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By MKS Vel, S. Mukhopadhyay, R. Mishra

Off late, the criteria of selecting the refractory have acquired a trend line aiming to a cleaner environment and the utmost importance is given to the eco-friendly approach. The stainless steel making furnaces normally use mag-chrome refractories for the obvious reasons of changing slag basicity from acidic to basic. Such refractories generate toxic fumes and compounds with hexavalent chrome, which is unhygienic if inhaled. The present paper describes the development of a chrome free alumina magnesia carbon refractory, it's different test properties, simulative testing and microstructures. The optimum quantity and distribution of carbon in the brick restricts the carbon pick-up by the steel. Bricks with the same composition were manufactured in the commercial scale and used in a stainless steel making furnaces in USA. The performance of same refractory in this furnace was quite encouraging and at present the same quality brick has become a normal practice in this furnace. Since no chromite is used in making this brick, so no toxic compounds are generated environment remains pollution free.

Jan 1, 2004

In recent years, China and India have emerged as major players in the copper sector. Over the last decade, around 50% of additional global refined copper usage growth can be attributed to them. The paper provides an overview of the current and future copper supply and demand situation in both countries. Results from two market studies commissioned by the International Copper Study Group (ICSG) are complemented with recent copper statistics on North-East and South-East Asia, as well as further sectoral analysis. Developments and trends in copper mining and metal production, semis production, and major end use areas are highlighted. While providing insights into sectoral patterns and growth trends, the paper provides the basis for comparing structure and output of the copper sectors in some of the major copper-using countries in Asia. Afterwards, the current copper reservoir in use associated with infrastructure, buildings, industrial equipment, transportation systems and households is assessed using the ICSG Copper Flow Model. Finally, the identified copper flows are analyzed regarding the potential impact on the future world supply and demand situation.

Jan 1, 2007

By M. Sakamoto

Copper foil is an indispensable material for Printed Circuit Boards (PCBs). PCBs in turn are essential elements of all electronic equipment today and thus important for our living in the new age of IT. The requirements from the copper foil market have lately been increasingly strict and diversified due to the rapid technical advancements in miniaturized high-density electronic equipment and highly integrated semiconductors. Tight control of thickness, metallurgical properties, surface morphology and characteristics is needed. In this paper, both electrodeposited copper foil for PCB and rolled copper foil for the flexible printed circuit board are discussed, and the recent technical developments in these copper foil products are reviewed.

Jan 1, 2007

By S. Asano

Hydrometallurgical processes for treating copper sulfide concentrates have attracted considerable attention over thirty years and many processes have been developed. However there have been still problems in those processes because of difficulties of iron removal and high purity copper production with low operating cost. Although SX-EW is highly cost effective method, it is difficult to process the chalcopyrite. Sumitomo Metal Mining Co., Ltd. (SMM) conducted a review of hydrometallurgical copper concentrate processing and has successfully developed a novel process for the hydrometallurgical production of copper from copper concentrate. In this process, copper sulfide is leached by chlorine gas under atmospheric pressure. Most of hydro metallurgical processes can leach only some of chalcopyrite under atmospheric pressure then they need high pressure leaching facility like autoclave. In this process, copper in chalcopyrite can be leached completely by controlling oxidation reduction potential and chloride ion concentration. Cu(I) ion in leached liquor is separated from Fe(I!) ion by SX using TBP then pure copper powder is produced by electrowinning. Results in batch and continuous testworks and pilot plant tests at Niihama Research Laboratories are presented in this paper. Cu2007

Jan 1, 2007

By J. A. Muñoz

In this work, short and long-term tests were performed using different massive mineral sulfide specimens (chalcopyrite, pyrite, sphalerite, galena, covellite and chalcocite) of museum grade and quartz of analytical grade in an acid medium containing silver ions. After attack, the samples were observed by SEM and products characterized by EDS. Parallel, massive specimens of pyrite (FeS2) and chalcopyrite (CuFeS2) were embedded in an epoxy resin, either electrically isolated or in electrical contact, and treated with silver ions in the presence of bacteria. Finally, massive chalcopyrite and pyrite electrodes were subjected to electrochemical measurements in an acid medium under different experimental conditions (addition of silver ions and inoculation). The results showed that silver deposition takes place preferentially on specific mineral surfaces: chalcopyrite, galena, covellite and chalcocite. The chemical reaction of silver ions with pyrite and sphalerite was negligible at low silver concentration (8 ppm). But sphalerite reacted with silver ions at higher silver concentration (100 ppm). In a mixture of chalcopyrite and pyrite, silver was deposited on the former surface creating new cathodic sites which sped up the electrochemical reactions of chalcopyrite dissolution.

Jan 1, 2007

By Raj Thamburaj

"Over the last few decades, the emphasis on affordability and reduced cost of ownership has necessitated the development of innovative processes to carry out repairs in aero engine components. Conventional weld and braze repairs have evolved into advanced, sophisticated processes using state of the art knowledge in lasers, robotics and materials technology. This paper illustrates past and present scenarios in an attempt to illustrate progress that has been made in this area. The problems encountered in the past have been detailed along with the solutions that have been developed and commercially implemented to address these issues. Apart from technical progress, this presentation also addresses the progress made in business approaches and in Certification/Regulatory issues surrounding aero engine repair. Progress in Technology Repair technologies have also been the embryo from which new and revolutionary manufacturing technologies have evolved as well. Electron Beam Free Forming and LENS are examples of how a completely new manufacturing concept can evolve what was originally only a process to join metals. The current and future potential of these spin offs is discussed providing examples of application. While several problems have been solved over time with the implementation of advanced repair technologies, the demands of the industry have created new challenges. The paper describes these issues, outlines potential solutions and discusses the future of repair technologies in terms of the far reaching influence it is sure to have in design, manufacturing, maintenance management and life extension. Progress in Business Trends.Business approaches to repair and maintenance have also gone through considerable change with the introduction of ""Power by the Hour"" and other similar arrangements between the companies responsible for engine overhaul and the end-users. Program Based Logistics (PBL) is yet another innovation to provide a win-win situation for the repair service provider and the end user. This paper traces the development of these business initiatives and highlights successful applications. Progress in Repair Certification, Regulatory Issues.Understanding of the issues surrounding certification of repairs has also evolved with time and regulatory issues have been clarified considerably. Procedures for analysis and testing are much clearer and ""Check Lists"" are being drafted for certifying repairs on various engine components. The PMA phenomenon has added yet another dimension to the issues regarding certification and these are discussed as well."

Jan 1, 2010

"At the May 15, 2006 and the May 1, 2007 Canadian Securities Administrators (CSA) Canadian Institute of Mining, Metallurgy and Petroleum (CIM) meetings in Vancouver and Montreal, CSA requested CIM consider certain issues arising out of the CSA review of Technical Reports and public disclosure, in general, regarding the practice of estimation and reporting of Mineral Resources and Mineral Reserves. The following is a summary of the issues raised by the CSA and the responses of the CIM.Preamble: At the May 15, 2006 and the May 1, 2007 Canadian Securities Administrators (CSA)-Canadian Institute of Mining, Metallurgy and Petroleum (CIM) meetings in Vancouver and Montreal, CSA requested CIM consider certain issues arising out of the CSA review of Technical Reports and public disclosure, in general, regarding the practice of estimation and reporting of Mineral Resources and Mineral Reserves. The following is a summary of the issues raised by the CSA and the responses of the CIM Reserve Definition and the CIM Estimation Best Practices Committees (the Committees). This information is intended to provide the Qualified Person (QP) with further guidance when estimating Mineral Resources and Mineral Reserves and in preparing a technical report written under National Instrument 43-101 (NI 43-101). Several members of the CIM Reserve Definition Committee, the CIM Estimation Best Practices Committee and some members of the Committee for Mineral Resources International Reporting Standards have reviewed these issues and provide the following commentary.Issue 1. - CSA requested CIM review and comment on the selection of an appropriate commodity price to be used in Mineral Resources and Mineral Reserves estimates.Commodity prices are used in the estimation of Mineral Resources and Mineral Reserves and in the economic analysis of a property. In times of rapidly changing commodity prices, or when prices are at the extreme ends of a commodity price cycle, the QP has a difficult job in selecting an appropriate commodity price.• The selection of appropriate technical variables, including commodity price, is clearly the responsibility of the Qualified Person (QP). The QP must describe the reasons for selecting these variables, including price, in the technical report.• The definition of a ""Mineral Resource"" contains the wording ""reasonable prospects for economic extraction,"" therefore, a QP must select economic parameters, including commodity price, that will result in an estimate of Mineral Resources and Mineral Reserves that have ""reasonable prospects for economic extraction""."

Jan 1, 2003

By M. Matsuda

The Hitachi refinery of Nikko Smelting & Refining Co. Ltd. began its electrolytic copper refining operations in 1911. In December 2002, the refinery changed its operation scheme by introducing the ISA permanent cathode technology for the first time in Japan. The change resulted in higher productivity, better cathode quality, and lower operational costs. The operation has been continuously improved to reach a 20% higher production capacity than the original one. For the electrolyte purification process, the Hitachi refinery has developed a new process for removing impurities. The process involves As, Sb and Bi adsorption from the electrolyte by means of chelating and ion exchange resin. The new resin process will achieve higher efficiency in removing impurity.

Jan 1, 2007

By P. Lauzon, C. Oprea, S. Zhou, G. Oprea, J. Rigby, T. Troczynski

Hydration of basic refractories could occur during storage, drying after installation or in use. In order to assess the hydration resistance of various commercially available magnesia-chrome bricks, hydration tests were performed in steam at 110, 120, 130 and 150°C. The changes of the modulus of elasticity by the impulse excitation method, apparent porosity, air permeability, average pore size and pore size distribution were correlated with the hydration data. Mineralogical and microstructural changes were also studied on selected specimens by XRD and SEM/EDS. The hydration mechanisms were discussed in correlation with the chemical and mineralogical compositions of the experimental bricks, in particular with the nature of the mineralogical phases at the grain boundaries.

Jan 1, 2004

By V. C. Pandolfelli, S. F. Santos, L. A. Rodrigues

Under conditions of stable crack propagation at room temperature, the elastic energy stored in ceramic materials is converted mainly to surface energy. However, at high temperatures, creep may also occur in such materials, in which case it will present a ductile behavior. This paper discusses the brittle-ductile transition of a refractory material. Stable crack propagation and creep tests were carried out under a three-point bending device. A commercial ceramic containing 63 wt-% of SiO2 and 31 wt-% of Al2O3 was used as testing material. The results revealed that the change in behavior from brittle to ductile was caused by softening of a vitreous phase present in the material's microstructure.

Jan 1, 2004

By A. Ouellette, E. Nilsson

"Preventative maintenance is a burden for equipment users but a demand from the machine suppliers to ensure performance. Machine availability depends on preventative maintenance being followed.Mining equipment is becoming more and more sophisticated and productive, yet less and less time is available for preventative maintenance. Manufacturers invest in reducing costs, simplifying operating requirements, and lowering maintenance requirements, but it is the users who must invest more heavily in the advanced maintenance systems to keep the units operating.IntroductionPreventative maintenance has been, and still is a key factor in avoiding disturbances in production due to equipment downtime. Manufacturers ask for it in extensive maintenance schedules, check lists, programs, etc. often with a ""threat"" that, if not performed, the machine guarantee will not be valid. Modern mining and construction machinery has become sophisticated, like all other machinery, with elaborate hydraulic, electric and electronic systems and computerized controllers. Maintenance organizations within the mining industry have grown to heavy cost centres just to keep up the availability of the equipment.It is difficult for machine manufacturers to have maintenance programs that suit every user. International suppliers have to deal with different cultures, education levels, environments, organizations, etc. Maintenance programs recommended by manufacturers often do not meet some user's needs while they are ""overkilling"" to others. Preventative maintenance schemes recommendations of what to do, in what frequency, etc.) usually fit mechanical components in the equipment, e.g. wear measurements, crack indications, lubrication, oil changes, etc. But how does one perform preventative maintenance on huge hydraulic systems, electrical and electronic systems and computers? Failures in these systems usually occur without any warning and are more or less impossible to predict. Another difficulty in creating effective preventative maintenance programs for these kinds of systems is the relatively low volume of mining and construction equipment that is produced per year. For example, although Atlas Copco is one of the largest manufacturers in the world of underground blast hole drilling machines, the company still does not produce more than a few hundred drilling jumbos per year. These are made in more than 10 different models, with different systems and components, and very often are custom adapted to the end user's requirements."

Jan 1, 1992

By R. Ramirez

Atlantic Copper Refinery (Huelva, Spain) has operated the ISA permanent cathode technology since 1995. The current production rates are 260,000 t/y cathodes and 730 t/y anode slimes. These slimes undergo an atmospheric leaching in which their copper content is reduced from an average value of 24 % to 16 %. In June 2005 an optimization study of the leaching conditions was carried out aimed at lowering the copper content in the slimes to less than 8%. At the same time, a new mixer (Outukumpu Technology GLS-mixer) was installed in one of the three leaching reactors. As a result of the improvement of the leaching performance and to prevent the return of tellurium to the tankhouse, a cementation plant was commissioned in July 2005 to ensure a Te content below 50 ppm in the Cu-rich leachate. This paper describes the results of the improvement of the leaching conditions and the operation of the new tellurium removal plant.

Jan 1, 2007

By I. S. Laitinen

Outokumpu Technology has recently introduced new technology in both copper electrorefining and electrowinning. This technology includes, among other things, a new permanent cathode (Outokumpu Permanent Cathode) and new busbar technology (Outokumpu Double Contact System). The new technology has already been tested in commercial scale cells. To get a better understanding of the busbar system a multiphysical simulation model of the electrowinning and electrorefining cells was developed. A mathematical model of electrical conduction and heat transfer in a copper electrolysis cell was developed from partial differential equations. The model was expanded to a cell group including seven electrolysis cells connected electrically in series. The model was solved numerically using the finite element method (FEM). Using the model, different intercell busbar systems were simulated. Typical electrical disturbances, like loose contacts between cathodes and the main busbar and short circuits between electrodes, were included in the simulation. The results of the simulation runs with conclusions are presented in this paper.

Jan 1, 2007

By Steven Aiken

The East Boulder Mine located in Montana, U.S.A. utilizes snowmaking to assist with mine water treatment for nitrogen removal. Nitrogen species, including ammonia, are common contaminants in mine water from underground mining operations. Snowmaking provides secondary treatment of nitrogen during the winter due to the chemical and physical processes that occur during snowmaking, in the snow pack and in the snowmelt. The primary processes include atomization, evaporation, sublimation and volatilization. The snowmakers also provide secondary treatment for nitrogen removal when used as evaporators and/or land application units during the summer. In 2002, the snowmaking process was successful at reducing total nitrogen in the mine water by up to 87%. If additional losses due to soil and root zone processes are included, total nitrogen reduction would increase to between 87 and 97%. Snowmaking is an effective nitrogen reducing treatment method during the winter when other treatment methods such as land application cannot be used.

May 1, 2004

"In 2008, the Committee for Mineral Reserves and International Reporting Standards (CRIRSCO) and the Russian State Commission on Mineral Reserves (GKZ) entered into an agreement leading towards harmonization of Russian and international minerals reporting systems. The purpose of the protocol is to define an agreed method by which mineral resources and reserves, reported by companies in Russia according to the current Russian classification system, can be expressed in terms that are comparable to the CRIRSCO reporting codes in Russia and elsewhere."

Jan 1, 2003

"These guidelines have been prepared to assist the Qualified Person(s)in the planning and supervision of exploration programs which will be reported under National Instrument 43101. The Companion Policy of NI43101 references the guidelines and states that issuers and Qualified Persons should follow them.Exploration Best Practices GuidelinesPreamble: These guidelines have been prepared to assist the Qualified Person(s) in the planning and supervision of exploration programs which will be reported under National Instrument 43-101. Such exploration programs must be under the supervision of the Qualified Person who will be responsible and accountable for the planning, execution and interpretation of all exploration activity as well as the implementation of quality assurance programs and reporting. These guidelines are also recommended for use in the planning and execution of exploration programs which will not be reported under NI 43-101. This set of broad guidelines or ""best practices"" has been drawn up to ensure a consistently high quality of work that will maintain public confidence and assist securities regulators. The guidelines are not intended to inhibit the original thinking or application of new approaches, that are fundamental to successful mineral exploration.Results should be summarized and reported in a Technical Report of good professional quality in accordance with the National Instrument 43-101 and Form 1 contained in that instrument. All exploration work from which public reporting will ensue must be designed and carried out under the supervision of a Qualified Person (""QP""). A QP is defined in National Instrument 43-101 as an individual who is an engineer or geoscientist with at least five (5) years' experience in mineral exploration, mine development, mine operation or project assessment, has experience relevant to the subject matter of the project or report and is a member in good standing of a recognized professional association."

Jan 1, 2003

By F. Golestani-Fard, A. A. Nourbakhsh

In this paper microstructural development of nitride-Bonded SIC refractories is reported in presence of Al203, Mg() and Urea additives .The samples were prepared by mixing, shaping and firing at 1400-1500°c in a controlled atmosphere furnace. Phase analysis, microscopic observation and mechanical evaluation were taken for microstructural investigations. The strength of samples doped with Al203 was first increased and then decreased at higher amount of Al2O3 additions. The addition of MgO decreased the strength while the urea showed an improving effect on strength. These phenomena could be attributed to microstructural evolution and mainly to liquid phase formation and grain morphology. It was found that the additives such as Al203, MO and urea could modify the microstructure in terms of phase formation and texture modification, which in terms influences the mechanical behavior.

Jan 1, 2004

By L. Klatzel-Mudry, D. J. Nikols, J. D. Hughes

"The Geological Survey of Canada Paper 88-21, A Standardized Coal Resource/Reserve Reporting System for Canada, is referenced by National Instrument 43-101 for the preparation of resource and reserve estimates on coal deposits. However, for all disclosure of mineral resources or mineral reserves for coal, issuers are required by NI 43-101 to use the equivalent mineral resource or mineral reserve categories set out in the CIM Definition Standards and not the categories set out in Paper 88-21. “Because the framework is based on Canadian deposits and their tectonic regimes, the Canadian Securities Administrators believe it is not reasonable to apply Paper 88-21 to foreign coal properties. The “Resource Links” at the end of this volume provide website links to guidance documents for preparing coal resource and reserve estimates in Australia, South Africa, and the USA.”This report discusses definitions, concepts and parameters used to determine coal resource and reserve quantities, and provides a framework to facilitate consistent categorization of coal quantities found within various depositional and tectonic regimes in Canada.Coal deposits, or portions thereof, are first categorized in terms of their geological complexity <Geology Type), and probable recovery method (Deposit Type). Methods for determining quantification parameters including seam thickness, areal extent and bulk density are outlined for each geology/deposit category. Within each geology/deposit category, coal resources are further divided, based on their assurance of existence, into measured, indicated, inferred and speculative subdivisions and, according to their feasibility of exploitation, into immediate and future interest subdivisions. Coal reserves within each geology/deposit category are subdivided according to whether they are within or outside active mining areas, and may be reported on in place, recoverable and saleable bases.A wide cross-section of the coal industry in Canada contributed to the development of this reporting system. To ensure that the parameters and concepts expressed in the system continue to reflect technological and economic realities in the future, the Coal Association of Canada has established a committee to facilitate periodic reviews."

Jan 1, 2003

Recently, renewed interest in the recovery of uranium from leach solutions has necessitated a re-examination of the hydrometallurgy methods used for uranium in the 1960?s to 1970?s. A synthesizing overview of the lessons learned in those decades together with examination of recent developments in this area is warranted. This paper considers uranium recovery chemistry from acid and alkali leach solutions using solvent extraction and resin ion exchange, and provides information on circuit selection and configuration, equipment selection and design, as well as operational considerations. The unique thermodynamics of uranium solvent extraction are also presented and discussed.

Aug 1, 2010

By A. M. Hadian

The use of dolomite refractories in steel making and cement industries has advantages over other basic products particularly in countries where this type of refractories is produced. Due to existence of high-quality dolomite deposits in many regions of Iran, there is a good potential for producing dolomite refractories in the country. This study focuses on the effect of such additives as iron oxide and alumina on hydration resistance and density of Iranian dolomite. It was found that addition of Fe2O3 is more effective than Al2O3 on increasing density as well as resistance to hydration of dolomite.

Jan 1, 2004