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By J. R. Odekirk

The nature of mineral distributions and locking characteristics in mill products are important factors in understanding mill performance. Such data are obtained by microscopic point counting methods. Reduction 'of point-count data from volume to weight percentages, and reduction of data for each size fraction back to a head sample requires lengthy hand calculations. The use of computer processing for such data reduction results in obtaining information on a realistic time basis. An example of computer processed point-count data is presented.

Jan 1, 1981

By C. S. Ek

As a continuation of previous work, further tests have been carried out to recover silver from the residues obtained in a zinc jarosite process. Selective flotation has been performed with different reagents, and ?cleaning steps have been introduced to upgrade the silver concentrate. Leaching of crude residues, as well as flotation tailings, has been carried out with cyanide and thiourea. Finally, the different beneficiation methods are compared, and the industrial aspects? of their application are reviewed.

Jan 1, 1990

By Isadora Dias Perez, Denise C. Romano Espinosa, Flávia P. Cianga Silvas, Jorge A. Soares Tenório, Mónica M. Jiménez Correa

In view of the rising generation of wastewater containing metals, sustainable and clean techniques to recover them are being researched. This study investigated the adsorption of aluminum, cobalt, chromium, copper, iron (III), magnesium, manganese, nickel and zinc presents in a synthetic ef fluent by chelating ion exchange resin Dowex XUS43605. The resin was tested in columns experiments and was analyzed the flow rate (0.45, 0.66 and 1.11 BV/h), at pH 1.5 and 20 °C. After loading the column, the elution experiments occurred with 1 M of H2SO4 and 4 M of NH4O. The concentration of the metals in solution was obtained by X-ray fluorescence spectrometry energy dispersive (EDX). The results showed that the breakthrough experimental curves demonstrated that the main metals (aluminum, cobalt, manganese and zinc) were immediately broken through just after the initiation of the feeding, while the breakthrough of copper began later. Therefore, the study showed that the chelating resin could be used to treat contaminated effluents with metals.

Mar 1, 2017

By Juan H. Rojas C.

The Chuquicamata mining and metallurgical complex is the main Division belonging to Corporation Nacional del Cobre de Chile (CODELCO-CHILE) and it accounts for 50% of the 1.4 Mt of fine copper output of the Corporation. It has been producing copper since 1915. The paper refers to the challenges that Chuquicamata has to solve in the near future. These challenges are: the increasing operation costs associated to a 800 m depth pit with low prices in an overstocked copper market; the increasing people's sensitivity to environmental preservation; and, the transformation needed for achieving high levels of organizational effectiveness. According to Corporate policy, Chuquicamata is making efforts to switch from a management style focused on supply to a management style focused on demand side of the industry. In this direction is tempting to establish strategic alliances to develop both new copper products and uses, to rise the metal demand. In more than 80 years of operation, Chuquicamata had exploited just one third of its geological resources. The exploitation of the remaining two third is a huge engineering challenge, taking into account the depth of the deposit, the impurities content, the decreasing ore grades and the transportation distances for waste dumping. All those factors are relevant in the economical process of transforming geological resources into ore reserves. Chuquicamata has other limitations. First, a 20,000 people town just aside the pit that limits the mining rates because of dust generation; second the scarceness of water in the desert area where Chuquicamata deposit is located; and, finally, the new tailing pond is a problem which solution will demand huge engineering efforts and investments. People are the principal factor associated to a company success. In this field, Chuquicamata have been progressing, but much more efforts from people will be necessary to reduce production costs for being successful as any other price-taker within the copper industry. Chuquicamata must develop the skills of its Supervisors to transform them into leaders and entrepreneurs, who additionally have the challenge of passing on their knowledge to non-professional workers. It is an ethic commitment to assure personal and professional growth of workers, as the only sustainable way to get real and integral success.

Jan 1, 1999

By Timothy W. Ellis, John A. Howes

The production of lead-acid batteries is defined by a closed-loop product life-cycle. Active material and grid alloys converge on an adaptable specification that improves both performance and recyclability. This mapping of product requirements for lead-acid batteries has taken over 80 years to develop. But, as the use of batteries made with other chemistries continues to grow, the need for a comparable life-cycle management process becomes increasingly apparent given societal needs to manage raw materials, e.g. the European Union Battery Directive recycling targets. What has taken more than 80 years for lead-acid to evolve in a closed-loop paradigm must now be accomplished in less time for batteries using other chemistries and technologies. End-of-life costs are embedded in the product cost of lead-acid batteries. However, end-of-life costs are not reflected in the product cost of batteries made with other chemistries. Those costs are borne by other constituencies with often inefficient and environmentally damaging results. Lead-acid is a materials technology management model for other products.

Mar 1, 2017

By Christine Wenzl, Christoph Wagner, Christoph Sagadin, Stefan Luidold

Corrosion mechanisms have been investigated between MgO refractory substrates and synthetic FeNi slags. The materials taken into consideration comprised a simple synthetically mixed slag with specific oxides of slags from a ferroalloy producer. The MgO refractory substrates with the slag specimens on it were heated in a hot stage microscope to two different characteristic temperatures, 1350 and 1650 °C. The experiments proceeded under a controlled gas atmosphere that simulates the relevant process conditions. The corrosion mechanisms of each system were determined by SEM analyses. The obtained results showed that slag corrosion is dominating with a pronounced partial dissolution of refractory. It was also observed that iron oxide present in the slag diffused into the coarse refractory grains forming the relative low melting magnesia wuestite. Finally,the comparison of these findings with those predicted by thermodynamic calculation (FactSage) indicated the corrosion mechanisms and draw implications for improving the refractory performance and lifetime.

Mar 1, 2017

By J. L. Holman

The Bureau of Mines is investigating recovery of Ni, Co, Cr, and other metals from mixed contaminated supera110y scrap. The scrap is melt-refined and cast into anodes for electrodeposition of recyclable Ni-Co alloy. Melt oxidation using roasted superalloy grinding sludge as oxygen source can divert the Cr to the slag but with excessive Ni-Co loss. Melt oxidation-carburization or direct melt carburization retains -95 pct of the Ni-Co in the anode alloy. With direct carburization, -90 pct or more of the Cr and other refractory metals report to the anode alloy, largely as carbide phases insoluble in electrolysis. Electrorefining data relate parameters such as controlled cathode potential, Fe and Cr impurities, pH, and compartmented cell use, to current efficiency and Ni-Co deposit quality. Recovery of -90 pct of the Ni-Co in the scrap can be achieved. Preliminary experiments to recover Cr, W, and other metals from the anode sludge and other byproducts are discussed. 347

Jan 1, 1987

By D. G. Hattingh, A Els-Botes

"Considerable information is available on the factors influencing the iron-zinc reaction rate at 450° C of low carbon steels, in comparison there is a scarcity _of similar fundamental information of spheroidal graphite irons. This can be attributed to the more complex microstructure and ferrous alloy chemical analysis of spheroidal graphite irons. Hot-dip galvanizers have identified the complexity in controlling and predicting the thickness of the galvanized coating formed on commercial cast irons, which has serious financial implications for both the galvanizer and customer.Commercial hot-dip galvanizing has been in use for over 160 years and yet an elementary understanding of the dynamics associated with the hot-dip galvanizing of spheroidal graphite cast iron is still insufficient. To allow the. process to become a modem surface engineering technology, the fundamental aspects of the process must be thoroughly understood.When a clean iron or steel article is dipped into the molten zinc, zinc initially solidifies around the steel or iron. As heat is transferred to the article form the bath, this initial solidified zinc layer remelts and a series of iron-zinc alloy is formed by the reaction of the zinc with the surface of the article; on removal from the bath, some of the molten zinc is taken out on top of the alloy layers. At normal galvanizing temperature (450 °C), the reaction between iron and zinc is usually parabolic with time. The rate of reaction is rapid at first but then slows down and the coating thickness does not increase greatly if the article is immersed in the bath for longer times(1)."

Jan 1, 2000

By Lingzhi Yang, Feng Chen, Yufeng Guo, Tao Jiang, Zeqiang Xie

Zinc ferrite (ZnFe2O4), one of the major forms of zinc in Electric Arc Furnace (EAF) dust and zinc leaching residue, is very difficult to chemically dissolve in either acidic or alkaline solutions. In spite of the zinc resources in the Electric Arc Furnace (EAF) dust and zinc leaching residue are abundant, there is no mature utilization technology. This situation not only causes the waste of resources, but also produces the harm to the environment. In the paper, the basic principle of this process has been established by revealing the phase equilibria in the CaO–Fe2O3–ZnO system, where Ca2Fe2O5 can be in equilibrium with ZnO rather than ZnFe2O4 at higher CaO region. It has also been demonstrated that the formed ZnO can be solved by ammonia-leaching and Ca2Fe2O5 keep in solid residue, which can be used as a flux for steel refining.

Mar 1, 2017

By Roberto Parreiras Tavares, Frederico da Costa Fernandes, Guilherme Antonio Defendi, Vangleik Ferreira da Cruz, Júlio César de Sousa Pena

"Near-net-shape casting is an important area of research in the iron and steel industry today. Among the near-net-shape casting processes, the single-belt caster seems to be the most promising, since it is the only one that can achieve levels of productivity similar to those obtained with conventional continuous casting machines. One of the most important aspects in the single-belt casting is the feeding system used to deliver liquid metal over the belt. This system determines the velocity distribution and the levels of turbulence of the liquid metal and affects the quality of the strips. In the present work, a metal delivery system having a simple geometry was proposed. Using the CFD code CFX 5.6, a mathematical model to simulate three-dimensional turbulent fluid flow and heat transfer in that system has been developed. This model was used to analyze different configurations of the metal delivery system and the free surface shape of the fluid was also determined. A physical model of the feeding system was built and used to validate the predictions of the mathematical model. The fluid flow calculations have been validated by dye injection experiments and laser doppler anemometry. Measurements of the free surface levels have also been performed. These experiments provided supporting evidence for the predictions of the mathematical model.IntroductionTo maintain its competitiveness in the present market, the metallurgical sector, particularly the steelmaking companies, are developing new techniques of production. Some of these new processes are focussed on the strip casting technologies. Among these technologies, the SingleBelt process is considered the most interesting option, reducing the number of rolling steps and, consequently, the final cost of the product, especially the part associated to the energy consumption (fuel and/or electric energy). This process can also reach levels of productivity that can not be matched by other strip casting methods(1). One of the most important aspects concerning these new processes is related to the liquid metal delivery system. This system can have a significant effect on the final quality of the strips, since it determines the velocity distribution and the levels of turbulence of the liquid metal."

Jan 1, 2004

By Zhi Yang, Ahmad Ghahreman, Farzaneh Sadri

Impurity removal is a very important stage of the hydrometallurgical treatment of rare earth elements (REE) processing circuit, which is performed after water leaching of the acid baked REE concentrate. Lime neutralization has a high efficiency in removal of impurities and is the preferred process due to its economic advantage; however, the process has its own problems, such as the production of large volumes of gypsum and co-precipitation of REE with gypsum, i.e. REE loss. This work deals with the effect of several additives (cetryltrimethylammonium bromide (CTAB), polyvinylsulfonic acid (PVS) and polyacrylic acid (PAA)) on the uptake of REE by gypsum from synthesized acidic solutions. The main purpose of this study is to investigate the changes in the crystalline morphology of gypsum precipitated by the addition of crystal habit modifiers and to determine the crystal changes’ effects on the uptake of REE by gypsum. In this regard, different concentrations (0.2, 2 and 5 g L−1) of above-mentioned additives were studied at room temperature.

Mar 1, 2018

By T. V. Jayaraman, D. Das, B. Mallesham, A. R. James

The PNN-PZT xPb(Ni0.3Nb0.67)03-(1-x)Pb(Zr0.31 Ti0 69)03 (0.2=x=0.6) based relaxor-ferroelectric material was synthesized by colurnbite precursor (NiNb206) method via conventional solid state reaction. Homogeneous mixture of required oxides and precursor was calcined at 850°C for 4 hrs to obtain phase pure perovskite. Pellets of PNN-PZT ceramics were sintered at 1100oC for 4 hrs. Phase pure perovskite structure was confirmed by the X-ray diffraction analysis. From the X-ray diffraction analysis it is also confirmed that there is a structural transformation from the rhombohedral to tetragonal with increase in PZT content and existence of morphotrophic phase boundary (MPB) at x = 0.5 composition. The morphology and microstructure of the sintered pellets were observed using the scanning electron microscope. P-E loop measurement shows the high remnant polarization (19.12 µC/cm2) and low coercive field (6.89 kV/cm) at MPB compared to all other compositions. The electromechanical planar coupling coefficient (kp) was measured through the resonance and anti-resonance method using the LCR meter. The piezoelectric strain coefficient (d33) measured directly using the d33-meter. At x = 0.5 composition the highest value of d33 = 398 pC/N is obtained.

Jan 1, 2012

By W. K. Tolley

The U.S. Bureau of Mines (USBM) is currently investigating improved technology for mineral flotation. A variable often neglected in flotation control is redox potential. The use of redox control is illustrated by the separation of molybdenite from chalcopyrite. Laboratory testing showed that redox potential had a greater effect on product quality than collector addition. A significant need in froth flotation is greater reliability of the sensors used in measuring and controlling redox potential in mineral slurries. The USBM has developed an automated method for removing scale and reconditioning gold redox-sensing electrodes. Fouled electrodes are anodically polarized to 1.2 V versus the AglAgCI reference potential to remove scale. The electrodes then are conditioned by a brief potentiodynamic treatment to re-establish electrochemical equilibrium. In laboratory tests, this technique removed calcarious deposits from gold electrodes and reconditioned them for useful service in approximately 10 min. In plant practice, this technique would obviate the need for plant operators to manually polish electrodes, and also should result in greater reliability in redox measurements. Inexpensive, automated equipment to condition electrodes in a plant setting is described.

Jan 1, 1995

By Roland Loewen

A review of the aqua regia method for the recovery of gold from jewelry shop wastes is given. Also outlined is a specialized procedure for the recovery of the silver that occurs in these wastes. A classic method for the recovery of platinum and palladium is, given. There is a brief review of other gold and silver refining methods. Environmental conditions are discussed and a few perhaps, new and useful processes ,are mentioned. References are by author or editor and are listed alphabetically. Suggestions for further information in the field of precious metals, are given in a final list.

Jan 1, 1989

By Jafar Safarian, Gabriella Tranell, Stine Espelien

Hydrometallurgical treatment of silicon is an effective process for the removal of metallic impurities for producing solar grade silicon feedstock. In the present research, the removal of impurities from silicon is studied through the addition of Mg into a commercial silicon, its solidi fication, and acid leaching. The effect of concentration of HCl, temperature and leaching duration on the removal of impurities are studied. It is shown that the impurities such as P, Fe, Al, Ti, Ca, …are effectively removed through the applied method and Mg improves the segregation and the removal of the impurities. Scanning electron microscopy examination of the samples indicates the disintegration and dissolution of Mg2Si phase in acid leaching which causes the chemical and physical removal of the impurities existing in the phases between the silicon grains. It is shown that the leaching process rate can be optimized through the control of the acid leaching conditions.

Mar 1, 2017

By Nagy El-Kaddah, T. T. Natarajan

This paper describes a novel approach for modeling three-dimensional electromagnetically driven flow in inductively stirred systems, and its application to modeling electromagnetic and flow phenomena in sub-mold rotary stirring of billets. It is based on a new T-\jf potential formulation of electromagnetic field, which does not require the calculation of the field in free space. A finite element algorithm has been developed for solving the electromagnetic field and Navier-Stokes equations in the fluid flow domain. The computed results have shown that the electromagnetic force field generates a strong rotational flow within the vertical section covered by the stirrer, and a relatively strong secondary flow beyond the stirrer. It has also been shown that the rotational and secondary flows were driven primarily by the vorticity of the force field at the billet corners. The induced flow in the molten pool was found to be turbulent and the effective mixing region in the molten pool was about three times the length of the stirrer. The mathematical approach presented in this paper provides the theoretical framework for quantifying these effects for any given stirrer configuration and operating parameters.

Jan 1, 1999

By Anand Kumar, Pradeep kumar Jha, Suman Kant, Pradeep Kumar

"It has been a major challenge to reduce the intermixed grade formation during ladle change-over operation in continuous casting process of tundish steelmaking. The F-curve generated by step input of the tracer (new grade steel) tells about the intermixed grade amount for different grade specifications. Use of flow modifiers is beneficial in reducing the intermixed grade because of the change in slope (in different time zones) and position of the F-curve due to their placement at tundish bottom. Present study aims at investigating the role of dam placed before the outlet in a multi-strand tundish with reference to the slope behavior of F-curve in different time zones during the teeming operation plays an important role in determining the intermixed amount.Introduction In Continuous casting process, the old grade steel remaining in the tundish (reservoir between ladle and mould) from the old ladle gets mixed with new grade steel from new ladle and leads to intermixed grade which is considered to be of inferior quality. Although formation of intermixed grade is inevitable with the sequential method of casting, its amount can be controlled by changing the flow behavior of steel inside the steel. Intermixing in a slab caster tundish was simulated using 3-D numerical model based on k-å turbulence equation and compared their result with that of water model experiment Yeh and Hwang [1]. Huang and Thomas [2] reported that quantity of residual fluid in tundish affects the composition distribution in the transitional slab and thus the intermixed length. Huang and Thomas [3] developed three sub models to predict mixing in tundish, liquid core of strand and solidification. Thomas [4] developed a one dimensional model to simulate the final composition distributions in slab caster of continuous casting and investigated the effect of process variables on the intermixing. Alizadeh mehdi et al., [5] simulated of the intermixing phenomenon for slab casting for three different sub models. Goldschmidt et al. [6] developed a numerical model that predicted the location of the intermixed steel in a four line round caster. Lan and Khodadadi [7] studied for the transient fluid flow of liquid steel, heat transfer and solidification during the flying tundish change process. Cho and Kim [8] developed a mixing model to predict the outlet concentration of the tundish during grade transition. Most of the work reported in the literature has dealt with intermixing in slab caster tundish. Billet caster units are more often being used by steel industries due to growing demand of billets. The multiple outlets lead to varying degree of intermixing with time owing to their different distance (location) from the inlet. Use of flow modifier to minimize the intermixed amount, however has also not been discussed in detail so far. Further no work has been reported regarding effect of slope of F-curves obtained through different outlets on intermixing. Hence keeping these objectives in mind attempt has been made by authors to analyze the slope of Fcurves after dividing them into three different time zones and the effect of these time zones on intermixing."

Jan 1, 2012

By André Laplante

The mineralogy of the Joe Mann mine differs from that of other deposits of the Chibougamau area that are exploited by Les Mines Camchib Inc.. It is characterized by very fine first generation gold and very coarse second generation electrurn. Successful milling required adjustments of the processing flowsheet, which includes gravity, flotation, and cyanidation. A study of coarse gold liberation in the gravity/grinding circuit is described. Modifications to the flotation circuit and the reconditioning of a small capacity cyanidation circuit are presented. As a result of the circuit modifications, gold recovery increased from 65 to 81% in flotation and cyanidation. Overall gold recovery increased from 77% to 88-89%. These improvements are mostly attibutable to the recovery of -10 urn gold, whose presence in the Joe Mann ore and original circuit tails had been identified by process mineralogy.

Jan 1, 1989

By J. A. Holmes

Due to varying and complex mineralogy, the flotation tailings from the Chingola Concentrator have, for some years, contained upwards of 0.4% acid soluble copper. In 1968, an investigation was initiated, to determine a method for recovering this acid soluble copper. This initial investigation concluded with a recommendation to install a leach-solvent extraction-electrowinning plant at Chingola, to treat up to 900 000 tonnes of material per month, for an additional copper production of some 4 500 tonnes per month. The process consists basically of six stages :- Materials reclamation handling and preparation, acid leaching in air agitated pachucas, solid-liquid separation by countercurrent washing in thickeners, solution concentration and purification by solvent extraction, copper recovery by electrowinning, and residue neutralisation and disposal. This paper describes the development of the main parameters for design of each of the six sections, and gives details of the final plant design. Problems encountered in commissioning and initial operations are commented on, particularly insofar as they indicated any errors or misjudgements in the design. The choice of materials of construction is commented on in some detail.

Jan 1, 1976

By Atinuke Oladoye, David Esezobor

"Particulate Copper Silicon carbide (Cu-SiCp) composites find application as wear and heat resistant materials in electrical sliding contacts such as in homopolar machines, railway overhead current collector systems where high electrical/thermal conductivity combined with good wear properties is required. However, challenges occur during machining due to the presence of hard reinforcement in the matrix. This may lead to high turnover of tool wear and poor surface finish. The adoption of near-net shape technology to produce such hard-to-machine metal matrix composites and subsequent finish machining with its attendant cost has reported limited success. This paper critically appraises the challenges and opportunities in the improvement of tribological characteristics of particulate Cu-SiC composites and identifies low cost reinforcement material that could be used to improve its tribological characteristics.IntroductionTribology consideration is increasingly becoming a decisive factor in the design and selection of materials for applications involving interacting surfaces in relative motion. The consideration is mainly on the combined effects of friction and lubrication on material's wear integrity and performance amongst other. Annual losses due to tribology in the US industries are estimated at between 1-2% of the Gross National Income [1], in Russia it is about 1-4% of the GDP [2]. Thus, the attributes of tribology has become imperative in modem machinery especially those applications involving sliding and rolling surfaces, and electrical contacts [3- 8].These are readily found in homopolar machines, internal combustion engines, aircraft engines, gears, cams, seals and railway overhead current collector systems [9-12]. In these systems, the dissipation of frictional heat arising from the interacting surfaces as quickly as possible imposes constraints on the choice of materials for such application to prevent softening, plastic and shear flow and the transfer of metal as wear debris onto the interacting surfaces. If these possibilities occur, system performance is compromised and premature failure may result. Materials for these systems are expected to possess high electrical and thermal conductivities, low coefficient of thermal expansion, good corrosion resistance and high melting point [3-8, 13]."

Jan 1, 2011