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By R. K. Sidhu, N. L. Richards, M. C. Chaturvedi

Nickel base superalloy IN-738LC, strengthened mainly by the precipitation of y' phase, is extensively used in hot sections of land-based and aero gas turbine engines. Fusion welding, which is one of the most commonly used joining techniques for the repair and fabrication of superalloy components, however, finds a very limited application in case of IN-738LC components, as the alloy suffers from HAZ cracking during welding and during subsequent postweld heat treatment (PWHT). The present paper reports on the two methods studied to reduce the HAZ cracking in as-welded and postweld heat treated GTA welded IN-738LC, viz., the use of various fillers during welding, and the use of appropriate heat treatments prior to welding. The results of the microstructural analysis and crack measurements indicated that the HAZ cracking in GTA welds of IN-738LC was significantly reduced by using age-hardenable fillers with Al+Ti concentration less than that in the base metal in conjunction with a preweld heat treatment developed by the authors.

Jan 1, 2006

By X. Cao, M. Xiao, M. Jahazi

Magnesium alloys have low hardness, wear, erosion and corrosion resistance. The repair of service-damaged aerospace components made of magnesium alloys is an attractive solution in terms of time and cost saving. The feasibility of applying laser beam technology to repair ZE41A-T5 magnesium alloy sand castings in the machined surface conditions was studied using a continuous wave 4 kW Nd:YAG laser system. The influence of process parameters such as laser power, cladding speed, wire feed rate and defocusing distance on the shape, size and area of single cladding beads is discussed using a process optimization software. Sound single clad beads with good geometric characteristics were obtained using strictly controlled laser process parameters. The overall results indicate that laser surface cladding using filler wire has the potential for repairing aerospace components made of cast magnesium alloys.

Jan 1, 2006

By Donald Lindell

Safety Share ?Dad receives fryer for Christmas 2009 and makes delicious sweet potato fries ?When the oil fryer was pushed back on the stove for cooling, the back edge comes into contact with the stove top controls, unknowingly activating the cooking element, family leaves kitchen. ?Faint smell of smoke from the melting plastic alerted the family; teenager arrives first and pulls the fryer forward causing oil to spill onto hot stove and burst into flames that reach the microwave ?Teen runs for sink to grab pan of water but is stopped by Dad ?Dad opens refrigerator, grabs baking soda and pours it on fire, extinguishing flames Lessons 1.DO NOT USE WATER ON GREASE FIRE 2.Where is the baking soda in your kitchen?

May 1, 2010

By A. A. Burgoyne

"The McDame chrysotile asbestos deposit located near Cassiar in northern British Columbia isfound at depth and on trend to the southeast of the currently mined open-pit Cassiar asbestos deposit. The ultramafic rock hosting the McDame is serpentinized peridotite of the Upper Paleozoic Sylvester Group contained in an ophiolitic sequence preserved within a lower thrust sheet of the Sylvester Allochthon. The Sylvester stratigraphic package is a series of thrust slices composed of argillite, tuff and volcanic flows, diorite and serpentinite. Contacts between units are often fault-controlled.The McDame asbestos-bearing ultramafite is considered to represent a separate interleaved fault-bounded slice of rock distinct from the Cassiar asbestos deposit.Asbestos mineralization of the McDame deposit was discovered in /978. Exploration during /980 and /98/ focused on extensive underground drilling of the deposit and in /983 on geological mapping, airborne and ground magnetic surveys. In /984 a 622.5 m borehole was drilled with a 242 m intersection of McDame ultramafite of which the lower 15/ metres contain potentially economic chrysotile asbestos. The McDame deposit averages 90 m thick, trends north-south, dips easterly and plunges southeasterly. The deposit is estimated to contain geological reserves in the order of 62 million tonnes containing asbestos fibre similar in value to the Cassiar deposit.The McDame is considered a major world-class asbestos deposit. A decision to develop and mine the deposit will require further substantial underground exploration and evaluation. A + 1200 m exploration adit driven to the hanging wall of the deposit was undertaken in 1985 in anticipation of bulk sampling and diamond drilling in 1986."

Jan 1, 1986

By V. I. Peresypkin, A. Y. Lein, N. S. Bortnikov, Yu. A. Bogdanov

"Abstract - The lipid component in hydrothermal deposits of the Logachev vent field, at 14°45_N of the Mid-Atlantic Ridge (MAR) and Broken Spur vent field, at 29°N of the MAR, was studied. Biochemical, gas chromatographic (GS), and molecular mass methods (GC-MS) research established the mixed nature of the organic matter (OM) including phytoplanktonogenous, chemosynthesized lipids, and lipids of questionable origin. Specific local conditions around the sulfide ores of the black smokers (absence of free oxygen and presence of reduced copper, which prevents OM degradation) facilitate the preservation of biogenic material, including bacteria. The main differences between the lipid compositions of the hydrothermal deposits of these two vent fields relate to the variable nature of hydrothermal circulation systems.At the 14°45_N vent field, high-temperature hydrothermal fields are forming due to the reaction of sea water with upper mantle ultrabasic rocks during serpentinization (a deep hydrothermal circulation system). High pressure and temperature (>400°C), a reducing environment and the presence of various metal oxides are favorable for the abiogenic synthesis of CH4 and oil hydrocarbons (HC). At the Broken Spur vent field, hydrothermal deposits are forming above axial crust magma chambers due to the interaction of sea water and basalts (an axial hydrothermal circulation system). Abiogenic synthesis of HC also occurs in this situation, but to a considerably lesser extent."

Jan 1, 1999

By Joël P. T. Kapusta, Liam J. Watt

The last extended copper smelting and converting survey dates back to the 2003 International Copper Conference held in Santiago, Chile. The following year, the Minerals, Metals, and Materials Society of AIME (TMS) started a new series in its Journal of Metals (JOM) called JOM World Nonferrous Smelters Survey devoting its first Part to Copper. The copper smelting landscape has significantly changed in the past 15 years, both in geographical terms with the shift of copper smelting production from the Americas to China and in technological terms with the growing adoption rate of Top-Submerged Lancing (TSL) technologies and the development and implementation of Bottom-Blowing technologies. A copper smelting survey update, even if not as in-depth as the 2003 Copper Smelting Survey, is therefore in order. The authors will review the latest trends in copper smelting technologies and production worldwide in comparison to the landscape of the early 2000s. INTRODUCTION This 2019 copper smelting survey is different from previous surveys as our data does not originate exclusively from responses to a questionnaire sent to all the copper smelters. Our data comes from several sources. We are therefore very thankful to the International Copper Study Group (ICSG) and Wood Mackenzie for sharing some of their information and to ENFI, Outotec, and Glencore Technologies for helping us cross-check our numbers for the Chinese smelters, flash smelting, Ausmelt, and Isasmelt technologies. Our survey presents data reporting from a total of 96 operating copper smelters from around the globe, which is significantly higher than the 50 surveyed in 2003. Although secondary smelting numbers have steadily increased over time, this paper focuses on primary smelting operations with copper concentrate as feed material. The list in this survey is still far from complete, with missing information from several known smelting operations. The total primary copper production tonnage of the smelters we surveyed amounts to 18.3 million metric tonnes from 29 countries representing 92% and 94% of total world primary production for 2018 estimated by ICSG and Wood Mackenzie, respectively. This representation has increased from 2003 when the total was 9.71 million metric tonnes from 23 countries accounting for 73% of world production. The trends presented and analyzed within this paper have stronger significance because of the increase in production accounted for. The Chinese and Russian smelter information collected is more detailed than years past. Our complete dataset is summarized in Table 1 at the end of our paper.

Jan 1, 2019

By J. C. Moreno, G. Rios, M. Palacios

The Huelva smelter was commissioned in 1970 coinciding with the shutdown of the old smelter in the Rio Tinto mine site. That new smelter consisted of two Momoda blast furnaces with a capacity of 500 dmtpd of concentrate. Nevertheless, soon after their start-up, it was clear that an increase in the smelting capacity was needed. After an analysis of the existing alternatives at that time, the flash smelting technology was chosen. The new Outokumpu Flash Smelting Furnace (FSF) came into operation on 18 September1975, with an initial capacity of 900 dmtpd of concentrate, using four Venturi-type burners and preheated atmospheric air. Since that date the Huelva Smelter team, together with Outokumpu (now called Outotec), have continuously improved our FSF design, process conditions and operational practices, leading to a present capacity of 3,500 dmtpd of concentrate. Since 1975, five smelting campaigns have been completed, the last ending in November 2013 with the rebuilding of the original FSF hearth. This paper describes the history of these improvements and the lessons learned.

Jan 1, 2014

By Barton G. Stone

The mining and exploration industries have been using Geostatistics (Matheron, 1963) for the past forty years. It has been extensively incorporated into three dimensional block modeling software whose usage has reflected the growth in the use of personal computers since 1980. Because of the utility of geostatistical models in mining and production planning, much of the modern reserve and resource modeling is done by mining engineers, geostatisticians and geological engineers. Explorationists are initially less concerned with three dimensional models until such time as a deposit has been roughly delineated. However, the concept of regionalized variables in ore deposits deals with the effect of spatial correlations between data points in a three dimensional sample space and should be useful for optimizing the spacing of drill holes to allow maximum bang-for-the-buck in drilling programs. This paper examines three common deposit types (porphyry copper, VMS and intrusive gold) to examine whether geostatistical methods have been used to minimize drilling costs because of better understanding of spatial correlations. The three model types were chosen from publicly available corporate websites of Canadian based Junior Mining Companies. They include the Wolverine polymetallic zinc deposit of Yukon Zinc in Yukon, Canada; the El Morro Deposit in Chile (30 percent ownership by New Gold Mining Company, and the Fort Knox Gold deposit in Alaska and 50 percent ownership by Nova Gold Resources). Typically, individual mining corporations post their technical reports as CNI 43-101 reports on their corporate website as indications of the favorability or progress on their more exciting properties. Data considered for this paper was not collected or generated by the author, but the information was extracted from these publicly available sites and had a variety of authorship.

Oct 1, 2009

Real time analysis of ore quality between the mine and mill provides major benefits to copper mining and processing operations. Prompt gamma neutron activation analysis (PGNAA) is a proven technique that has been successfully applied for real time conveyed flow multi-elemental measurement. The advantage of PGNAA is that it measures through the full conveyed cross section continuously and provides representative element measurement without the need to constantly sample coarse (primary crushed) conveyed flows. High specification PGNAA analyzers enable accurate measurement over time increments as short as thirty seconds. Elements such as copper can be measured to a precision of 0.02% copper which is sufficient for high confidence in decisions for bulk flow diversion. Increments of eight tonnes are being diverted through a bulk ore sorting application to remove batches of waste from mill feed as well as divert material to different stockpiles based on ore quality. Longer measurement increments of two to five minutes are suitable for blending control of ores to reduce feed quality variability and to control average ore quality within a target range. Feed blends can be adjusted as frequently as required but typically multiple measurement increments are composited to produce a rolling average ore quality. The paper details two case studies where analyzers have been successfully used to measure conveyed flows for blending and bulk diversion applications. The real time measurements of ore composition are also used for ore reconciliation, in metal accounting and providing process operators with advance warning of ore quality changes that may affect grinding performance and cause process upsets. Real time ore quality measurement has proven beneficial in improving copper processing performance through better utilising plant capacity in a leaching operation, optimising ore feed quality, and reducing unnecessary processing of waste. INTRODUCTION Representative real time elemental analysis of conveyed ore quality using fully penetrative technologies has been available to the minerals industry since the 1990s. The Prompt Gamma Neutron Activation Analysis (PGNAA) technique was developed into a conveyed material analyser and soon adopted by the cement and coal industries which recognised the benefits in real time quality management. These commodities were ideally suited to this measurement technique as operations generally involved conveying bulk material prior to processing. Measured quality was used to divert material to different destinations or used to control blending for improved quality consistency. Uptake in the minerals industry, however, has been slow until the last ten years, and particularly until the mid-2010s.

Jan 1, 2019

By Sean Dessureault

Technological Revolution ?Information age ? brought about by: ?Low-cost processing, storage, information sharing ?Shared & integrated data ? Increasingly more sensors & data sources From data collection to data use ??Data mining??analyzing the huge volumes of data ?Key example used in MBAs: ?Wal-mart, Google Explosion of data, trickle of information ?Paralysis of action Outline Trying to provoke- What drives innovation now? ?Challenges in mining Data Action Approach ?Examples from research & consulting upon request Conclusions ?Unaddressed challenges (Research Opportunities)

May 1, 2006

By A. Valdivieso

Reducing accident rates keeps getting more and more complex as the usual tools enter a curve of diminishing results. Fortunately, nothing modifies behaviour in a stronger and wider way than having a robust safety culture. On the other hand, managing cultural change is difficult and the risk of back-fire is very high, especially if the workforce does not trust our intentions. A personalized approach of well chosen and targeted actions tends to be the only yet difficult option. We have found, via experience in the metallurgy and chemistry industries, a way of preparing the company and the workforce to accept these sorts of culture changing measures faster and easier. Using company-wide changes based on workplace perception, yields the most optimal acceptance. It is based in the principle that we all use clues in our environment as guides to choose our behaviour. So, controlling the perception that our workplace generates can affect behaviour and simplify our task before it even starts. It is a matter of using the tools that other disciplines such as marketing, social engineering and architecture bring to us and adapting them to a very defined objective: Having our installations “sell” safety so that our people unconsciously believe that they must adapt to safety values in order to “do well” in said environment. INTRODUCTION After decades of improvements in accident rates, we are understandably hitting a diminishing results curve: most actions that spectacularly reduced accidents in the past (e.g., Innovation in Personal Protection equipment, adapting international standards and legislation, and innovative safety programs; Figure 1) now hardly get us the exponential gains we saw years back, regardless of the investment we put on them. Furthermore, the improvements in safety of the last 3 decades have been creating new sets of issues that start to show their face such as: By reducing accidents we can create feelings of invulnerability as we lose view of the consequences. With innovative protection equipment we increase Risk Homeostasis, meaning that people behave in a more dangerous way in order to maintain a constant level of risk in their lives (Getting closer to fire after getting better fire-proof garments for example). Too much Legislation can create a feeling of disengagement from personal responsibility. And despite improvements, we haven’t really solved the production vs safety confrontation, it is now stigmatized and less visible, yet it tends to reappear in moments of weakness.

Jan 1, 2019

By R. C. Urquhart

Since the first use of the electric arc furnace Henri Moissan (1892) and its use by Paul Hérholdt (1902) to melt steel, it has been successfully used as a pyrometallurgical smelting tool in the production of calcium carbide, iron, ferrous and non-ferrous alloys. Commercial forms of the electric arc furnace have evolved from round, single-phase single electrode units to rectangular three electrode three-phase units to round three electrode three phase units and ultimately to rectangular six electrode three-phase units. DC electrical supply has also been used to replace the three phase power supplies in some cases. This paper examines how these electric arc smelting furnaces have evolved in size, efficiency and configuration within the constraints of the smelting process, electrodes and electrical power supply equipment.

Jan 1, 2014

By Bryan Tisch

Goal of GMGE ??To advance mine reclamation through the beneficial use of organic residuals for the sustainable establishment of bioenergy crops and other productive land uses Objectives ??To advance the current ?standard? of mine reclamation by demonstrating that mining lands can safely become agriculturally ?productive? through the use of organic residuals. ??To generate and compile sound scientific data that can be utilized by stakeholders to better assess the environmental impacts of utilizing these materials. ??To complete a manual of best practices regarding the utilization of organic residuals on mine lands. *Considerable effort to be placed on operations/implementation side of utilizing residuals ?rather than just pure research

May 1, 2011

By B. T. Lu

The corrosion and wear properties of a series of chrome white iron (CWI) castings were study using electrochemical and low-stress sliding abrasion tests. The results confirm that the corrosion resistance of these materials is largely dependant on the quantity of chromium in the matrix, while the wear resistance is mainly controlled by the volume fraction of chromium carbides. A pseudo-wear/corrosion map is developed to identify alloy compositions that may be suited for erosion/corrosion conditions.

Jan 1, 2005

By S. Gheibi, H. S. B. Duzgun, N. Dadashzadeh

It is widely recognized that there are various uncertainties in the analysis of rock slope stability owing to inadequate information for site characterization and inherent variability and measurement errors in geological and corresponding parameters. Therefore, reliability-based approaches that allow the systematic and quantitative treatment of these uncertainties have become a topic of increasing interest in rock slope engineering. There has been extensive reliability analysis of rock slope stability in the literature. However, all of these analyses are based on the First-Order Reliability Method (FORM). The probability of failure of a rock slope in the First-Order Reliability Method is provided by a linear approximation of the failure function. The FORM is most commonly used because it is efficient; its accuracy, however, deteriorates when the nonlinearity of limit-state function increases. A better approximation of the failure function can establish a more accurate value of the probability of failure. The Second-Order Reliability Method (SORM) overcomes this drawback with a cost of lower efficiency in terms of the number of function calls and computation expenses. Despite considerable studies of the application of the SORM in other engineering fields, a few attempts have been made in the slope stability studies. In this study, a recently published Second-Order Reliability Method with First-Order Efficiency (SORM-FOE) is implemented on a selected rock slope in Amasya, Turkey. The SORM-FOE overcomes the low efficiency of the SORM by decreasing the number of function calls. The probability of failure of both FORM and SORM-FOE are obtained and the results are compared. It is shown that, in high value of failure probability, SORM’s do not significantly affect the analysis and design. However, in very low failure probability, the discrepancy between FORM and SORM-FOE becomes pronounced. It is also shown that, where the second order methods are required, the SORM-FOE is more efficient than the conventional curvature fitting methods in terms of computational costs.

Jan 1, 2015

By D. Thibault, A. Akhiate, M. Brochu, E. Braud

Cast martensitic stainless steels, 13%Cr-4%Ni, having carbon contents between 0.018 wt% and 0.067 wt% were normalized, air quenched, and tempered at two different temperatures (550°C and 610°C). Their microstructures were characterized by optical microscopy and X-ray diffraction (XRD). Macro and microhardness, tensile strengths, and impact resistance were quantified for each material and condition. Results show that the prior-austenite grain size is constant through the materials but the percentage of reformed austenite, contained in the martensitic matrix, depends strongly on the material chemistry and on the tempering temperature and on its duration. It is observed that, independently of tempering conditions, an increase in carbon content increases the material hardness and tensile strengths, whereas the elongation remains constant. In contrast, the results of Charpy type impact toughness tests show a different trend. The material containing the average carbon content (0.034 wt%) is significantly tougher than the two other alloys. Surprisingly, the toughness of the steel containing 0.034 wt% carbon was found independent of the reformed austenite content. It is thus concluded that carbon and reformed austenite contents are not the only parameters affecting the toughness of these steels.

Jan 1, 2014

By Jeff Smith

Agenda About NORTHPARKES The NEED The INITIATIVE The SEARCH The PRODUCTS The SOLUTION The RESULTS The Northparkes copper-gold mine in Central Western NSW commenced operations in 1994. Copper concentrate is produced and shipped to smelters in Japan, China & India under long term contracts with spot sales to other Asian countries.

May 1, 2006

By Jianhong Xu, Hailong Hou, Yu Jing, Yundong Wang

Microcapsules containing extractants have been applied to the extraction of metal ions, organic acid, pesticide, and herbicide. The difficulties of conventional liquid-liquid extraction in phase mixing and phase separation (e.g. high energy consumption, emulsification phenomenon, and large equipment requiring housing) could be overcome in a liquid-solid system by using microcapsules. Even some extractants with high viscosity and poison can be encapsulated conveniently into microcapsules. In the work described in this paper, polysulfone microcapsules containing 2-ethylhexylphosphonic acid mono-2-ethylhexyl ester (P507) were successfully prepared. Then, the extraction rate of lanthanum, samarium, and erbium in dilute solution into the microcapsules containing P507 was studied. An extraction kinetic model is proposed based on the interfacial reaction model accompanied by intraparticle diffusion expressed by Fick’s law. The extraction efficiency was obtained by using the kinetic model with the separately determined complex formation rate constant and the intraparticle diffusion coefficient. From the results, it was confirmed that the kinetic model could predict the experiment in a microcapsule system over a wide concentration range of lanthanide solution. In the future, the model could provide good guidance for the design and application in extraction of lanthanides.

Jan 1, 2014

By Chris McBean

Due diligence mistakes ? lost opportunity ? High profile write-downs and cost overruns ? Result ? tight market for financing ? Implications for due diligence ? need to get it right ? maybe only one chance ? Where should focus be?

May 1, 2013

By James A. Deeks

"Motor failures and equipment bearing failures are responsible for reduced productivity.With the introduction of computers and data acquisition systems, users are now able to monitor, report and trend deteriorating conditions and take corrective action before a critical shutdown occurs.This paper discusses the monitoring and trend analysis of' motors, and motor and equipment bearings. With today's digital electronics technology users are now able to monitor their equipment, detect deteriorating or abnormal conditions quickly, alarm the condition locally and or remotely, and decide if immediate corrective action is necessary or if it can be delayed until the end of a work Shift. All of this can be done long before any damage is done to the equipment.Monitoring Trend AnalysisIt is no longer necessary to compromise in selecting products, since state-of-the-art designs allow the adjustment in such small increments that the users are able to detect minute changes in a system's performance.Monitoring and trending of motors and equipment bearings is now available in economical packages which can be expanded as a system grows. Simply select the information you need, set the parameters, choose the scan time, and decide on the degree of reporting.Buffer storage of short-term monitoring of a number of analogue channels permit the user to view the recent history of motor data such as: motor average load, unbalance, motor current, ground fault, reserve thermal capacity, plus all of the settings of the protective device.A decision can be made to freeze the stored information after the motor stops or after the motor starts. Then the user is able to recall the conditions and diagnose the performance and the cause of the abnormal condition. Typical scan times range from ¼ second to 5 seconds ."

Jan 1, 1992