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Mineral processes are relatively simple and metallurgical accounting would also be simple if it were not for the nature of the raw materials and the large scale of operations. Essentially the balance between input and output requires only weighing and assaying of the feed, salable products, and waste. but because of complexities to be described in the following pages there are few plants that do not encounter difficulties that cause some sacrifice of precision for economy and practicality. In arriving at a sound compromise, capable

Jan 1, 1985

By R Morrison, R Dunn

In many mineral processing operations, the reported production figures for an accounting period may not make the best use of available data. While most of the mathematical approaches, such as check-in/check-out, mass balancing, used in effective metallurgical accounting strategies are well understood, the sources and magnitude of measurement errors generally are not. As part of the æAMIRA P754-Metal Accounting and ReconciliationÆ project, a study was undertaken at the Northparkes copper/gold concentrator near Parkes, New South Wales to examine the data used in their concentrator metallurgical accounting system. This paper summarises the results of a detailed examination of the mass measurement systems around the concentrator as well as the primary sampling system used for grade estimation. The goal of this work was to develop practical techniques to quantify the error (ie both accuracy and precision) of the measured metal accounting information. With this information, statistical confidence levels for this data can then be calculated. If the errors are small, the effect of error in each piece of measured data can then be propagated to other calculated production figures such as recovery and feed grade using a statistical technique called æthe propagation of errorÆ.

Jan 1, 2007

By W. M. Jansen

In many mineral processing operations, the reported production figures for an accounting period may not make the best use of available data. While most of the mathematical approaches, such as check-in/check-out, mass balancing, used in effective metallurgical accounting strategies are well understood, the sources and magnitude of measurement errors generally are not. As part of the 'AMIRA P754-Metal Accounting and Reconciliation' project, a study was undertaken at the Northparkes copper/gold concentrator near Parkes, New South Wales to examine the data used in their concentrator metallurgical accounting system. This paper summarises the results of a detailed examination of the mass measurement systems around the concentrator as well as the primary sampling system used for grade estimation. The goal of this work was to develop practical techniques to quantify the error (ie both accuracy and precision) of the measured metal accounting information. With this information, statistical confidence levels for this data can then be calculated. If the errors are small, the effect of error in each piece of measured data can then be propagated to other calculated production figures such as recovery and feed grade using a statistical technique called `the propagation of error'.

Jan 1, 2007

By Douglas Glenn Stalheim

Production of structural steel with a minimum yield strength of 700 Mpa produced as hot rolled coil has become increasingly popular due to cost considerations when compared to quench and temper equivalent product. This grade when produced as hot rolled coil requires the use of microalloy precipitation strengthening mechanisms. This is typically a combination of niobium and titanium microalloys. While the metallurgical concept of structural steel precipitation strengthening mechanisms has been well researched and published, actual implementation into the production process can be very challenging. In addition to achieving a minimum yield strength of 700 Mpa, in many applications additional mechanical property attributes of formability as measured by hole expansion testing along with low temperature toughness properties are now required. Achieving a balance of all the mechanical properties in a stable and repeatable performance in production using microalloy precipitation strengthening mechanisms further increases the challenges. This paper will discuss the metallurgical/process strategies required to successfully produce 700 Mpa minimum yield strength hot rolled structural steel coil. In addition, the role and goals of both niobium and titanium in this product design will be presented.

Oct 30, 2017

By N. L. Piret

In copper smelting minimization of solid waste generation is receiving increased attention with more stringent environmental legislation and lower disposal space availability. Copper smelting slags generally being valorizable, solid waste generation is attributed to the presence in the feed of unvalorizable impurities which do not report to the slag and to the unavoidable formation of contaminated dilute acid solutions which need neutralization. As to unvalorizable impurities, solid waste minimization is achieved by rejecting them in the highest possible concentration. Dilute acid is mainly due to the formation of SO3 in the smelter gases and to the discard of decopperized bleed-off electrolyte. Its generation is substantially lowered by preventing SO3 formation, by converting the dilute acid to a valorizable product, e.g., by thermal decomposition for H2S04 recovery or by precipitation as chemical gypsum, and by suitable treatment of the bleed-off electrolyte for impurity removal. Industrial processes are evaluated and alternatives are discussed.

Jan 1, 1994

This paper aims to collate the metallurgical test work undertaken on the Barrytown mineral sands deposit. It is intended to serve as a summary of mineral dressing work undertaken by all interested parties up to the time of writing. Areas requiring further investigation are: in situ grades and recoveries of accessory minerals,the question of 'rank' of ilmenite within the deposit,flow sheet development for the recovery of gold and monazite, andcost analysis to investigate the relative worth of other minerals; notably rutile. Flow sheet development with respect to the Accessory Minerals cannot be accurately defined until the importance of each mineral in terms of grade, recovery and expected revenue is determined. To date, ilmenite and zircon flows are well documented. Further work is needed to quantify recovery's and flows of the other minerals; notably monazite, gold and rutile.

Jan 1, 1989

By L. Joncourt, N. Touchard, G. Pochart, C. Perdon

Worldwide, the major Manganese ores can be separated into three different types: ?Oxidized ores (MnO2): in Australia, Gabon, Brazil,?. ?Semi-oxidized ores (Mn2O3): in South-Africa, Australia,?. ?Carbonated ore (MnCO3): in Ghana, South Africa, Kazhakstan?. The other Manganese ores are less rich but can be used locally or in the neighbour countries (China, Ukraina, India?). Since the beginning of the 20th Century, Manganese has played a big role in the steel industry process average usage ratio: 9,5 kg/mt of steel). The recent grow-up of this industry has led to an increase of Manganese ores demand. In parallel, several companies have increased their Manganese ore producing capacity. In this presentation, we explain the link between the main Manganese ores characteristics and the key different factors for an effective and low cost Mn alloys production (HCFeMn and SiMn): ?Chemistry ?Size ?Reactivity Then we will point out the advantages of Comilog ore and Sintec ® usages in various Manganese alloy metallurgical process compared with the other main ores and with the local ores. Some advised formulations for the different kinds of furnaces and alloys will be also discussed.

Jan 1, 2007

By Norbert Patzelt, Johann Knecht, Wolfgang Baum

High pressure roll grinding (HPGR) is a mature but still expanding comminution technology. In the metals mining industry, HPGR is slowly gaining acceptance as a cost-efficient, high-throughput alternative for plant optimization. The increasing need to treat ores with progressively lower grades, complex mineralogies, refractory metal occurrence and variable rock types requires an energy-efficient comminution technology that reduces metallurgical problems inherent in conventional crushing and grinding, while stabilizing leach and flotation circuits and increasing metals extraction. This paper will summarize our latest HPGR pilot test results for gold and copper projects in the United States and South America and their confirmation through the first HPGR operation in copper mining. This paper will also stress the use of the high pressure grinding roll as a metallurgical tool. The application of HPGR for the treatment of heap leach SX-EW ores, semi-refractory gold ores, waste rock material and concentrator feeds will be illustrated.

Jan 1, 1998

By I. Baltov

The Chelopech Mine, located in Central Bulgaria, is one of Europe?s largest underground copper- gold mines, currently mines and processes approximately one million tonnes of ore per year. Copper concentrates containing gold and silver with significant arsenic content are produced and sold on the world markets. The operation was acquired by Dundee Precious Metals in 2003. A modernization program for the Mine and Plant has since been in progress to increase both production and mechanical reliability, and also to optimize metallurgical recoveries. Since then, mine output and plant throughput have doubled, plant availabilities and utilization have increased significantly, and overall metallurgical performance for copper and gold improved. The paper presents the systematic approach for obtaining and analyzing data, communicating it, and making suggestions for changes to the technological parameters and flowsheet in order to maximize metal recoveries. These studies have correlated the ore characteristics (particle size distributions, metal assays, and Cu and Au mineralogical and phase analyses) with the actual plant performance (kinetics, recoveries, and throughput). Cu recovery by size has been calculated from the mineralogical analyses of feed, concentrate and tails, with the most significant losses being identified in terms of fraction and phase recoveries. This has provided the recommendations (some of them tested in plant) for changes in the grinding and flotation circuits.

Jan 1, 2014

By J. Alexis, G. Ye, E. Burström

Over the past twenty years the 3 MW DC arc furnace at MEFOS has been frequently used for development of new processes. These processes include recovery of valuable metals from slag, sludge and dust from steel and other metallurgical industry, treatment of ashes from power plant and incinerators, smelting reduction of minerals and zinc recovery from EAF dust. The process characteristics of the DC arc furnace operation in terms of: ? selective reduction, ? total reduction, ? process stability and flexibility, ? dust carry-over, ? thermodynamic conditions provided in the hot spot area, ? precision in composing slag products These are analysed and described in this paper based on technical results from selected test campaigns over the years and thermodynamic considerations. The electromagnetic properties of DC arcs beneath the electrode have been studied by CFD simulation. The calculated result enables us to understand some interesting technical phenomena observed. The heat balance has also been considered based on data obtained from test campaigns and heat balance calculation.

Jan 1, 2004

By F. Henríquez, V. Iriarte, L. Vinnett, J. Yianatos, F. Díaz

Metallurgical characterizations of the collective (Cu/Mo) and selective flotation plants were carried out in Minera Los Pelambres, Chile. The selective plant allows the valuable minerals of Cu and Mo to be separated. The evaluation involved two surveys consisting of metallurgical sampling as well as residence time distribution (RTD) measurements to determine load distribution. The RTD data were obtained in real-time by means of the radioactive tracer technique. In addition, metallurgical data was reconciled and supported by effective residence times. In the collective plant, a performance comparison of parallel rougher circuits was carried out, which included a bank of six mechanical cells of 250 m3 and banks of nine mechanical cells of 130 m3. In the selective plant, the Cu and Mo evolution along the plant was evaluated. The results in the selective plant allowed for performance evaluation of mechanical and pneumatic cells in primary flotation. In both plants, mineral losses were evaluated and their relationship with circuit configuration (cell types and circuit layout) was determined. The metallurgical characterization was a powerful tool to evaluate circuit performance and to detect improvement opportunities at industrial scale.

Jan 1, 2015

By C. Carreno, A. D. Gonzalez Escarcega, M. A. Neri, A. Martinez –Villafane, O. Cobarrubias-Alvarado

"Waspaloy is a superalloy used to manufacture some aeronautical parts subjected to high temperatures and stresses. During thermo-mechanical processing cracks are generated, causing some parts to be rejected. In order to determine the causes of these cracks, this alloy was characterized using techniques such as chemical analysis, optical microscopy, scanning electron microscopy, and EDX analysis. Heterogeneous grain sizes in the microstructure cause a non-uniform strain distribution in these parts, creating cracks in zones with different grain sizes.IntroductionNickel-base superalloys are important materials for high-temperature service applications. The manufacture of components from these materials is typically based on solidification or powder-metallurgy processes [1]. Solidification techniques comprise either the direct casting of parts or the casting of ingots which subsequently undergo a series of thermo-mechanical-processing steps to refine the microstructure. During solidification, microsegregation is usually unavoidable. The primary solidification product is a disordered nickel solid solution with an fee crystal structure (?). In many alloys, the material which solidifies last is a mixture of ã and an ordered fee phase (? '). In prototypical nickel-base superalloys, the ?'-phase is Ni3(Al,Ti) [2-3].Waspaloy is a superalloy that is used in demanding high-temperature environments in which good creep and fatigue resistance are required. One of the most common applications of Waspaloy is for turbine engine rings. To ensure the required mechanical properties, the rings are usually forged and heat treated (Figure 1). Two distinct types of microstructures are usually found to be attractive for such applications: a) A microstructure with a grain size of ASTM 10 to 14 for tensile strength, ductility, and resistance to crack nucleation in low-cycle fatigue; or b) A microstructure with a grain size of ASTM 4 to 8 required for creep strength and resistance to crack propagation [4]. Because it is impossible to refine the grain size through heat treatment, a skillfully designed forging process is crucial for the control of the grain size and, hence the properties of the forged ring [5-6]."

Jan 1, 2012

By A. D. Fisher

This paper describes the future position of metallurgical coal, particularly as applied to Canadian reserves. Quality coking coal is declining in availability, but preheating practices may alleviate this situation to some extent. Two new processes are discussed in the paper - formed coke and direct reduction - and their coal specifications are outlined.

Jan 1, 1972

By E. J. Burrough

Coal Reserves The Crowsnest Pass coal fields form part of a greater area which comprises the Inner Foothills belt of the Alberta coal fields and the southeastern coal fields of British Columbia. The most valuable and most extensive reserves of the bituminous coals of Canada are concentrated in this?area, of which the Crowsnest Pass fields form an important part. The extent of these coal reserves together with those of the rest of Canada were recently studied by the Geological Survey of Canada for the Royal Commission on Coal of 1946 (1). Quotin from the report, it is of interest to note that, prior to this work, the most widely known, and in fact the only Canadian-wide estimates of, coal reserves of Canada available to the Commission were those prepared by Dr. Dowling in 1913 (2). At that time it was estimated that Canada's reserves of coal were over twelve hundred billion tons. The more recent estimates of mineable coal for the whole of Canada are of the order of 10 per cent of that figure and are reported. as 99 billion tons, which is further reduced to 40 billion tons on the basis of the estimation of recoverable coal. This considerable divergence in estimated reserves is explained in part by the big difference in the bases of measurements. For example, in the original report, seams of one foot occurring at a depth of 4,000 feet were included in the estimates.

Jan 1, 1951

By E. J. Burrough

MR. J. J. McIntyre (International Coal & Coke Company, Ltd., and McGi1livray Creek Coal & Coke Company, Ltd., Coleman, Alta): Mr. Burrough's excellent paper, Metallurgical Coals of the Crowsnest Area, seems especially timely now, when the need for developing iron industries in the west, as well as in the east, is receiving so much attention. His -thorough review of the 'coking' industry is an especially valuable contribution, along with which the following brief remarks on coking in the Crowsnest Pass area of British Columbia and Alberta may be in order. When the Crowsnest Pass line of the Canadian Pacific railway was built there were great expectations for the non-ferrous metal industry; quite a number of smelter's were al-ready in operation in British Columbia and the northwestern United States, and further expansion was confidently expected. The suitability of the medium-volatile coking coals of the Pass for making metallurgical coke had been recognized from the time the fields were first explored. By the time the mines were fairly well developed there was already a market to war-rant the building of coking plants, and a common belief that expansion of the market would require a large coking industry. The first coke production was from plants built by the Crowsnest Pass Coal Company, Ltd., at Fernie, B.C. in 1903, and the International Coal and Coke Company, Ltd., at Coleman, Alberta. These plants were followed by others built by the Crowsnest Pass Coal Company, at Michel, B.C., by West Canadian Collieries, Ltd., at Lille, Alberta, and by Leitch Collieries, Ltd., at Passburg Alberta, and by a plant at Hosmer, B.C.

Jan 1, 1951

By Wm. Snow, J. R. Wallace, E. P. Duchemin

"GeneralA NOT INCONSIDERABLE proportion of the Canadian economy is dependent on the coal mining industry. This is particularly true of the eastern portion of Canada and especially so of the ( authors') province of Nova Scotia. Much has been said about the trying economic straits of the coal industry in Nova Scotia ( 1), faced, as it is, with difficult mining problems, with considerable distance from large markets, and with •competition from other (and usually foreign) fuels. It is of particular interest, at this time, therefore, to discuss one of the larger outlets for coal -that of the production of metallurgical coke.Scope of PaperWhile the title of this paper indicates that it deals with Metallurgical Coke in Canada, the authors beg leave to treat the Canadian industry very briefly and to deal specifically with coal, •coke, and smelting problems with which they are familiar, namely, the operation of the Dominion Steel and Coal Corporation in the Sydney, N.S., area. No mention is made of metallurgical coke for use in the •many foundries in Canada or in the non-ferrons metallurgical industries.Coal and Coke StatisticsA few statistics of the total output of .Canadian coal, production of metallurgical coke, and similar figures for the Dosco holdings (Sydney area only) are shown in Table I."

Jan 1, 1955

By B. Ignasiak

Laboratory studies suggest that improvements of coke strength brought about by pre-heating caking coals before carbonization accrue from inadvertent oxidation rather than from other low-temperature changes in the coal mass. Controlled oxidation of highly caking coal, followed by laboratory carbonization, produces cokes which, in terms of a laboratory scale tumble test index, are equivalent to those obtained from prime metallurgical blends. Appropriately formulated blends of exhaustively oxidized and fresh caking coal similarly yield cokes with strength indices comparable to those of cokes made from the same coal after oxidation under optimum conditions.

Jan 1, 1979

By Fumito Tanaka

The Mitsubishi Process is the sole pyrometallurgical process for the continuous production of blister copper from copper concentrates. Continuous converting originates from the application of the proven technology of a lime-ferrite slag (CaO-FeOX-Cu2O) on the Converting Furnace (C-furnace). Recent improvements on the C-furnace operation have included increasing the processing of recycled materials and the investigation of alternative fluxing agents. However, some minor oxides adversely affect C-furnace operation, with respect to magnetite behavior of the slag, with the most significant impact having been observed with the silica content of the slag. This paper will quantify the impact of silica on the lime-based slag, and discusses the controls that have been identified to sustain continuous converting operation.

Jan 1, 2005

By O. E. KEOUGH

AT the Tooele custom lead-zinc ore concentrator,' two sections, each having a daily capacity of 500 to 600 tons, are operated on slightly different types of ores with but little difference in flow sheet and reagents. The ores comprising the two general classes are the coarsely crystalline type, with low pyrite and sphalerite low in iron content, from the Park City district, and the more finely disseminated higher pyrite ores from Bingham, which are more difficult to treat by flotation. Laboratory testing determines with which general class a new ore will work better. The ores are crushed to minus 1 1/4-in. size at either the Utah Ore Sampling Company's plant at Murray, Utah, the Tooele smelter sampling plant, or the crushing plant at the concentrator. The ores for each section are mixed to maintain as nearly as possible uniform lead and zinc contents.

Jan 1, 1930

By Y Yang

This paper discusses various issues surrounding the metallurgical control for furnaces, especially focusing on processes with long time-constants and æmetallurgical memoriesÆ. Examples will focus on furnaces accepting particulate and sometimes ill-defined feeds, eg submerged-arc furnaces, blast furnaces, secondary scrap smelting operations, recycling operations, waste incinerators, etc. Generally, because of the usually higher metallurgical time constant of these furnaces, these reactors have to be controlled in a feed-forward manner by the use of a hybrid of æblack boxÆ or empirical and ægrey boxÆ semi-empirical first principles metallurgical modelling and simulation techniques in a supervisory metallurgical control capacity.

Jan 1, 2000