsorption of gold–chloride complexes onto mineral surfaces, such as goethite, quartz, and alumina. In preliminary testing, gold recovery from gravity circuit gold bearing concentrates processed by agitation leaching in chloride-hypochlorite solution, gold recovery has reached up 82% after 4 hours of leaching. Chloride-hypochlorite leaching of copper-gold oxidized ore with preliminary processing by sulfuric acid provided for 94 % gold recovery to solution. Understanding of ecological hazard of cyanides is the motive power of researches in the field of search non-cyanic chemistries to provide for technologically and economically effective solvents of gold. Soluble compounds of chlorine with a suitable oxidizer are one of the alternatives to cyanides. Basic researches of gold extraction by chloride-hypochlorite solution have shown high rates of gold recovery.INTRODUCTION Because of the continued and growing environmental concern for the use of cyanide for gold processing, interest for the use of non-cyanide lixiviants, especially with halides has renewed recently (Tran et al., 2001; Ferron et al., 2003; Bhaghalha, 2007). Leaching solutions based on halides (chloride, bromide and iodide) are viable alternative to cyanide (Kwang et al., 2008). The major disadvantage of the chlorine–chloride system is the high reactivity of chlorine in reaction with sulfide and gangue carbonate minerals. It is believed that only high grade materials may be treated by chlorine–chloride systems economically (Baghalha, 2007). Another important problem of the application of gold–chloride complex is that it tends to be rather unstable and may re-precipitate upon contact with a reductant, such as sulfidic minerals of ore. It is well known that Au(III)–chloride hydrolysis species are strongly adsorbed by goethite, quartz, and alumina (Machfsky et al., 1991). To minimize adsorption of gold–chloro complexes, it works best to minimize the adsorption time."

Jan 1, 2018

By D. J. Borrow, K. van Netten

"A fine coal tailings feed was selectively agglomerated using a concentrated water in oil emulsion binder consisting of 95% aqueous phase and 5% organic phase. The purpose of the study was to investigate a continuous system in plug flow, providing a rapid beneficiation technique with high selectivity and recovery. The development of the novel binder was undertaken in previous work in a batch system consisting of a high-speed blender. In this previous work, it was found that agglomeration could be achieved in 3 s, providing the binder was pre-dispersed. Furthermore, it was found that, depending on the feed, only ~1 wt% of oil was required to achieve agglomeration, some 10 times less than required in traditional oil agglomeration. In a more recent study, the technique was adapted into a continuous process. Due to the rapid speed of the process using the emulsion binder it was found that a simple flow constriction within a 1 inch pipe was sufficient to achieve the selective agglomeration observed in the batch system. In this previous study, a coal feed consisting of a flotation product was agglomerated at a superficial slurry velocity of 1.3 m/s using a partially closed ball valve as the flow constriction. In the current study, a feed consisting of fine coal tailings with an ash content of 50.1% was used to establish the influence of superficial slurry velocity on the agglomeration process. The superficial slurry velocity was varied between 1.3- 4.2 m/s, while maintaining a constant pressure drop of 100 kPa across the flow constriction. The flow constriction consisted of a partially closed ball valve. It was found that increasing the superficial slurry velocity across the flow constriction reduced the amount of organic liquid required to achieve agglomeration. Under the optimum conditions, a combustible recovery of 80.4% was achieved at a product ash content of 9.6%. This work demonstrates a valuable product can be rapidly produced from tailings material using the novel emulsion binder. INTRODUCTION A significant opportunity exists to recover fine coal from material that is currently classified as waste. This waste material, also called tailings, is currently considered not economic to process due to its high ash content, low solids concentration, and the fine size of the particles. Thus, for this opportunity to be realised, a process is required that is highly selective and has the ability to economically recover fine particles at high throughputs. The technique of oil agglomeration has previously been considered as a candidate for the recovery of fine coal, as it is highly selective and has no lower limit on the size of particle that can be recovered (Capes and Jonasson, 1989). However, the cost of the oil required as the binding agent in the process has proven to be a significant barrier to any long-term applications (Swanson, Nicol, and Bensley, 1977). Recently, however, Yoon and co-workers have developed an ultrafine coal separation process that utilizes an oil phase for the recovery of the hydrophobic coal particles and have implemented an oil recycle to greatly reduce the consumption and thus cost of the oil (Yoon et al., 2016)."

Jan 1, 2018

By S. K. Kawatra, J. A. Halt

"INTRODUCTION Iron ore beneficiation needs advances in areas such as process control, automation, burner and furnace designs, silica-free binders, and even alternative iron making routes. While some – like new binders – are only step-changes, all are tools that can help make the ironmaking industry more sustainable. This paper focuses on binders. Binders are added to iron ore fines before they are agglomerated. Binders are used to control the balling process and increase the mechanical quality (e.g. strength) of green-balls and pellets. Agglomeration usually follows thickening and filtration. Good-grade ores, which don't require upgrading, are wet ground to decrease particle size and increase specific surface area. Low-grade ores are often extensively upgraded through wet operations (flotation, dispersion and selective flocculation, magnetic separation, etc.). For both types of ores, thickening and filtration conclude the circuits so that moisture contents are lowered and the ores can be agglomerated. It's been known for a long time that thickening and filtration behaviors are influenced by zeta potential (Sandvik, 1979). Highly-negative zeta potential is good for dispersion while low zeta potential is good for filtration. So, the zeta potentials of iron ore particles are lowered with additions of acid or carbon dioxide, for example, to increase filtration rates and throughputs (Eisele et al., 2005). What happens to particles as their zeta potentials are lowered? Particles aggregate together, effectively forming larger particles. How stable then, are those aggregates during mixing and balling? Are they easily broken up during mixing (if mixers are even used)? Are they broken up during balling? Or, do the aggregates resist breakage so that the availability of ultra-fines, which are so beneficial for agglomeration (Stone, 1968), is decreased? For plants where high doses of bentonite are used as binder, the above questions may be of no concern. The bentonite adds the necessary amount of fines; however, even at those plants, the calcium and magnesium contents in the water affect bentonite's effectiveness (more magnesium and calcium means less effective bentonite). (Engesser, 2003) For plants where new silica-free organic binders are being developed and used, the above questions may need to be considered. The binder is only amongst the iron ore particles for a short period of time – until it burns away or thermally decomposes in the induration furnace – so the liberation, availability and distribution of fine particulates is very critical for the quality of balls and pellets. It was hypothesized that high zeta potential conditions would lead to good pellets, while low zeta potential conditions would lead to relatively bad pellets."

Jan 1, 2018

By Jayesh B. Patel, Zhongyun Fan, Hu-Tian Li

"Melt conditioned direct-chill (MC-DC) casting is a novel technology which combines vertical direct-chill (DC) casting with a high shear device directly immersed in the sump for in situ microstructural control. In this paper, the solidification mechanism of DC casting under varying conditions is discussed. The temperature profiles in the sump were measured under the steady state casting conditions by using sacrificing thermocouples. Detailed comparisons of the derived thermal condition are made. The individual role of grain refiner additions, natural thermosolutal convection and forced convection in the sump and the interplay of these factors in determining the solidification structures of DC cast billets are discussed. The MC-DC casting technology can be used to control microstructural constituents and casting defects in DC cast billets/ingots by in situ manipulating of the thermal and fluid flow conditions.INTRODUCTION Direct-chill (DC) casting of aluminium, has been the essential commercial process for producing feedstock suitable for subsequent processing, such as extrusion, rolling or forging. Fine and equiaxed grain structures in the as-cast billets/ingots are required to enable a fine and uniform distribution of second phase particles and microporosity. This leads to higher productivity, more cost-effective homogenisation and more efficient downstream thermomechanical processing. The addition of chemical inoculants has been the standard industrial operation prior to casting for grain refinement of Al alloys. However, it has been established that less than 1% of the grain refiner particles added actually act as heterogeneous nuclei to refine the grain structures, showing a very low grain refining efficiency (Greer, Bunn, Tronche, Evans, & Bristow, 2000). Moreover, the remaining particles from the grain refiner addition in the final casting may cause surface defects during downstream processing. A major issue of the metallurgical quality of large sized ingots/billets is the non-uniformity of microstructures even with chemical grain refiner additions. This is due to the fact that the grain structure formed in the different zones of the billet depends on the local chemical composition and local cooling rate. The local cooling rate can vary from 0.4~1 K/s at the centre of the billet to around 10–20 K/s at its surface zone (Nadella, Eskin, Du, & Katgerman, 2008). The large thermal gradient along radial direction between billet surface and interior of the melt during conventional DC casting induces thermal stress and cold cracking even with grain refiner addition. Therefore the control of casting defects, such as macrosegregation, porosity, cold/hot cracking and distortion of the billets/slabs, etc., is still challenging in industry, causing high scrap rate of DC cast ingots/billets even with grain refiner addition."

Jan 1, 2018

By Sazol Das, Hany Ahmed, Ganesh Bhaskaran, Zhuoru Wu

"Friction stir welding (FSW) process in lap configuration for dissimilar materials has been developed and tested for steel to aluminum joining. A novel cylindrical tool was designed for improved material flow. The joining of steel to high strength 5xxx and 6xxx aluminum was carried out by FSW technique using optimized process parameters. The microstructure, micro-hardness, joint strength and corrosion properties at the weld interface have been investigated. Optical and scanning electron microscopy reveled a well layered structure at the interface and lap shear tests of the welds showed excellent fracture resistance. Neutral salt spray tests for up to 500 hours (ASTM B117) were carried out on the bare steel to aluminum FSW joints, which did not show neither evidence of corrosion at the weld interface, nor any degradation of the weld strength. The FSW lap configuration was applied to prototype commercial vehicle structural component whereby a steel stiffener insert was friction stir welded to high strength 6xxx aluminum alloy. The interface microstructure showed layered root without any steel shattering in aluminum side. A finite element study was carried out to quantify the benefits where it was found that the stiffness increases by 76% under bending loads and 36% in torsion loads.INTRODUCTION Energy preservation and environmental issues, namely carbon footprint and legislation around emission in transportation industries has led to a growing need to use of lightweight materials such as aluminum and magnesium alloys along with various grades of steel in structural application, while still maintaining their strength and crashworthiness. Assembling dissimilar materials within integrated structure is thus a stringent requirement related to optimum performance. In order to achieve an efficient technology of joining dissimilar materials such as aluminum to steel, it remains difficult to select an effective welding process for a given joint configuration. The use of aluminum in transportation industries for structural component is not exclusive in a design and is almost always used along with various steel grades for a mixed materials solution, thus dissimilar aluminum/steel lap joining is of great interest since this is widely used in the assembly of parts (e.g. pillar, frame rails, chassis, body in white (BIW), CAB, etc.)."

Jan 1, 2018

By David E. Albus, Ahmadreza Mortezaie, Bidjan Ghahreman

The structural evaluation of seismic performance of an existing hospital in Long Beach, California, required spring constants of foundation elements. The structure included support by deep foundation elements comprised of belled (underreamed) caissons. The available relationships in the governing building code (ASCE41-13) to compute axial stiffness is not applicable due to the belled configuration of the caissons. The large diameter of the bells required consideration of the foundation medium to the axial stiffness; a detail not clearly described in ASCE 41-13. Furthermore, prescriptive equations in ASCE 41- 13 used to estimate lateral stiffness only consider pile groups with the assumption that the only source of lateral stiffness is the axial reaction of individual piles. These assumptions were invalid for the project at hand where all caissons are configured as single foundation elements, not a pile group. In the present work, the approach taken to estimate seismic stiffness of single-belled caissons is described which accounts for the elastic behavior of the foundation medium below the bell base and lateral behavior of single-pile shafts. Results of the work provide a more satisfactory derivation of the spring constants consistent with current modeling methods. INTRODUCTION Seismic evaluation of an existing hospital in Long Beach, California, required geotechnical investigation followed by site-specific ground motion analysis. This evaluation was required by the Office of Statewide Health Planning and Development (OSHPD) in order to meet the requirements of the Structural Performance Category 4D (SPC-4D) published as a part of the 2016 California Building Code, CBC (Section 3412A). SPC-4D utilizes ASCE41-13, as modified by OSHPD, and involves two seismic performance objectives: BSE-1E (20% probability of exceedance in 50 years) and BSE-2E (5% probability of exceedance in 50 years). Spring constants and capacities of foundation elements were needed for evaluation of the structural performance of the building subjected to these two performance objectives. Our review of the as-built foundation plans indicated that both shallow footings and caissons were used for support of the structure. The plans demonstrated that all caissons are belled (under-reamed) and are individual, i.e. not part of pile groups. In this paper, the subject site condition and foundation elements are described first. This is followed by details of assessing spring constants and vertical capacities for belled caissons. The new requirements of the 2016 CBC concerning the evaluation of critical facilities will likely entail evaluation of other structures with belled caissons due to the more extensive use of these foundations in the past. This paper proposes a method to address the conditions of individual belled caissons not explicitly considered in the current code provisions.

Jan 1, 2018

By Z. Y. Ma, M. D. Liu, Z. Z. Liu, J. K. Zhou

"An optimization method of microwave assisted leaching of copper anode slime was proposed based on Taguchi method. The results showed that the solid-liquid ratio was the most important factor affecting SNR(signal noise ratio) of the copper, tellurium and selenium leaching efficiencies, and its contributions to the copper, tellurium and selenium leaching efficiencies were 58.34%, 55.54% and 60.74%, respectively. Solid-liquid ratio was a significant factor to SNR(copper, tellurium and selenium). Reaction period was a less significant factor to SNR(copper and tellurium) and concentration of sulphuric acid was a less significant factor to SNR(selenium) while microwave power was an non-significant factor, its contributions to the copper, tellurium and selenium efficiencies were 3.22%, 11.73% and 12.73%, respectively. The optimized parameters of the microwave assisted leaching of copper were as follow: microwave power of 500 W, reaction period of 10 min, solid-liquid ratio of 0.10 g·mL-1 and H2SO4 concentration of 1.0 mol·L-1. The optimized parameters of the microwave assisted leaching of tellurium and selenium were as follow: microwave power of 800 W, reaction period of 15 min, solid-liquid ratio of 0.10 g·mL-1 and H2SO4 concentration of 1.0 mol·L-1. The validation experiments under the optimized conditions has been carried out, the copper, tellurium and selenium leaching efficiencies were 98.66%, 84.32% and 64.54%, respectively. INTRODUCTION As important valuable by-products, copper anode slimes are collected from the bottom of the electrolytic bath in the electrolytic copper refining process(Kilic, 2013). The value of the anode slime is determined by the content of rare metals and precious metals(Liu, 2014). Generally, pretreatment of copper anode slime is the first stage of the whole process. The aim of the pretreatment process is to remove Cu, Te and Se etc and enrich the valuable metals. The methods of pretreatment process can be differentiated into: pyrometallurgical processing and hydrometallurgical processing(Amer, 2003). The hydrometallurgical processes are more promising compared to pyrometallurgical processes in terms of cost effectiveness, low energy consumption and environmental concerns(Ranjbar, 2014). However, the disadvantages of the hydrometallurgy process are evident, such as lengthy processing times and low efficiency. Therefore, it is necessary to develop a highly efficient and environmentally friendly pretreatment method."

Jan 1, 2018

By Andre Zingano, Anderson Weiss

"The objective of this paper is to study the behavior of a low thick and low depth coal seam and the overburden rock mass. The mining method is room and pillar in retreat and partial pillar recovery. The excavation method is conventional drill and blast because of the small production. The partial pillar recovery is about 30% of the previous pillar size, 7m x 7m. The roof displacement was monitored during retreat operation; the surface movement was also monitored. The effect of the blasting vibration on the final pillar strength had been considered. Due to blasting, the pillar reduced about 20%. The consequence is more pillar deformation and roof vertical displacement. The pillar retreat and ground movement were simulated in a three-dimensional numerical model. This model was created to predict the surface subsidence and compare to the subsidence measured. This study showed that the remaining pillar and low seam reduce the subsidence that was predicted with conventional methods.INTRODUCTIONMining low coal seams (less than 1 meter) with the room-and-pillar mining method implies the excavation of part of the roof or floor to maintain adequate entry height for equipment and compliance with labor regulations with respect to ergonomic issues. The direct consequence of this is an increase in coal contamination and the increased cost of transportation and preparation at the plant. Traditional room-and-pillar mining only uses a development operation, even with a continuous miner or drill-and-blasting. Therefore, all the run of mine (ROM) coal is carried out with part of the roof or floor. However, if the retreat mining method were to be considered, the quality of the coal could increase because only the coal seam is excavated from the pillar recovery. The quality of ROM coal will increase, and the cost will decrease proportionally to the amount of coal produced from the retreat operation.However, the retreat mining with partial or total pillar recovery implies greater subsidence. This is particularly true if the coal seam depth is shallow, under 100m depth. Subsidence prediction in room-and-pillar retreat mining is complex; it depends upon the remaining pillar (stump pillar) size, as well as the pillar height, and the behavior of the pillar after retreat. This is related to the strength of the remaining pillar, which is related to the excavated method (drill-and-blast or mechanical)."

Jan 1, 2018

By A. V. Kozub, D. O. Sharkovsky, R. I. Ismagilov

"Due to complex mineral composition and fine ingrained nature concentration of iron ores deposited in Mikhailovskoye mine field requires application of wet magnetic separation to produce 65–66% Fetotal and 8.2–8.6 %SiO2, concentrate with 90–94% of material being –0.044micron grain size. Higher specific consumption of ROM, increase of production costs with concurrent reduction of output - those are inevitable side effects of desired concentrate grade improvement. Large-scale complex analysis and surveys have been carried out aimed at concentrate grade improvement with concurrent output increase. Classification of feed in hydraulic cyclones (hereinafter referred to as hydrocyclones) has been the bottleneck for improvement of processing throughput and concentrate output. Hydrocyclone classification efficiency is 50-60% and further improvement is practically impossible. Actual circulating load may achieve as much as 500-600% while the optimal rate is 200-250%. Application of wet fine screening has been considered to improve iron ore concentrate grade. Objective of this work is to design processing flow diagram for unoxidized ferruginous quartzites with implementation of wet fine screening. Large-scale tests have been run in Crushing and Concentrating Plant with application of wet fine screening stage. These tests included application of wet fine screening in 2 and 3 stages of classification to separate desired grain sized material; replacement of hydrocyclone classification with fine screening; application of fine screening as additional stages to concentration process and screening of final concentrate. Testing Methods. EXPERIMENTS AS WELL AS THEORETICAL RESEARCH HAVE BEEN APPLIED FOR THE PURPOSES OF THIS WORK; INCLUDING MAGNETIC, GRAIN-SIZE AND CHEMICAL ANALYSIS OF CONCENTRATION PRODUCTS. MODERN ANALYTICAL DATABASE HAS BEEN APPLIED TO STUDY WET FINE SCREENING FEATURES, MINERAL AND PHYSICAL COMPOSITION OF CONCENTRATION PRODUCTS. Work Results: - analysis of wet fine screening application for iron ore concentration. - technological solutions enabling to improve slurry classification of fine ingrained low magnetic iron ore have been developed. - effective process flow diagram including fine screening has been designed based on the feasible and reasonable arrangement solutions."

Jan 1, 2018

By S. Ali Bastani, Ashley Varni

Design acceleration response spectra (ARS) are directly correlated with dynamic forces and estimated dynamic bridge displacements, which make them a critical aspect of dynamic bridge design. Nonlinear site response analyses are performed for a 1,400-linear-foot bridge site with a SC soil profile at the sides and a SF soil profile in the middle to evaluate the soil profile effects on the bridge analyses. One-dimensional seismic response analysis is commonly performed for site-specific response analysis. SHAKE or similar one-dimensional total-stress equivalent-linear approaches have been used since the 1970s. However, the equivalent linear method has deficiencies when the subsurface soils are susceptible to strain softening. Therefore, various assumptions are made when using the equivalent linear method by practitioners to estimate the SF soil profile site response. With recent advancements in constitutive models, effective stress models have become more popular. Although the effective stress models are generally more complicated and require additional input parameters, they shed further light on the liquefaction mechanism and its effect on the surface ARS. An equivalent-linear one-dimensional seismic response analysis and a non-linear effective-stress seismic response analysis, using DEEPSOIL, were performed to evaluate the ground surface ARS for a proposed bridge site in Orange County. The soil shear strengths were estimated based on cone penetration test results using empirical relationships. The shear modulus degradations (backbone curves) of soil layers were adjusted to match the estimated soil strength at failure. The ARS curves developed from each method were compared to determine the most suitable method for estimating a site-specific design ARS curve for a liquefiable site. Considering that the bridge abutments and the outer bents are founded in bedrock, while the middle bents are founded in liquefiable soils, ARS curves were created for each subsurface condition. Taking into account limitations of the structural analysis software, recommendations were made to combine the multiple ARS curves into a single ARS curve for the structural bridge design.

Jan 1, 2018