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By PáDeáBosscher, A Bruwier, M Weidenbach, C Philippe, T Ly, A Van Den Bosch

In the mining business the cost of grinding media represents up to 40 per cent of the total milling cost and therefore grinding media optimisation has a direct impact on the concentratorsÆ bottom line. In the process of optimising grinding media alloys, Magotteaux developed its own methodology which consists of a series of analyses, tests, calculations and evaluations and assist the concentrator in optimising their processes.This paper presents the Prominent Hill case study where this methodology has been applied on both the secondary ball mill and regrind IsaMill«.The analysis of the wear conditions in the secondary ball mill allows Magotteaux to select a series of grinding media alloys to be tested to reduce grinding media consumption. By marking these different grinding media types with a unique drilling pattern, one can quantify the relative wear performance and cost effectiveness of each grinding media type within the same milling environment. After selecting the most economical grinding media composition a full scale industrial trial, involving topping up the selected grinding media is carried out and the media wear performance closely monitored and analysed.For stirred grinding mills, suppliers propose different grinding media, mainly ceramic beads, with specific properties and cost. Therefore the concentratorsÆ choice is a compromise between grinding efficiency, wear resistance and cost. The selection of the correct grinding media for stirred milling and the assessment procedure will be presented in this paper. The test results of the new stirred grinding media type in the regrind IsaMill« at Prominent Hill are presented and analysed.CITATION:Weidenbach, M, Van Den Bosch, A, Bruwier, A, Ly, T, De Bosscher, P and Philippe, C, 2012. Forging ahead - A collaboration between the OZ Minerals Prominent Hill Concentrator and Magotteaux to improve plant performance, in Proceedings 11th AusIMM Mill OperatorsÆ Conference, pp 105-110 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Oct 29, 2012

By A. R. Khodabandeh, T. Nematkhah

Correct selection of forging parameters is very important to produce sound superalloy parts. In this investigation nickel-iron base superalloy IN901 successfully forged and seal spacer, which is a part of airplane with about 11 kg weight has been produced. Forging has been performed on the basis of hot compression results, which show deformation above 1100°C associated with dynamic recrystallization (DRX) which can increase the workability of material. On the other hand annealing at 1100°C decreases the flow stress during hot compression, and then increases the material formability. Then billets annealed at 1100°C in electrical furnace for 24 hours and reheated again to 1100°C before forging. Initial square cross section billet with 128mm side and 202mm length forged immediately after reheating by 80MN mechanical press. Specimens forged in five steps: upsetting, three steps molding and finishing. Preformed and molded specimens reheated in electrical furnace before later step of forming. Finally specimens trimmed by 1 OMn mechanical press and hot set by hydraulic press and then cooled in air to room temperature. Results show that reheating temperatures has been selected correctly because there isn't any surface crack and die cavities filled completely by forging material. Material flow has been carried out properly and there isn't any defect in critical points especially in extradoses and intradoses. Microstructural examinations show that grain boundaries contain Ti-rich globular particles that formed during cooling.

Jan 1, 2006

By Bin Du

In recent years, concurrent product design and process is gaining popularity and will become a norm of the industry of the future. Forging has been a critical manufacturing process for production of components with superior tensile strength, toughness and grain flow. This paper describes an expen system which is being developed for forging die design and forging process analysis in concurrent engineering environment. Rules and guidelines pertaining to forgeability are formulated and incorporated into the knowledge-base in building the system. The system is built using an object-oriented paradigm. The object-oriented approach and hierarchical rule structure paradigm are briefly discussed. Finite element analysis packages (ALPID-2D) were incorporated into the program to give the simulation result of the forging process. The system can automatically produce a competent design and recommend a set of processing parameters for a given product. The designer can modify the design according to the result of the simulation.

Jan 1, 1992

By F. E. Bash

IN recent years, there have been a number of experiments conducted to determine the rates of heating and cooling of various sizes and shapes of steel ingots. Up to date, however,-most of the published data has dealt with small sized ingots, the largest being an 18-in. (46 cm.) cube, the data on which was presented before the Iron and Steel Institute in May, 1918, by E. F. Law. It is due to thus lack of information on the rate at which large ingots absorb heat and come to temperature that the heating- practice varies so widely in different plants. One of the questions over which there is much debate is the proper rate of heating of large ingots for forging and the time actually required for the center of a mass of steel to come to forging temperature. As a continuation of experiments described by M. E. Leeds1 and at the request of Mr. G. R. Norton of the Sizer Forge Co. and Mr. R. C. Drinker of the Emergency Fleet Corpn., the test described in this paper was carried out on a 24-in. (61 cm.) round ingot and the rate of heating and cooling determined under regular production conditions. The ingot had been partly forged at one end but, on developing a flaw, had been scrapped so that it was available for test. The size and shape of the ingot and its position in the furnace are shown in Fig. 1.

Jan 9, 1919

LAWFORD H. FRY, Burnham, Pa. (written discussion*).-As a sup-plement to the information given by Mr. Bash, a diagram is submitted showing the results of a somewhat similar experiment carried out at the ordnance plant of the Standard Steel Works Co. In this case the ingot to be heated was a nickel-steel octagon ingot, weighing 14,700 lb. (6667 kg.). This ingot was to be forged into two 255-mm. howitzer jackets. A hole was bored half way of the length of the ingot, extending into the longitudinal axis, and a base-metal thermocouple inserted in this hole.

Jan 11, 1919

By Jamie N. Burdeski, Susan E. Hartfield-Wünsch

Aluminum sheet use has been steadily increasing in the automotive industry to achieve mass reduction and improve fuel economy. One significant manufacturing challenge for aluminum sheet implementation is the reduced formability compared to the steel alloys it replaces. This paper includes friction results from the draw bead simulator (DBS), twist compression (TCT) and strip draw (SDT) tests, for two oil based lubricants and four hot melt lubricants. Formability testing was done with the same lubricants and materials, testing in pure stretch with a hemispherical punch, and in draw with a breadpan shaped die.

Jan 1, 2015

By H. Utsunomiya, J. Su, K. S. Tamimi, S. Yue, M. Sanjari, L. Kestens, A. S. Kabir, R. Petrov

The recrystallization and texture evolution of AZ31 sheets obtained through two stages was investigated at different stages of post-rolling annealing. The specimens were rolled at the temperature of 100? and at a fast speed of 1000m/min and low speed of 15m/min with a reduction of 30% in one pass. The results show thatAZ31B sheets rolled at 15 m/min and 100 °C has fractured for reductions of more than 30% per pass. However, by increasing the rolling speed to 1000 m/min the rollability was improved significantly and the material can be rolled to reductions of more than 70% per pass. The high speed and heavily deformed materials are fully recrystallized even at 100 °C.

Jan 1, 2015

By H. Utsunomiya, J. Su, K. S. Tamimi, S. Yue, M. Sanjari, L. Kestens, Hara, A. S. Kabir, R. Petrov

Manufacturing of thin sheet is difficult in industries. Some approaches, such as small-draft multi-pass rolling, intermediate annealing, isothermal rolling and high-speed rolling were proposed to overcome the deformability. In this study, different rolling speeds from 15 to 1000 m/min were employed to twin rolled cast AZ31B magnesium alloy to different reductions. The results show thatAZ31B sheets rolled at 15 m/min and 100 °C has fractured for reductions of more than 30% per pass. However, by increasing the rolling speed to 1000 m/min the rollability was improved significantly and the material can be rolled to reductions of more than 70% per pass. The high speed and heavily deformed materials are fully recrystallized even at 100 °C.

Jan 1, 2014

By Fernando Altamirano

El presente trabajo refiere la prevención de incendios en los campamentos mineros metalúrgicos a través de un programa de formación de brigadas. Los principales objetivos del programa son identificar los riesgos de incendio para asi corregir las condiciones inseguras mediante las inspecciones de rutina, aplicar los medios de control y extinción de fuegos de que disponga el minero y la educación al personal en la prevención de incendios para adiestrarlo en la respuesta inicial y calificada.

Oct 6, 1999

By Alcides Meléndez González

La formación profesional del personal minero es importante en tanto mejora su desempeño y responsabilidades con la empresa y actividad minero. En ese sentido, el presente trabajo describe los programas de educación profesional desarrollados por el Estado u organizaciones privadas a través de tres etapas: formación profesional elemental, formación profesional especializada y la formación profesional universitaria. Los principales objetivos son: adquirir los fundamentos técnicos, científicos y tecnológicos de la actividad minera y establecer mejores métodos de trabajo como nuevos procesos tecnológicos.

Nov 1, 1972

By Jorge Vargas Fernández

Con el objetivo de incrementar la productividad de la minería, se plantea la realización de una positiva acción nacional de formación y capacitación en todos los niveles de la industria minera a través de un análisis de la situación actual respecto de los mineros, ingenierios y técnicos. Por ello, el presente texto señala la descripción del sistema "B" en funcionamiento de la productividad minera y la tecnología adecuada a la realidad.

Nov 1, 1972

This book has employed miners' narratives to illustrate basic concepts about the escape process. One of the most powerful means by which people make sense of their experiences is through the telling and internalization of stories [Bruner 1990]. By couching one's own and others' motives and actions in terms of a coherent narrative, a person is able to learn from mistakes and plan future behaviors that may help ensure survival. A growing body of research suggests that decision-making skills used to deal with emergency situations can be taught and assessed by simulations based on narratives from the real world [Bransford et al. 1986; Brecke 1982; Brener 1984; Connolly et al. 1989; Halff et al. 1986; Jones and Keith 1983; Lacefield and Cole 1986]. Such techniques have been used to address the decision-making of medical personnel, civil and military flight crews, and even people involved in broader life events such as political and military situations [Babbott and Halter 1983; Dugdale et al. 1982; Farrand et al. 1982; Gilbert 1975; McGuire 1985; McGuire et al. 1976; Flathers et al. 1982; Giffin and Rockwell 1984; Jensen 1982; Janis and Mann 1987]. Given the validity of this method of study and the promise it holds for helping people improve the quality of their responses to nonroutine occurrences, it is perhaps surprising that there have been no studies of emergency decision-making among blue-collar workers prior to those conducted by the present authors and their colleagues. The purpose of this chapter is to describe underground coal miners' decision-making performance on a table-top simulation whose problem structure is derived from interviews with a group of eight miners who escaped from the 5 Left section at Brownfield Mine. The exercise was constructed by a panel of domain experts (mine safety and rescue personnel) with the assistance of an educational psychologist. The simulation includes actual predicaments with wise and unwise decision alternatives that, in the opinion of these domain experts, are characteristic of such escapes. Results reported in this chapter are the scores of a sample of experienced mine workers who completed the simulation. Because the exercise is a series of objective performance tasks coupled with detailed and immediate feedback, this simulation can be used to teach and refresh critical escape skills, as well as to provide data concerning the proficiency of miners at the time of exercise administration.

Jan 1, 2000

By D Nourry

Optimising the blast is a major issue in the blasting business. It generally means acting on the blasting pattern (drilling, charging, detonating) in order to get a given æresultÆ. This result may either be related to economic reasons, such as the fragmentation influencing productivity, or technical reasons, for example vibrations and projections. Within the frame of the EEC funded Brite-Euram project entitled æBlast-ControlÆ, involving academic research and applied expertise, a general methodology was developed to approach such a problem and currently applied to the industrial partners of the project and final end-users of the generated results. These partners are the limestone ALZO quarry of the CALCINOR group in the north of Spain and the dolomite DMD (Dolomies-de-Marche-les-Dames) quarry of the LHOIST group in the east of Belgium. A first part of the project, over 18 months, was dedicated to establishing a clear relationship between productivity of operations from drilling to primary crushing and the fragmentation resulting from the blast. Extensive monitoring of blasting, production performance and fragmentation data was carried out and automatically collected into a database on both quarries. As expected, it appeared that excessive amounts of fines or boulders were substantially reducing productivity and thus profitability of the operation. Furthermore, an æoptimalÆ fragmentation was assessed for the quarries to run at the best (high throughput, low cost). The second and last part, for the remaining 18 months, was then dedicated to adapting the blasting practice in order to orientate the fragmentation towards a æbetterÆ one. A very common problem normally addressed by any consultant. Nevertheless, the target was not limited to solving the problem for these two quarries, but also to develop a generic method to address this blasting adaptation process and to implement it into a computerised tool. At this stage, it is then obvious that portability of the method and the system are major qualities to be looked for. This paper is aimed to present how this method was developed, how the system was implemented and how it was finally used.

Jan 1, 2001

By Carl Swartz

METALLURGISTS differ considerably in their opinions regarding the effect, if any, of small amounts of iron pyrites, or other iron compounds on zinc sulfide ores during the roasting operation. As a result, the literature on this subject expresses many conflicting ideas. The ore, previously crushed to pass through a one-millimeter screen, dries in the roasting kiln, losing water up to 200° to 300° C. At 150° C. iron pyrites begin to lose sulfur. As the temperature increases, while the ore is passing to the hotter part of the furnace, the sulfur burns to sulfur dioxide, leaving the metals as zinc oxide and ferric oxide. These two substances then interact to form zinc ferrite, a compound, yellow brown in, color, having the general characteristics of a spinet Like magnetite, another spinel, zinc ferrite is insoluble in alkalis and dilute acids. As a result, when leached with 10 per cent. sulfuric acid solution zinc values tied up in this compound remain behind. HISTORY In the electrolytic recovery of zinc from its ores, the roasted ores are usually leached with a 10 per cent. sulfuric acid solution. When the zinc ore contains iron pyrites as an impurity in an appreciable amount, the actual yield of metallic zinc is much lower than a theoretical calculation would indicate. Further, losses of zinc are, in a rough way, directly proportional to the amount of iron pyrites or other iron compounds present. When the iron is present in the ore in an isomorphous relation to the zinc, as in the case of a marmatite, a greater amount of zinc remains insoluble than when present as a true pyrite or marcasite. Work on the insoluble residues obtained from leaching of the calcines shows that the zinc lost is intimately tied up in this residue. Some investigators have suggested a definite compound, such as zinc ferrite, others merely a mixture of zinc and iron compounds.

Jan 1, 1927

By R. K. Clifford

The formation of elemental sulfur on the surface of sphalerite in aqueous systems was investigated. Hallimond tube flotation tests showed that unoxidized sphalerite did not float well without a collector. Flotation recoveries of greater than 95 percent were obtained without the use of a collector or frother after the sphalerite had been reacted with oxygen under pressure and water at pH 2.8 at room temperature. High flotation recoveries also resulted when sphalerite was reacted in acidic solutions in the presence of platinum sponge, titanium sponge, 316 stainless steel, copper turnings, or [10-5M++]. Conditions which produced high flotation recoveries of sphalerite yielded contact angles of 37° to 40° and also produced elemental sulfur. The increase in elemental sulfur on the surface of sphalerite was detected by elemental sulfur extraction with petroleum ether, electron spectroscopy for chemical analysis (ESCA), and the electron beam microprobe. The quantity of elemental sulfur formed was insufficient to be detected by infrared or Raman spectroscopy, or by the optical microscope or by the scanning electron microscope. An electrochemical type reaction for the production of elemental sulfur in acidic solutions was proposed. The cathodic reduction of oxygen was the slow step which needed to be catalyzed. A chemical type reaction which produced H2S rather than elemental sulfur was evident in non-oxidizing conditions.

Jan 1, 1974

By A. Jowett

An attempt is made to explain differences in the size-by-size response to flotation of some sulphide minerals. Physical factors involved in particle-bubble collision and adhesion, and also in possible subsequent disruption of aggregates, are considered especially in relation to flotation of the coarser sizes. Emphasis is on practical observations and their significance, with an essentially qualitative theoretical treatment designed to form hypotheses for further experiments. In particular, the theoretical effects of contact angle and induction time are examined. An argument is developed which suggests a rapid increase in induction time as particle size increases, except for particles small enough to be moving under laminar flow conditions. This can adequately explain poor recoveries of coarse particles in flotation without a need to assume disruption of particle-bubble aggregates in turbulent zones in a flotation cell. Flotation recovery is shown to be very sensitive to small changes in induction time. Consideration of the physics of disruption of particle-bubble aggregates leads to the conclusion that this mechanism does not adequately explain differences in flotation recovery of coarser sizes of some sulphide minerals. For example, to explain differences in recovery of coarse galena and chalcopyrite by this mechanism would necessitate accepting that conditioning with ethyl xanthate which would promote a 60º contact angle at a galena surface would promote only an 11º angle at a chalcopyrite surface. Small differences in induction time arising from differences in surface chemical characteristics of the various minerals offer a more satisfactory explanation of differences in recovery of coarser sizes.

Jan 1, 1980

By G. C. Yao

Iron and silicon impurities can form needle and branch shape intermetallie compounds in molten aluminum when there is no manganese. It is difficult to separate them from molten aluminum by electromagnetic separation. The Fe-Si-AI and Fe-Al intermetallic compounds were transformed into Mn-Fe-Si-Al and Mn-Fe-Al compounds by the addition of manganese into molten aluminum. In molten aluminum the morphology of these intermetallic compound particles is lumpish and spherical. Migration resistance of these impurity particles is small, which is beneficial to separation. FeSiMnA4 and FeMnAI6 are paramagnetic. These impurity particles can be moved by magnetic force and can be separated from the molten aluminum.

Jan 1, 2003

By G. C. Yao

Iron and silicon impurities can form needle and branch shape intermetallie compounds in molten aluminum when there is no manganese. It is difficult to separate them from molten aluminum by electromagnetic separation. The Fe-Si-AI and Fe-AI intcrmetallic compounds were transformed into Mn-Fe-Si-AI and Mn-Fe-AI compounds by the addition of manganesc into molten aluminum, In molten aluminum the morphology of these intermetallic compound particles is lumpish and spherical. Migration resistance of these impurity particles is small, which is beneficial to separation. FeSiMnAl4 and FeMnAl6 arc paramagnetic. These impurity particles can be moved by magnetic force and can be separated from the molten aluminum.

Jan 1, 2003

By Phipps P. J

The rate of precipitation of ferric iron as ammonium jarosite, NH4.Fe3(SO4)2(0H)6 from acidic solutions near 100¦C, was found to increase with weight of jarosite seed crystals, and with concentration of ammonium ion, but to decrease with increasing acidity. The particle size of the product crystals was larger at low sulphate concentrations and at high ammonium concentrations. Particles appeared to be agglomerates, with diameters ranging from 0.5 up to 25 um, and composed of individual crystals of diameters ranging from 2 um apparently down to 0.1 um or Lass

Jan 1, 1977

By Charles H. Moore

In the study of the properties of rutile pigments it became apparent several years ago that certain physical and optical properties could not be determined on particles of pigmentary size. Since reflected light is the dominant type which reaches the eye from small particles, the true color of pure rutile was not known. Most rutile pigments are acicular in habit, elongated parallel to the "c" axis. It was considered important to know the nature and tone of light transmitted, for example, by a basal plate. Further, as shown by spectrophotometric curves, there is a very strong absorption of light of 4000 k as measured on particles with random orientation. It would be interesting to see whether this absorption position varied with predetermined and selected orientations. Also, since the behavior of titanium pigments in a vehicle is important, a knowledge of the surface wettability of single crystals by various media should prove very fruitful. Finally, the optical properties of rutile are such that it should show, in a single pure crystal, greater fire and brilliance than the diamond. Mineralogists had long speculated that this would be the case and curiosity was strong to produce a single crystal large enough to cut.

Jan 1, 1949