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By Ezra L. Kotzin

Foundry sands used to make molds and cores have been very important to foundrymen since metal casting began hundreds of years ago. They are now used in two basic ways, either in an uncured green state, grain-bonded with clay, or in a set cured state achieved with sand that, mixed with resins or oils, is cured by baking or by chemical reaction. The term sand, as generally used in foundry applications, may best be defined as material composed of granular particles of mineral matter, ranging in size from 0.5 to 2 mm in diameter. The particulate nature of the material may be the result of natural disaggregation or result from crushing and screening of rock or ceramic materials; crushed and screened products are sometimes referred to as "manufactured sand." Based on their origin, the raw materials for foundry sands will vary in grain shape, grain composition, relative surface, grain size, and grain distribution patterns. These properties, in addition to their chemical analyses, sintering point and expansion characteristics play an important part in the choice of sands used as the base molding or core aggregate in metal casting. Sands with different origins may be blended to produce specific compositions and grain size distributions. Early raw material requirements based on silica sand were simple, but as sand/core/mold technology became more sophisticated and binder technology continued to be developed, the physical properties of foundry sands became more critical. Silica sand is composed of quartz, along with, in most cases, small amounts of feldspar, mica, clay, and other common minerals. Although silica sand is still by far the most widely used base material in production of molds and cores used in metal casting, other natural mineral sands have their own unique characteristics and fill an important niche in special applications. As a result, the term sand, as applied to raw materials used in metal casting, has been logically extended to include granular materials composed of a group of minerals other than quartz. With increased use in advanced foundry technology, natural sands composed predominantly of zircon, chromite, staurolite, or aluminum silicate minerals and of granularized chromite or olivine, have become more than just alternate materials and are now commonly classified as sands when the grains are sand-sized. Foundry sand may therefore be considered under two categories: silica sands and non-silica sands.

Jan 1, 1994

By Andreas Nolte

This paper includes a comprehensive report about the metallurgical utilisation of reusable products from electronic scrap recycling, car shredding industry, used glasses an various waste products, such as slimes and flue dusts, generated in a secondary copper smelter. Depending on the copper content, the type of copper compounds and the characteristics of accompanying substances, the materials are treated by smelting in furnaces, operating under reducing or oxidizing conditions. HKs pyro- and hydrometallurgical processes, blast furnaces, converters anode furnaces, tin lead alloy plant and tankhouse will be outlined. The reusable products are categorized according to the origin of the materials and then presented in the form of quantity and quality balances. Processing methods, process able quantities and quality requirements of inputs are described. The utilization degree of the most important metals (copper, tin, lead and zinc) is described with graphics. The report is rounded by information on operating licence according to the environmental regulations of the Federal Republic of Germany and data concerning supply and contracts

Jan 1, 1997

By E. Van Den Neste

A concise historical review is given of the Overpelt plant and the general principles of zinc hydrometallurgy are briefly outlined, together with a description of the new electrolytic zinc plant ore roasting process and, more particularly, the original Overpelt roasting process. A detailed description of the flowsheet of the zinc electrowinning plant, .with an annual capacity of 100,000 t, successfully put into operation in May 1974, is given. The treatment of the residues is performed following the goethite process ; the purification is continuous in two steps; the tank house is equipped with cells containing jumbo cathodes; the handling and stripping of the cathodes is fully mechanized. Concluding the description, some metallurgical and other features of the project are explained in detail.

Jan 1, 1977

By Walter Crafts

KEYNOTE of the technical sessions of the Iron and Steel Division at the Annual Meeting was struck by Leo F. Reinartz in his Howe Memorial Lecture on "The Development of Research and Quality Control in a Modern Steel Mill." In describing recent developments in steel-producing practices at the American Rolling Mill Co. the co-ordination of practical observation and directed research with operations was stressed and was shown to have resulted in economical production of steels of uniformly high quality. Empirical methods based on inaccurate and incomplete experience resulted in the production of commercial products of variable quality and were recognized as inadequate; a research program was therefore initiated that has been justified by its fruits. To name a few outstanding achievements such as Armco iron, steel for electrical sheets, wide continuous strip of superior surface and quality, and non-aging steel is not sufficient to summarize the results of this increasing effort toward better steel products. In addition to the development of new products the faithful observation of operating procedures, the co-ordination of the resulting information, and the standardization of processes have made the steel of today much more uniform and thus more economical and useful to the nation.

Jan 1, 1943

By AIME AIME

MANY interesting papers, opportunity of seeing o1d friends, and an exposition showing all that is latest in equipment, all were factors in bringing a large crowd to Detroit during "Metal Week," October 2-6. The Institute's Iron and Steel and Institute of Metals Divisions held technical sessions at the Statler Hotel on October 4 and 5, and that hotel was also headquarters for the American Society for Steel Treating and the American Society of Mechanical Engineers, both of which also had technical sessions. The American Welding Society and the Wire Association met at the Book-Cadillac Hotel, and the exposition was staged at Convention Hall, out Woodward Avenue. All in all it was a big week for men interested in metal working. One of them stated to your reporter on the train en route to Detroit that this was the one convention that he never missed, and doubtless others felt the same way about it.

Jan 1, 1933

By Osvaldo Bascur, Barun Gorain, Jaco Steyn

"The last few decades have seen some remarkable advancement in information technology, but recently various digital technologies have resulted in several synergies to deliver innovation in diverse applications. The mining industry has been relatively slow in adopting these technologies compared to the other industries, but this scenario is changing fast.Challenges. Mining companies globally are going through a series of challenges such as declining ore grades with complex metallurgy, increasing depth of ore bodies, high capital and operating costs, lower productivity, shortage of technical resources, significant pressure from stake-holders to deliver, along with growing environmental and corporate social responsibility issues. Improvement in profitability would need significant improvements in operational performance.Consequently, over the last few years, there has been a major focus among some mining companies to imbibe operational excellence. This has been only possible because of the replacement of a silos-based approach by an integrated view of the organization. Such an integrated view is now possible via the evolving digital technologies. Even so, such a transformation calls for a change in culture, which, for most organizations is not trivial. Attempts in the past to integrate functions, such as through mine-to-mill initiatives in the mining industry, have demonstrated significant benefits to many operations (McKee, 2013). Still, sustaining these benefits has clearly been a challenge due to manpower turnover and lack of proper systems and structures that integrate information between business functions within an operation and between operations and the corporate level.Opportunities. The advent of digital technology has opened up opportunities to integrate interdepartmental information for a unified understanding across an entire organization. The advances in instrumentation, equipment control systems, supervisory control systems (SCADA/ Historian) and industrial networks have helped in the direction of enterprise- wide integration. The availability of real time information across an enterprise has given rise to numerous possibilities to improve organization performance. As suggested by Seshan and Gorain (2016), some of the potential opportunities are as follows:"

Jan 9, 2018

By B. Gorain

"INTRODUCTION The last few decades have seen some remarkable advancement in information technology, but recently various digital technologies have resulted in several synergies to deliver innovation in diverse applications. The mining industry has been relatively slow in adopting these technologies compared to the other industries, but this scenario is changing fast. Keywords: Digital Transformation, Operational Intelligence, Gold Recovery, Mine to Mill integration, Planning and Execution strategy, Theory of Constraints. Challenges Mining companies globally are going through a series of challenges such as declining ore grades with complex metallurgy, increasing depth of ore bodies, high capital and operating costs, lower productivity, shortage of technical resources, significant pressure from stake-holders to deliver, along with growing environmental and corporate social responsibility issues. Improvement in profitability would need significant improvements in operational performance. Consequently, over the last few years, there has been a major focus amongst some mining companies to imbibe Operational Excellence. This has been only possible because of the replacement of a silos based approach by an integrated view of the organization. Such an integrated view is now possible via the evolving digital technologies. Even so, such a transformation calls for a change in culture, which, for most organization is not trivial. Attempts in the past to integrate functions such as through Mine-to-Mill initiatives in the mining industry have demonstrated significant benefits to many operations (McKee, 2013). Still, sustaining these benefits has clearly been a challenge due to manpower turn over and lack of proper systems and structures that integrate information between business functions within an operation and between operations and the corporate.Opportunities The advent of digital technology has opened-up opportunities to integrate inter-departmental information for a unified understanding of, and across, an entire organization. The advances in instrumentation, equipment control systems, supervisory control systems (SCADA/Historian) and industrial networks have helped in the direction of enterprise wide integration. The availability of real time information across an enterprise has given rise to numerous possibilities to improve organization performance. As suggested by Seshan & Gorain (2016), some of the potential opportunities are as follows:"

Jan 1, 2018

The development of metallurgical training is briefly reviewed. The reasons for the current trend for Metallurgy Schools to become Schools of Materials Engineering or Materials Science are mentioned as is the role of Departments of Chemical Engineering in the teaching of extraction metallurgy. Some problems on academic staff recruit- ment are highlighted and predictions concerning future difficulties in industry getting adequately trained professional staff are made. The need for a special effort to attract and retain the best undergraduate students is put Forward.

Jan 1, 1987

By Fred Wise

THE Getchell mine, a comparatively recent gold discovery, is in the old Potosi mining district, Humboldt County, Nevada. All ore is mined from open pits using Diesel shovels and gasoline trucks. Two types of ore are mined, oxide and sulphide. Oxide ores are siliceous or shaly; sulphide ores either gougy, siliceous or shaly. In mining, the sulphide ore is segregated into hard and gougy ore, because the gouge must be dried before it can be crushed, The oxide ore is not segregated. GENERAL METALLURGY The oxide ore is the leached outcrop that overlies the sulphide ore body. All of the iron and arsenic sulphides found in the sulphide ores have been thoroughly oxi-dized, The sulphur and arsenic have been leached out while the iron is present as hematite and limonite. The oxide ore is amenable to direct cyanidation, and although no visible free gold is present it is released at a comparatively coarse grind. The sulphide ore is more refractory, since the gold is all of micron size and some of it is locked in fine sulphides. It has been established microscopically that the free gold is coated with an impervious shell, which is probably some form of iron compound. The sulphide ores contain from 1.5 to 2 per cent of arsenic, which is present as orpiment and realgar with minor amounts of arsenopyrite. The orpiment and realgar are of a later mineralization than the gold and are barren. Roasting and washing of the sulphide ore prior to cyanidation is necessary to eliminate the arsenic, to alter the gold coating from an insoluble form to a soluble form, and to release the gold associated with the fine sulphides. Washing the ground calcine in weak sulphuric acid, trona, or hot water are beneficial in the order named, but to date the water is the best from an economic standpoint. Metallurgical tests as well as plant practice indicate that a certain amount of gold cannot be recovered even by going beyond economic practices, On this basis metallurgical results are viewed in the light of an optimum tailing rather than a per-centage of extraction.

Jan 1, 1940

By E. H. Smith

St. Joe Minerals Corp., a subsidiary of Fluor Corp., treats high-grade gold, silver, and copper ore at its El Indio plant at an altitude of 4 km in the Chilean Andes. The ore is complex, being a mixture of massive pyrite-enargite and quartz, both containing very fine gold and silver. Treatment produces a copper flotation concentrate containing high levels of gold, silver, and arsenic, and also dore bullion. Part of the flotation concentrate is roasted to remove the arsenic content, and arsenic trioxide is collected as a by-product.

Jan 1, 1987

By Edward Hall Smith

The E1 Indio Mine is located in the Andes mountains about 180 kilometers East of La Serena, capital of the Fourth Region of Chile. It is reached by an international highway running up the Elqui Valley as far as Juntas from where the last 42 kilometers is on a road constructed by the Company. The plant is located at 3.900 meters above sea level among extremely rugged terrain with nearby mountains rising about 5.500 meters. Climatic conditions at these altitudes are severe with winter temperatures down to -20°C. Snow storms lasting several days and leaving up to two meters of snow have been experienced, while fierce winds are corm=.

Jan 1, 1984

By Frank R. Milliken

SCOPE THIS paper is a running commentary on metallurgical problems and developments, stressing ilmenite flotation, since the start of operations five years ago, at the mill of National Lead Company, Titanium Division, Maclntyre Development, Tahawus, New York. [ ] GENERAL In early 1941, when, world conditions threatened to cut off the supply of ilmenite (obtained largely from India) to this country, the National Lead Company started to develop and bring into production their Maclntyre Development. This operation supplied the bulk of the ilmenite used during the war period for the manufacture of the much needed titanium pigments. Maclntyre Development is at Tahawus, New York, on the headwaters of the Hudson River in the center of the scenic Adirondack Mountains. A general description of the operation was given in the Adirondack Issue of Mining and Metallurgy for November 1943. Operating tonnages and production have increased since 1943, however. Nearly 10,000 tons of ore and waste is broken and loaded daily in the open-pit mine. About half of this tonnage is ore, from which is produced nearly 800 tons of ilmenite concentrate and 1600 tons of magnetite concentrate daily. ORE-TYPES From an ore-dressing standpoint, there are five rather distinct ore types and two waste-rock types in the mine. The ore types are shown in Table 1. The anorthosite waste is a coarse-grained white rock, largely labradorite feldspar. The gabbro waste is generally finer grained, and contains, in addition to feldspar, 35 to 75 pct iron silicates such as hornblende, pyroxene, garnet and biotite. A minor mineral mineralogically, but important metallurgically, is apatite. A few calcite

Jan 1, 1947

By Q. C. Reynolds

Keywords: Pyrometallurgy, plant, photography, GIS, satellite images, Google Earth Google Earth is a piece of software able to display an interactive three-dimensional map of the world, combining aerial and satellite photography with maps, terrain, and user-generated geographical information systems (GIS). Many structural features of the planet, both natural and man-made, are of great interest to the mining and metallurgy field, and in this paper a study is made of the current state of the art of data accessible by Google Earth.

Jan 1, 2006

By P. D. I. Honeyman

DURING 1938 many copper companies again felt the economic pinch and smelter operations were often on a reduced basis which some- times resulted in intermittent operations and complete shutdowns. During the last half of the year production was stepped up and smelting operations resumed a more normal appearance. One of the present-day trends in reverberatory sme1ting is definitely toward high-tonnage operations. i\ t the Phelps Dodge Corporation's Douglas plant, the reconstructed 107 by 26- ft. reverberatory furnaces are operated at the rate of 1000 tons of solid charge per day. The arch, all of silica brick; is sufficiently high above the bath to give

Jan 1, 1939

By R. Ordóñez Olivares

This manuscript focuses on the design and development of steels for the railroad industry and methods of testing them. Here are summarized the results of research focusing on alloy development and design, with particular focus on advanced rails and wheels. The high-performance steels are characterized for their mechanical and service characteristics. The relationship between properties and cleanliness is discussed and compared to the regular railroad steel. Some of the tests presented are standard tests that are complemented with the nonstandard test recommended by the Association of American Railroads (AAR) and recommended modifications of this. The paper presents the results of metallurgical analysis, mechanical, and residual stress tests. The laboratory methods include microstructure, residual stresses, tensile, hardness, fracture toughness, and microcleanliness tests.

Jan 1, 2013

By E. P. Fleming

COMPARED to the situation abroad, the domestic industry continues to lag both as regards the production and consumption of newly mined lead. During 1938 we produced and consumed slightly over 20 per cent of the world output, whereas ten years ago the figure was nearly double this pro- portion. Labor difficulties and absence of demand were chiefly responsible for the general inactivity. In the foreign field, in spite of low metal prices, production and consumption of lead equaled or exceeded all previous records. Practically all the large companies, with the exception of those in Spain, increased operations, though it should be noted that the foreign lead mines have higher-grade ores than domestic mines. In view of the rapid expansion of the foreign industry, it is natural to expect greater progress abroad, particularly in process metallurgy.

Jan 1, 1939

By Carle R. Hayward

THOUGH recent months have seen a rapid decline in lead-smelting activity and consequent uncertainty as to the future, the first half of the year showed progress in keeping with similar activity in other metals. Demand for scrap increased and various lead-bearing materials found their way to plants producing secondary lead. Some of these materials introduced complications into normal smelting procedure and were the cause of many conferences among plant officials attempting to find the most satisfactory method of treatment. If a blast furnace is to do itself justice it must be run with an open charge. Troubles inevitably result when materials are added to a charge which tighten it up and pre- vent free burning of the coke and con- sequent rapid smelting with a clean hearth This fact has long been recognized by plants producing primary lead, but only recently only it received the attention it deserves.

Jan 1, 1938

By T. D. Jones

MUCH the same story can be told for the lead industry for the year 1945 as for the three previous years. In response to inquiries as to new developments, invariably the answer has been, "No new developments-our men either too busy with the man-power problem or trying to get production out." Time and efforts of industry have been concentrated for the most part on war or readjustment problems. Now that V-E and V-1 day have passed, the lead industry can justly be proud of its record in World War II. As in previous wars, lead played an important role and one of its most spectacular uses was in the production of the atomic bomb. We read that the part lead played was rather obscure, but as a protective agent, lead played a most significant role. "Since the materials in the Pile Plant are intensely radioactive, all storage and handling must be done behind thick concrete walls or lead shields. The material is never seen and all operations are auto matically controlled by a foolproof remote control system especially designed for this purpose." (Chews. & Met., Sept. 1945.) When our armies invaded the European theater of war and made a landing on Normandy beach, gasoline and oil for the motive power were furnished through miles of armored lead pipe. This amaz-

Jan 1, 1946

By Gustave E. Behr

The peculiar and changing conditions of a wartime market and the necessary governmental restrictions have resulted in an accumulation of a large amount of certain secondary metals in the tin-lead alloy class. With certain of these metals this accumulation has reached such proportions that it has been proposed that government agencies finance the creation of stockpiles of these secondaries just as stockpiles of primary metals have been created. The purpose of such financing would be to keep the secondary metal dealers engaged in collecting these metals, which they might

Jan 1, 1943

By David Segura

THE Huitzuco mercury deposits have been described by C. W. Vaupell,1 therefore the general information such as location, history, production, etc. will not be repeated here. The present owners acquired the property when the deep levels of the Cruz mine were flooded, and it was believed that a relatively large tonnage of low-grade ore and fills would be encountered in the flooded section, because f the early mining methods used in the Cruz mine. The mine was partly unwatered and about 187,000 tons of fills was pit-sampled in the San Cayetano stope. These fills average 2.4 kg. Hg per. ton. During the period of maximum production at Huitzuco, the ores were sorted in the mine and cobbed into 3-in. pieces, which were treated in Scott furnaces. Large pieces of raw ore are found in the sinter, and it is indicated that both recovery and, costs were not very satisfactory. Recent practice has been to treat the ores in closed retorts made of 10-in. pipes. Because f the presence of combined antimony in the mineral livingstonite (HgS.2Sb2S3) and considerable native sulphur, little or no metallic mercury is recovered in the condensers and a second retorting of the condenser muds is-necessary. This makes the treatment of the ores expensive and tends to low recoveries of mercury. The prin-cipal costs of retorting are, in their relative order: (1) fuel, (2) low recov-ery of mercury, (3) replacement of retort pipes, (4) labor.

Jan 1, 1938