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By C. Dupuis, P. Waite, S. Leboeuf

Casthouses throughout the aluminium industry commonly use chlorine gas as a fluxing agent for furnace and in-line treatment of molten aluminium alloys. Its positive impact on the removal of alkali elements and non-metallic inclusions is well known. Nevertheless, the elimination of its use is highly desirable due to the safety and environmental risks associated with storage and handling. Over the past decade, the aluminium industry has significantly reduced its chlorine consumption. This has been achieved by maximizing the chlorine gas utilization efficiency during metal processing, and by the chlorine replacement for crucible and furnace metal treatment applications. Operation of sealed in-line treatment units without chlorine is now possible, but with lower or inconsistent removal efficiency penalties for alkali and inclusions respectively. This paper reviews the progress made at Arvida Research and Development Centre regarding the reduction of chlorine and the development of an alternative to chlorine for in-line metal treatment without penalizing the metallurgical performance.

Jan 1, 2006

1 INFORMATIONS GÉOLOGIQUES ET PLANIFICATION MINIÈRE La notion de gisement exploitable s'appuie sur les connaissances de géologie, d'ingénierie et tablir la rentabilité en fonction des investissements requis, des coûts de production, et des revenus qui sont tributaires de la demande et des prix des marchés. C'est une notion qui est d'abord diffuse lors de la découverte et de la première délimitation d'un gisement "d'intérêt économique potentiel" mais qui doit se confirmer et se préciser par des travaux additionnels pour devenir de plus en plus quantitative et assurée. 1.1 Informations géologiques Les conditions géologiques varient d'un gisement à l'autre (forme, dimensions, attitude, concentration et continuité -litages, effets de pépites - de la minéralisation). D'autre part, chaque méthodes minière a des contraintes différentes quant aux possibilités de sélectivité d'une part, d'acquisition d'information additionnelle lors du développement de la mine d'autre part. Cette problématique a été résumée au tableau 1, modifié de Vallée et al. (1993) [tableau 5, CIM Bulletin, avril 93, p. 74.].

May 1, 2002

By Raj K. Rajamani, Nikhil Dhawan

"Agglomeration has become common pre-treatment step to improve heap leach percolation thereby recovery, the fundamental understanding of the agglomeration process for crushed ores is still lacking. Agglomeration is required for ores which either contain excessive amounts of clay or an excessive quantity of fines generated during mining and crushing. Numerous experiments have been carried out in laboratory scale batch drums using different ores. It has been found out that experimental agglomerate size distributions exhibit self-preserving spectra. The self-preserving/ similarity distribution of the agglomerates is found to be independent of operating conditions and is uniquely determined by the size enlargement mechanism. An empirical model based on the absolute difference between moisture applied and optimum moisture was developed. This model uses self-preserving spectra in the form of a Rosin-Rammler distribution function to predict size distribution at different operating conditions. The empirical model was considerably easier to work with plant scale agglomeration drums. Also, a test known as dip test is developed which improves fundamental understanding of the agglomerate formation and growth mechanisms. This test also provides the progeny size distribution of each agglomerate size. The progeny size distribution was analyzed with a model that partitions the particles into a host and guest category. The ensuing partition coefficient identifies the behaviour of a particle as a host for other particles or a guest layering on other particles. This concept helps in identifying the type of agglomerate that would result for a specific feed size distribution. INTRODUCTIONHeap leaching is one of the hydrometallurgical processes that have served as a green and economically viable process for the treatment of low grade complex ores of copper, uranium, nickel, silver and gold (Dhawan et al., 2013). Heap leaching appears to be a favorable candidate for the least energy consuming process for low grade ores. In heap leach operations nowadays a pretreatment step known as crushed ore agglomeration has been implemented (Dhawan et al., 2013). A bed of agglomerates improves the uniform percolation of solution through the heaps of ore. Therefore, it was possible to treat wastes and mill tailings via agglomeration and heap leaching. Agglomeration pretreatment is required for ores which either contain excessive amounts of clay or an excessive quantity of fines generated during mining and crushing (Bouffard, 2005; Dhawan et al., 2013).While agglomeration has become common practice pretreatment step in heap leach operations, the fundamental understanding of the crushed ore agglomeration process is still lacking. The author reviewed publications up to 2012 on the crushed ore agglomeration process and did not come up with modeling studies on the topic (Dhawan et al., 2013). Some of the possible reasons can be the stochastic nature of the process, experimental difficulties, and lack of instrumentation for fundamental studies."

Jan 1, 2016

By Z. Abbasloo, A. Masoomi, L. Ebrahimi, A. Mortazavi, A. Keshavarz

"Investigation and 3D analysis of Heap no. 2 of Meydook copper complex was the subject of this study. In this project all geological and geotechnical investigations conducted in the mine were evaluated aiming at determination of Heap no. 2 design parameters. The main objective of the project was to evaluate the potential for construction of Heap. No. 2 on a waste dump built in a valley in the north side of the pit.Considering the space limitation for dump location this was a viable alternative to reduce the costs associated with heap no. 2 construction. Moreover, it allowed for a significant reduction in overall mining costs. Considering the project condition, a 3D analysis of heap major structures including; valley rock foundation, waste dump, and low grade ore was carried out. Five sets of analyses were conducted and the displacement and stress fields were calculated within the heap no. 2 components. In all analyses conducted the subsident profile was determined for the valley base rock and heap foundation (waste dump). Moreover, the shear interaction between heap and waste dump was evaluated at the heap interface. The analyses results showed that the maximum settlement at the heap base is about 4-5 cm and the waste dump provides a safe and reliable base for heap construction. Moreover, the analysis results showed that the selected %5 grade for the heap interface is good and does not pose any risk in terms of heap Interface shear displacements. A sensitivity analysis of heap mechanical parameters was also conducted. The obtained results show that if the friction angle of heap material is reduced below 25 degree due to acid spraying process, the heap walls become unstable and the heap geometry must be redesigned."

Jan 1, 2015

By S. Banisi, M. Maleki-Moghaddam

Direct observation of charge shape and its motion in industrial mills is not possible; therefore, a combination of analytical and physical studies is used to determine charge trajectory. Software packages, which predict charge motion consider only the outermost layer of charge (single ball) and ignore the charge and the interactions of grinding elements. In the new version of the GMT (Grinding Media Trajectory) software, the effect of liners specification and bulk load on charge shape and trajectory are considered. The charge trajectory was measured in a laboratory mill with the diameter of 100 cm and length of 21.5 cm with the transparent end and compared with that of the old version of GMT. Four types of polyurethane rings were accurately machined to scale down the liners arrangements at two industrial mills. The model mill was operated at 55, 70 and 85% of the critical speed for five levels of mill filling (10, 15, 20, 25% and 30% by volume). The experiments indicated that the end walls effect was negligible for the model mill with the length of 10.8 cm and beyond. The proposed relationships to correct the trajectory and charge shape were validated by using the new liner of the Gol-E-Gohar iron ore company AG mill. The positions of shoulder, toe, toe departure and impact points were predicted with the relative errors of 5, 0.7, 2 and 0.2%, respectively. The GMT software was updated with the new relationships. The results of GMT simulation indicated that when the lifter face angle increased from 7 to 30°, the distance between the charge impact point and the toe decreased from 40.1 to 11.2° for 30% filling. The change in the position of the impact point meant increasing the probability of charge impacting the toe, not the liner which favored more efficient comminution practice.

Jan 1, 2016

By D. Kao, J. Gogal, S. Humphrey, T. Byrne, M. Davoodi

"High total and dissolved uranium values were noted in the process water at the Cigar Lake Operation (CLO) during early production start-up period, whereas significant levels of dissolved uranium had not been observed previously at similar operations. The excess dissolved uranium resulted in higher demands on the water treatment plant, along with higher operating costs, environmental risks and some unrealized revenue potential. A species balance indicated that uranium was leaching into solution in the grinding, dewatering, and storage circuits under normal operating conditions. Jet boring, water recycle, ball milling, and the use of Pachuca tanks for ore storage results in a highly oxidative environment, which is favourable to leaching.This paper will outline the testwork performed to identify the conditions under which the uranium leaches into solution and to determine required conditions for uranium precipitation. Maximum uranium leaching was found to occur under normal operating conditions (pH ranging from 7.0 to 8.5); testwork indicated that both lowering and raising the pH can significantly reduce the uranium leaching. Analytical results combined with the batch scale testwork indicate that the uranium solubility is associated with carbonate species in the ore. Uranium precipitation was maximized at pH values greater than 10.5 or less than 6, corresponding well to carbonate leaching and precipitation values from literature. Higher precipitation efficiencies were noted at high pH ranges.As a result of this work, a pH control system has been implemented in the Pachuca storage vessels and thickener prior to water treatment plant on a trial basis. Caustic soda is recommended for pH control due to ease of operation, economic viability and material requirements and downstream constraints."

Jan 1, 2016

By Lionel Roberge, Borge J. G. Fredriksson

"Late in 1981, a six-rope friction hoist was installed in the Number 2 shaft at Les Mines Seleine Inc. on the Madeleine Islands in Quebec. This paper deals with the reasoning behind the selection of hoisting equipment from the economical point of view, safety point of view, future needs point of view, etc.After establishing the basic parameters for the hoisting system, features of the most common types of hoists (i.e. single-drum hoist, double-drum hoist, Koepe hoist) are briefly laid out. The reasons for selecting a friction (Koepe) hoist are summarized. However, why go for a six-rope hoist rather than the (in North America) more common four-rope hoist? As the subject hoist is the first six-rope hoist in Canada, this question is studied in more detail, covering initial cost, maintenance cost, etc., as well as practical aspects, such as safety, physical dimensions, etc.In summary, experiences from other multi-rope hoist installations world-wide are presented.BackgroundIn 1980, Seleine Mines Inc. was established as a subsidiary of SOQUEM. The new mining company was to develop and operate a salt mine and associated harbour on the Madeleine Islands in the Gulf of St. Lawrence. The Madeleine Islands form part of the Province of Quebec. The mine has a planned annual output of 1.2 million metric tonnes of salt, with reserves in sight for over 20 years. Mining will be by room and pillar, with an underground primary crusher and treatment plant. From the underground treatment plant, the salt will be transferred via conveyors to a 5.5-metre-diameter circular shaft and hoisted to the surface. Surface transportation to the warehouse will again be via conveyor, and a conveyor will also transport the salt from the warehouse to the point of shiploading."

Jan 1, 1983

By W. A. Plachner, Schiller E. A., S. P. Santiago

"The Monkman Coal Property is located in the Northeast Coal Block of British Columbia. It is divided into the Duke Mountain Block on the north east and the Dip Slope on the west. Together, these areas cover 39,503 ha of coal licences.The property is underlain by Jurassic and Lower Cretaceous marine and continental sedimentary rocks. Economic coal measures are contained within the Gates Formation. Exploration of the property began in the early I970s, with drilling commencing in 1975. To date, 255 holes have been drilled and nine adits have been driven to recover unoxidized coal samples.The property has a geological resource potential of 2.8 billion tonnes of medium and high-volatile bituminous coal. Medium-volatile bituminous reserves, totalling 68.9 million ROM tonnes at an over-all strip ratio of 6.3:1, have been identified in three pit areas in the Duke Mountain Block.Construction start-up will commence when sales contracts are arranged. The clean coal will be exported via the Ridley Island Terminal at Prince Rupert.IntroductionThe Monkman Coal Property is located in the Northeast Coal Block of British Columbia in the southern port ion of the Peace River Coalfield. The coal field encompasses a strike length of 250 km of Lower Cretaceous coal-bearing strata in which 13 companies have identified several billion tonnes of resources and several hundred million tonnes of reserves. Currently, two companies with contracts are in the construction phase, and are scheduled to produce coal by early 1984. Quintette Coal Ltd. has a contract with Japanese steel mills to supply annually 5.0 million tonnes of metallurgical and 1.5 million tonnes of thermal coal. Teck Corporation (Bullmoose property) has a contract to supply 1.7 million tonnes of metallurgical coal annually."

Jan 1, 1983

By C. Desmeules

"Carbon addition in the oxide pelletizing process is a big concern at the Sidbec-Normines pelletizing plant since 1976.Laboratory pot-grate testing carried out before the initial start-up of the Port-Cartier plant indicated that the nominal pelletizing grate capacity could be increased by fifteen per cent with a suitable carbon addition. Also an improved induration cycle offered the possibility of a significant energy reduction within the process with no adverse effect on pellet quality. A one-month plant scale program duplicated the lab test results and confirmed the anticipated cost saving by using these techniques. Since March 1980, Sidbec-Normines used coke addition as a current operation.This paper reviews briefly earlier laboratory and in-plant test work carried out to investigate the effects of adding carbon materials to the Fire Lake hematite concentrate, and presents operation techniques and plant results of carbon addition in the Port -Cattier pellet plant.IntroductionThe Sidbec-Normines pelletizing plant at Port-Cartier, Quebec, is designed to produce six million ton s per year of oxide pellet s. It is a Dravo-built two-line plant; one line to produce three million s tons per year of blast furnace grade pellets averaging 5.5 per cent silica, and another line of three million ton s to produce direct reduction grade pellets of about 2.0 percent silica.The laboratory pot-grate test program was conducted in 1977 at the British Steel Corporation Research Laboratories in England, with the assistance of J .E. Appleby, consultant to British Steel Corporation (overseas services) Limited.The purpose of that test program was to determine the optimum energy saving cycle and to study the physical and metallurgical effects on blast furnace and direct reduction pellets."

Jan 1, 1983

By S. Banisi, A. R. Hasankhoei, Gh. Parsapour, A. R. Ghasemi

At the Gol-E-Gohar mining and industrial Company, a pelletizing plant, which includes two parallel dry closed grinding circuits and a pellet production circuit, produces 600 t/h. Each grinding circuit consists of a burner, a dry ball mill (6 m×13 m) and an air separator. Each ball mill consists of a 2 m-long dryer chamber and an 11 m-long grinding chamber. Iron ore concentrate is fed to the drying chamber to decrease its moisture from 2.5% to below 0.2%. The drying chamber consists of 56 flights in two rows. It was found when the feed moisture content decreased from 1.3 to 3.5%, the throughput decreased by 14% (40 t/h) indicating a low performance of the dryer. In order to improve the efficiency of the drying section, a scale down version of the dryer was constructed in a 1m diameter mill with a transparent end to make image analysis possible. It was found that because of the inappropriate veiling profile in the drying section, most of materials are not subjected to the hot gas tunnel. To overcome this problem, various flights with different geometries were physically tested and also simulated by the KMPCDEM © software. With the aim of arriving at a proper veiling profile which maximizes the particles contact with hot air, a new flight design was obtained and tested. The installation of the rectangular tooth type flights in one of the mills in the plant made the comparison of the old and new designs possible. The evaluation of the designs in a period of three months indicated 15 t/h increase in the throughput in the case of the new flight design.

Jan 1, 2016

By G. Landry

"IntroductionThe Cape Breton Development Corporation (CBDC) is constantly searching for new technologies that will enhance the marketability of its coal. One technology which shows promise in utilizing Cape Breton coal while at the same time addressing the traditional problem of high sulphur inherent in the Sydney coalfield, is coal-water fuel (CWF).The CWF process incorporates a physical change of coal by grinding it to a flour-like consistency and then mixing additives with it to make a fine coal slurry. The result is a liquid dispersion of fine coal particles that looks like oil, stores and flows like oil but burns like coal. The equipment used in the CWF process is standard mineral processing equipment but application of the equipment to manufacture a specific coal particle size and the specified additives used in the mixing make it a unique technology.The product, which CBDC calls Carbofuel, consists of 70% coal, 29.5% water and 0.5% chemical additives. The key properties of the product are: (I) high solids loading, (2) medium viscosity levels, (3) stability against sedimentation, and (4) good atomization behaviour. Carbofuel specifications are presented in Table I. Carbofuel ProductionThe production of Carbofuel is based on the controlled processing of coal. This involves wet grinding of the coal to a specified fine size (-250 um), cleaning this fine product to remove mineral impurities and formulating (with chemical additives) a finalproduct from the cleaned coal. The flow diagram in Figure 1 indicates the processing circuit for Carbofuel production.CBDC operates a 7-tonne-per-hour continuous production plant complete with state-of-the-art control, full laboratory services, product storage and loadout facilities. The plant has operated since 1983 and has produced over 12000 tonnes for several major demonstrations. The plant is shown in Figure 2."

Jan 1, 1987

By R. Lepsoe

THE basic products of the Company are lead and zinc. Around 950 tons of these metals are produced each day. In the last decade, the production of by-products has increased to such an extent that they are now nearly as large an operation as that of the base-metals. Of the many by-products, the most objectionable, and up to a few years ago the most useless, was the sulphur. The sulphur comes in the ore from the Sullivan mine. It is in the ore chiefly as lead, zinc, and iron sulphide. By selective flotation, these three sulphides are separated into the lead concentrates, the zinc concentrates, and the mill tailings. These mill tailings contain the bulk of the iron and the sulphur. Of the 6,5CO tons of ore treated per day, about 5,000 tons are wasted to the mill tailings dump, and, while now valueless, will in future years undoubtedly be used as a source of iron and sulphur. There are about 1,500 tons of sulphur and 2,200 tons of iron per day in the tailings, and about 400 tons of sulphur left in the total concentrates. In the recovery of lead and zinc in the pure form, the first step is the roasting operation. Here, most of the sulphur is driven off as sulphur dioxide in the gases. It has always been apparent that this sulphur should be. recovered and utilized if possible. At the same time, this would cure the smoke nuisance. Because, in spite of the low concentration of sulphur dioxide and the fact that it was discharged from stacks at an elevation of 400 feet above the plant, some damage to vegetation close to the plant had been experienced.

Jan 1, 1937

By J. Wild, M. Ounpuu, G. Chevalier

"The requirements for a finer grind at Heath Steele have resulted in the investigation of agitated milling as a cost effective alternative to conventional tumbling ball mills.The grinding unit is a vertically agitated, or stirred ball mill. Grinding occurs as the result of the motion of a single vertical rotor equipped with protruding pins which impart a stirring action to the ball charge. A comparative evaluation of a 30 kW SALA Agitated Mill (SAM), and a 1.5 m x 2.5 m copper-lead regrind ball mill has been conducted at Heath Steele.An overview of agitated milling as it applies to the reduction of sulphide ore will be the primary topic for discussion. Specific parameters including energy efficiency, media consumption, operating costs, and the mechanical aspects of the SAM operation will be presented.Evaluation of the agitated mill has shown that improved grinding performance at much lower work indices than those of the conventional ball mill is possible. Media consumption has proven to be comparable on an average g/kWh basis, but the mechanical availability of the mill has been low.INTRODUCTIONConventional tumbling ball mill grinding has proven to be an energy inefficient process. Energy losses occurring within the ball mill itself can be attributed to particle friction without breakage, kinetic and potential energy losses, plastic and elastic deformation and the production of heat and sound (Lynch, 1977). It can be generally stated that a certain amount of the input energy will be converted to another form as a necessary by-product of particle breakage. Theoretical interpretation of experimental results indicate that the energy required for breaking the ore particles in a ball mill varies between I% and 25% of the total energy input (SME, 1985)."

Jan 1, 1993

By E. J. Marcotte

"INTRODUCTIONThe Upper Canada Mine is located at Dobie, approximately ten miles east of Kirkland Lake, Ontario.The mill contains Upper Canada's cyanide circuit and Upper Beaver's flotation circuit. The combined capacity is 590 tons per day consisting of 415 t.p.d. of Upper Canada gold ore and 175 t.p.d. of Upper Beaver copper-gold ore.The Upper Beaver ore is trucked five miles to the Upper Canada mine site.Crushing:The crushing circuit consists of primary, secondary and tertiary crushing employing one C .A. C. 15 in. x 24 in. Superior jaw crusher, one 4 ft. x 8 ft. Tyler-Niagara double deck screen, one 3 ft. Symons standard cone crusher and one 3 ft. Symons shorthead cone crusher.The -2 in. product from the jaw crusher is fed to the double deck screen. The+ 5/ 8 in. passes over the top deck to the 3 ft. standard cone crusher; the+ 3/ 16 in. material passes over the lower deck to the shorthead cone crusher. The - 3 / 16 in. material pas sing through the lower deck of screens is the product to the mill.The screens used prior to the installation of rubber screen cloths were: one 4 ft. x 4 ft. section with 3/ 4 in. square openings and one 4 ft. x 4 ft. section with 5/ 8 in. square openings on the top deck; two 4 ft. x 4 ft. sections with openings of 3/16 in. x 4 1/2 in. slot on the lower deck. The fine screens were positioned so that the 4 1/ 2 in. slots were parallel to the flow of feed.The crushing circuit is operated on a three shift per day basis by one operator per shift."

Jan 1, 1968

"In 1989, improved milling and recoveries resulted in a record production of 7 722 200 Ib Nb2P5 at the Niobec Mine. At the beginning of 1990, proven and probable reserves stood at 11 952 000 tons grading 0.65% Nb205. This year, the world steel market has slowed and as a result, niobium consumption is down. Consequently, production at the mine dropped 14% for the second quarter.IntroductionThe Niobec Mine is located approximately nine miles northwest of Chicoutimi, Quebec, (Fig. I). After ten years of production, the Niobec Mine is the only operating niobium mine in North America and the second largest producer of niobium in the world after Brazil.The Niobec Mine is a joint venture held equally by Teck Corporation and Carnbior. Teck Corporation operates the mine while Cambior is responsible for marketing and selling the niobium pentoxide concentrate (Nb2P5).The deposit was discovered in 1964 following an airborne radiometric survey in search of uranium. However, mining of the deposit did not begin until 1976. The initial production capacity of 1500 tons per day was increased several times to the present capacity of 2450 tons . The deposit is considered as an ample source of pyrochlore concentrate for at least 15 years at the present production rate.Niobium, also known as columbium, is a greyish-white metal used primarily as an alloy in various steels and other metals. The use of niobium in alloys heightens tensile strength and improves corrosion resistance while at the same time reducing the weight of the alloy. Niobium is also used in the fabrication of steel for the aerospace, automobile, and oil and gas pipeline industries. Although substitutes for niobium exist, their use often results in diminished performance and net cost increases."

Jan 1, 1990

By F. E. P. PEARSON

Sandstone quarried from an island in Lake Winnipeg is barged 130 km to a processing plant at Selkirk on the Red River. The stone is white, poorly consolidated, and consists of rounded quartz grains of high natural purity. It is an important supplier of silica in Western Canada for glass, fiberglass, foundry and other industrial uses.

Jan 1, 1984

By E. Dernedde

A few studies have suggested that the rate of adsorption of hydrogen fluoride on smelter grade alumina is determined by kinetic factors. However, no performance equation for dry scrubbers has appeared in the literature so far. Experimental data from a pilot dry scrubber with co-current flow were compared with results of kinetic models of adsorption, film diffusion and pore diffusion. The pore diffusion model was deemed the most appropriate. It was transformed into a performance equation for steady-state operations of dry scrubbers by the inclusion of the alumina recirculation. Operating results of industrial dry scrubbers with co-current flow were successfully evaluated by means of the performance equation. The average fluoride content of the alumina was also estimated by using the pore diffusion model.

Jan 1, 2011

By M. P. Amsden

"Ecstall Mining Limited, a subsidiary of Texasgulf, Inc., Operates the Kidd Creek Mine, Concentrator and Zinc Plant at Timmins, Ontario. Two different ore types are mined and milled to produce concentrates of copper, zinc, lead and tin. The ores are processed at the Concentrator in three separate individual milling circuits, each with the capacity to treat up to 3500 tons per day. Two circuits treat copper-zinc ore 1t an average combined rate of 6500 tons per day and the third circuit treats 3500 tons per day of silver-lead zinc ore. Conventional crushing, grinding and flotation procedures are followed. The purpose of this paper is to describe Ecstall's experience with rubber mill linings in the grinding circuits.CrushingBoth ores are crushed to minus 6 inches at the Mine and delivered by rail to the Concentrator where they are reduced by secondary and tertiary crushing to minus 5/8 inch.GrindingThe crushed ores are prepared for selective flotation by grinding with rod mills and two stages of ball milling. flotation circuit middling products are reground in regrind mills prior to further treatment. A typical flowsheet of one of the grinding circuits is shown in Figure 1.All the grinding units are Allis-Chalmers Mills. The rod mills are 10 1/2 feet diameter by 16 feet long. Both the primary and secondary ball mills are 12 feet diameter by 18 feet long and all regrind mills are 6 feet diameter by 12 feet long. The primary mills are charged with 1 13/16 inch forged balls. Secondary mills are charged with 1 1/2 inch forged balls and the regrind mills are charged with 1 inch forged balls. All cyclones are Kreb units. The primary cyclones are Dl5B hydrocyclones, the secondary cyclones are D6B hydrocyclones and all regrind cyclones are D6B hydrocyclones."

Jan 1, 1974

By Yosuke Ota, Makoto Tawara, Tetsuya Kojima

"Dry-lube has been used in Europe to enhance formability of aluminum sheet for automotive applications, but it is difficult to ensure degreasing performance with lower degreasing bath temperature. However, newly developed, highly lubricating pre-coats utilizing a urethane resin, which is soluble in water, have been found to show excellent degreasing performance. Furthermore, a richer pre-coat weight coincides with a lower friction coefficient and better formability. Combined use of anti-rust liquid oil showed different friction coefficient depending on applied surface pressure.INTRODUCTION The global demand for aluminum alloy products, especially for automotive application, has been increasing because aluminum alloys can offer excellent corrosion resistance with good strength and low density compared with steel. Aluminum alloys can contribute to saving much more energy and greenhouse gas emissions over the lifetime of the product. On the other hand, the amount of aluminum alloys in vehicle architectures is still somewhat limited due to relatively low formability. As a consequence of this low formability, it is necessary to set a certain limit to the shape of an aluminum alloy panel for automotive applications. So far hot melt wax dry lubricants have been in use especially in Europe as they have been recognized to provide better lubrication than conventional rust protection oils (Meiler & Jaschke, 2005). The benefit of hot-melt wax for automotive manufacturing is associated with a more stable forming process and the possibility to avoid extra lubrication in the press shop. But because of the low poorer solubility of hot-melt wax in degreasing aqueous bath solution, a higher degreasing temperature is required so that no remnant of hot melt wax can be carried over to the next manufacturing process. This temperature control is difficult to impress upon a manufacturing degreasing bath originally designed for liquid oil, especially in Japan. The typical temperature of degreasing bath in Europe is around 60°C, while it is only around 40°C. in Japan. Various types of pre-coats other than hot-melt with high lubricity have been reported (Tawara, 1993; Ueda, Hatsuno & Totani, 2013), but a balance between sufficient degreasing performance and high lubricity has not yet been achieved for an actual production process line."

Jan 1, 2018

By T. T. Chen, J. E. Dutrizac, G. Poirier

In the Waelz kiln process, EAF dust is converted to an Fe-rich slag, a (Zn, Fe)-rich dust that is recycled to the kiln and the Zn-rich Waelz oxide which is subsequently up-graded for the recovery of zinc. To clarify the reactions occurring, the Waelz kiln products from a European Waelz plant were characterized mineralogically to determine the mineral species present, their micro-textures and the metal carriers. The EAF dust contains 27 % Zn, and consists mainly of ZnFe2O4 and ZnO, together with minor to trace amounts of NaCl, PbCl2, KCl, CaO, Ca2Fe2O5, Fe203, FRO, Pb oxide and various Ca-Fe-Al-Mn silicates. The KCI and NaCI sometimes agglomerate the other particles. The slag consists of nodules which often exhibit colloform structures. The slag contains of variable amounts of Fe, FeO(OH), FeO, gypsum, Ca(OH)2, Ca2SiO4 and various Ca-Fe¬Al-Mg-Mn silicates as well as minor to trace amounts of ZnFe2O4, Cr-Fe oxide, Mn-Fe oxide and other species. The Waelz oxide contains 57-61 % Zn, and consists predominantly of ZnO, with minor to trace amounts of KCI NaCl, Pb(OH)Cl, Pb20(SO4), Pb chloride, ZnSO4, ZnFe2O4, Ca2SiO4, Ca2Fe2O5, Ca-Fe silicate and NaZn4(SO4)(OH)6Cl.6H2O. The KCI agglomerates the other particles in the Waelz oxide. The recycled dust appears to be a mixture of EAF dust and Waelz oxide, but it contains relatively more coarser-grained metallic Pb and Pb oxide particles.

Jan 1, 2004