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By R. Ratnagiri, B. Minaie

"In order to expeditiously produce defect-free metallic components in materials processing applications, the relationship between the process parameters and the product properties needs to be well understood while minimizing the production engineering iterations. To achieve this goal, a realistic mathematical formulation of the process should be carried out and an appropriate numerical modeling of various phenomena occurring in such process should be implemented. The materials processing of transforming the molten material into a finished metallic component involves fluid flow and solidification/melting. In the present paper, a finite element based analysis of the fluid flow ·and solidification/melting phenomena in cavities is presented and the various issues in modeling these phenomena are discussed. These transport phenomena play an important role in determining the final characteristics and material properties of the part by affecting the formation of defects and microstructure. A realistic numerical modeling of these phenomena can significantly reduce the rejection rates during the process and can increase the quality of the final product.IntroductionDuring the intelligent materials processing of various metallic components, it is often required to have a thorough knowledge of the behavior of the transport phenomena involved in this process. This is due in large to the coupling that exists between the transport phenomena and the final material properties of the components produced during materials processing. This interrelationship demands that the pertinent transport phenomena in the form of fluid flow and solidification/melting be studied and predicted accurately. In many materials processing applications, the fluid flow is in the form of either a forced convection free surface flow intended to fill a cavity or a natural convection flow resulting from the gravity when the cavity is filled. In either case, the phase change in the form of solidification/melting is also involved in order to complete the process. However, the thermal history during this phase change has a direct impact on the material properties of the final part and the possible defect formation that may be involved. This thermal history itself is dependent on the nature of the fluid flow during the earlier stages of the process. As such, there is a coupling between the fluid flow, phase change, microstructure, and defect formation in the resulting component. It is therefore necessary to analyze these phenomena in order to find optimum methods to produce good quality parts by minimizing the defects that may be generated. Such an analysis can result in the development of appropriate numerical models for the process that can facilitate the economical and timely manufacturing of various components with high consistency. The present paper discusses the issues related to the transport phenomena encountered during materials processing of components engineered largely by using various combination of convective fluid flow and solidification/melting in cavities."

Jan 1, 1994

By I. F. Walder

Mill tailings from skarn-type base metal deposits were studied in order to ascertain potential element mobility in response to weathering. Hypogene ore minerals are sphalerite, galena, and chalcopyrite, showing minor supergene oxidation to smithsonite, cerussite, and covellite. Gangue minerals are pyrite, pyrrhotite, magnetite, hematite, andradite and grossular gamet, hedenbergite, calcite, ankerite, and quartz. Foremost of the eleven tailing piles studied, the hypogene sulfide minerals show no or only incipient post-mining oxidation. Iron oxides and hydroxides form the main oxidation products in the tailings and are enriched in heavy metals. A distinction between pre-and post-mining oxide phases may be obtained based on petrographic observations which distinguish whole-grain versus partial grain replacement. Zn and Cd do not appear to be enriched in the weathering derived oxidation minerals and will be more easily leached from the tailings than other metals.

Jan 1, 1994

By T. P. Meloy

The packed column flotation cell is an awesome separation device. Virtually unknown and untested, the packed column flotation cell is one of the ten most important developments in mineral processing of the 21st century. Though experimental and industrial data is limited, it is clear that the packed column flotation cell is two to three orders of magnitude better than the conventional flotation cell and one to one and a half orders of magnitude better than the open column flotation cell. With the modern packing taking up less than one percent of the packed column, column blocking does not occur. For a packed column operating 24 hours a day, 365 days a year, the estimated mean time between failures (MTBF) is one hundred thousand hours or roughly twelve years. With no moving parts, lower maintenance costs, lower power consumption and inherent operating stability, the packed column is a powerful separating machine. Because there is little meaningful data for comparing the packed column to the conventional flotation cell and the open column flotation cell, much of the material presented in this paper are guesstimates. They are disinterested guesstimate made by the authors after extensive theoretical work and reviewing the known facts. In the authors' opinion, no available data contradicts the guesstimate. The authors expect that there may be errors as large as three hundred percent. Even three hundred percent errors will not change the conclusions of this paper. The packed column flotation cell is a formidable separating device. To understand the problems of comparing the three types of flotation cells, consider the fact that the three cells may have different modes of separation. One of the authors, Meloy, believes that in the conventional cell, the primary particle separation takes place in the liquor with secondary separation taking place in the froth, while for open column flotation, all the separation takes place in the froth. However, he believes that in the packed column a large part of the separation may take place on the walls of the packing. If this is true, not only is the method of modeling each type of cell different, but the method of particle selection in the cell is different. This means that one type of cell may be better at differentiating between two different types of particles. There is a growing body of literature on open and packed column flotation. Suggested reading: (Clarke et al; Hucko et al; Li; Smith & Warren; and Yang).

Jan 1, 1994

By J. O. Jensen

A method is described for the determination of cyanide in gold slurries, based on amperometry. The measured current is proportional to the concentration of cyanide, and is not effected by pH or by the concentration of oxygen in solution. It is also unaffected by other ions that may be present in gold-leaching solutions, including sulphide, thiocyanate, and thiosulphate. The current depends on the temperature, and an activation energy of 17,9 kJ/mol was determined Since the current is controlled by the mass transfer of cyanide to the anode, it depends on the conditions of agitation. In tests on an operational gold plant, slurry was pumped directly from the top of the leaching tank, through the measuring cell and back into the tank. The results indicate that the instrument is a promising alternative to the instruments currently available. The readings from the instrument remained in calibration for at least two days, showing that the instrument would need to be re-calibrated by the operating staff at regular periods.

Jan 1, 1994

By A. A. Hejja

The effect of composition on electrical conductivity, viscosity and liquidus temperature of the slags was investigated in the temperature range of 1300" to 1450°C. The synthetic slags containing CaO, MgO, SiO,, A1,0, and FeO were similar to those employed in the electric furnace smelting of sulphide Cu-Ni concentrates containing PGM (Platinum Group Metals) from the Merensky Reef of South Africa. FeO and SiO, were found to affect the viscosity and conductivity the most while liquidus temperature depended on MgO content in addition to these. The activation energy for electrical conduction was found to vary from 67 to 159 kJ/mol and that for viscosity from 125 to 209 kJ/mol. Optimization of the slag composition was attempted on the basis of opposite trend of the viscosity-electrical conductivity relationship with slag composition.

Jan 1, 1994

By Stuart M. S, Allen P. B

The Childe Harold deposit was mined by the Granny Smith Joint Venture (GSJV) from late-March through to early-December 1993. This was a fast-tracked mining project whose history began with an offer to purchase agreement being signed at the end of October 1992. A feasibility study was completed by the end of December 1992 after completion of a reverse circulation (RC) and diamond drilling program. Subsequent additional definition drilling culminated in a remodelling of the reserve by March 1993, by which time all necessary governmental and company approvals had been granted. The crucial aspect of mining Childe Harold quickly was to maintain oxide ore supply to the Granny Smith mill at the maximum possible rate for blending with existing fresh ore stocks. As a result, high production rates had to be balanced with

Jan 1, 1994

By Jogre A. S Tenório

he aim of the present investigation was to investigate technological features of the Fe-NbC dissolution in liquid Fe-C alloys. Fe-NbC is a Ferro-niobium alloy with 7%C, has a particle size smaller than 150 pm and its micro constituents are polygonal niobium carbides and an iron matrix. The obtained dissolution time was less than one-minute and the yields were in the range of 80-90% at 1873 K. In the Fe-NbC dissolution process, the dissolution occurs at first, and as a consequence the niobium carbides become free to dissolve. These carbides will dissolve until the melt reaches a saturation point. The non-dissolved carbides remain trapped in the liquid or will form a dross. The addition yields decreases when the niobium concentration reaches this limit value, that depends on the carbon concentration. These define a saturation curve.

Jan 1, 1994

By Zhang Qi

For the most part, the flying piece is serious endangerment in the demolition blasting. To prevent the endangerment, a large number of materials are needed as the protection. Therefore, the determination and design way of the flying distance of piece in demolition blasting have been concerned extensively. Previously, the experienced or half experienced formula was adopted to calculate the distance of the flying pieces. The calculating values of the distances of flying pieces are not identical with the practice results. The problems concerning the design way of flying distance of pieces are researched in the paper.

Jan 1, 1994

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Jan 1, 1994

By Stephen M. Jasinski

This report describes the materials flow of mercury in the United States. It examines the mining and production of mercury and the manufacturing, uses, and ultimate disposal of mercury. Materials flowcharts were prepared for 1989 and 1990. An effort was made to include estimates for all major anthropogenic sources including fossil fuel combustion, waste incineration, and nonferrous metal mining operations. Mining and mineral processing released about 100 mt/yr of mercury to the environment in both 1989 and 1990. The combustion o ii fu1s released 175 mt/yr in the same years. The manufacturing, use, and disposal of products containing mercury accounted fix the release of 1,037 mt of mercury in 1989 and 938 mt in 1990. The manufacture of chlorine and caustic soda was a major source of recycled mercury, but it was all reused within the industry. Recovery from all waste products accounted for 36% of reported consumption in 1989 and 42% in 1990. The losses from manufacturing and end use have been declining, whereas mercury emitted from combustion sources has not been strictly regulated and will likely become the largest source of mercury releases to the environment.

Jan 1, 1994

By Tatsuo Inoue, Marnoru Mizuno, Toru Matsuoka, Kenichiro Abe

"The distribution of particle reinforcements and the residual stresses in metal matrix composite are simulated by considering the motion of particles and the solidification of matrix associated with temperature variation in the course of centrifugal casting process. In the analysis, a heat conduction equation including heat generation due to latent heat and also mechanical work as well as heat input from successively accumulated element on the air/metal boundary is solved by the finite element technique. After the movement of particles subjected to the centrifugal force and drag are analyzed, the residual stresses are elucidated by using a unified constitutive equation which can describe the behavior both in liquid and solid states. Results of the simulation are compared with the experimental data, and the validity and utility of the procedure is confirmed.IntroductionProcess simulation of metal matrix composite (MMC) is required to determine the mechanical properties of the materials and the efficient process and conditions of the fabrication. Properties of bonding matrix with reinforcements in the course of the processing, for example, affects the strength of the composite, while the final costs of the productions depends on the efficiency of fabrication. Therefore, the simulation of processing of MMC is prerequisite in order to clarify the mechanism to fabricate the material which has been expected to maintain high mechanical properties and the cost performance.Some techniques of processing MMC[l] have been developed so far. Among them, the centrifugal casting technique [2-5] has many attractive characteristics as processing of the MMC: The centrifugal casting technique makes the reinforcements such as particles or short fibers to be distributed in the radial direction by the centrifugal force acting on reinforcements due to the difference in density between reinforcements and matrix. Since the distribution of reinforcements affect the mechanical properties of MMC, the composite with functionally gradient mechanical properties can be provided by the centrifugal casting technique."

Jan 1, 1994

By A. Durnan

Barrick Goldstrike Mines Inc. (Goldstrike) operates a six circuit (train) pressure oxidation plant for the pretreatment of gold bearing sulfide ores. The property is located 27 miles north of Carlin, Nevada. Since the commissioning and start-up of the first circuit in 1990 until the present total plant availabilities have exceeded 90%. The discussion that follows will detail the maintenance practices employed to consistently achieve this goal.

Jan 1, 1994

By Joseph C. Milbourne

The selection of a suitable nitrate removal process depends on a variety of site-specific chemical and environmental issues. The dominant technologies for nitrate removal include biological denitrification and continuous countercurrent ion exchange. The decision to apply either of these technologies, or both together, depends on the nature of the waste water to be treated. Factors that affect the selection of the biological system include the feed composition and feed temperature. Ion exchange nitrate removal systems are less sensitive to the feed composition but require disposal or destruction of the concentrated pregnant eluate. The paper discusses Tetra's continuous countercurrent ion exchange technology (CCIXTM) and fixed film biological reactor, Denite°. The treatment of the ion exchange pregnant eluant is also discussed.

Jan 1, 1994

By K. A. McDonald

This paper will describe the experiences of Hibernia Holdings, Inc. in constructing a mineral processing facility in Mexico. It will attempt to set forth a guideline on what companies attempting to operate in Mexico can expect and what actions they can take. Ownership laws, import/export laws, labor laws, security, transportation and operating experiences will be discussed.

Jan 1, 1994

By Steven Wright

The reduction of a slag produced 6om the recycling of lead batteries was studied in a kilogram scale laboratory investigation by reacting with graphite at temperatures of 1180 and 1200°C. Simultaneous reduction of PbO, Fe203, Sb203 and As203 occurred with the Sb and As reporting to the metal while the lead content in the slag was above 2 wt%. The Sb and As distributions between metal and slag were strongly affected by temperature and slag oxidation state. The rates of reduction of PbO and Sb203 increased with increasing slag basicity and temperature and decreased as the PbO content in the slag decreased. The reduction rate of PbO from these slags was similar to other industrial lead slags at the same CaO/SiO2 ratio and temperature. The implications of the behavioural similarities of the antimonous slags during reduction with carbonaceous reductants and other lead slags are briefly discussed.

Jan 1, 1994

By T. J. Fenner

Research conducted in South African mines has demonstrated the benefit of ground penetrating radar for the detection of geologic features and hazards. This is crucial for safety and production considerations in underground mines that are as much as 4 kilometers deep. This paper describes a new ground penetrating radar system designed specifically for high quality data acquisition, in the harsh conditions of deep underground environments, for use by operators with minimal geophysical experience. Design criteria included automated functions, intrinsic safety, light weight and minimal power requirements. Data is processed on the ground surface by geoscientists using a PC.

Jan 1, 1994

By Bhattacharyya A. K

A strata parameter is introduced to include the deformation characteristics of the undermined strata in the prediction of subsidence movement. By using the strata parameter and mining factors as parameters, a nomogram for predicting the maximu

Jan 1, 1994

By P. V. Avotins, D. R. Nagaraj, S. S. Wang

Xanthates and dithiophosphates are the most commonly used collectors in the flotation of sulfide minerals. Other reagents such as thionocarbamates, mercaptobenzothiazoles (MBT), mercaptans and xanthogen formates occupy niche positions in industrial collector use. Over the last ten years there has been much activity by chemical companies to develop new collector compositions. The new collectors are aimed at meeting specific process needs such as recovering an increment of valuable metals, improved sulfide separations, increased flotation kinetics, and reducing reagents costs. A review of the patent literature shows that American Cyanamid (Cytec), Dow Chemical, Phillips Petroleum, Sentrachem Ltd., Henkel, Montan Chemicals and Elf Aquitaine, among others, have been active in sulfide collector research. Several companies have achieved considerable success in laboratory and plant tests of the new collectors; however, commercial acceptance for plant usage has been slow. Those most advanced have been plant tested extensively and some are in day-to-day use. The new collector types in this category are: Modified thionocarbamates, dithiophosphinates, organic sulfides, trithiocarbonates, monothiophosphates, and modified thioureas. Others such as substituted mercaptobenzothiazoles and monothiophosphinates have been tested in the laboratory. The chemistry of collectors developed in the last 10 years, their preparation, physical properties and their potential for commercial use are reviewed in this paper.

Jan 1, 1994

By William E. Hill

The blasting program at the Valdez Creek Placer Mine must deal with challenging situations throughout the year. During the short summer, extreme water conditions must be confronted, while the winter months present problems of a different nature, where the overburden freezes to a depth of up to 18 feet. These obstacles require techniques borrowed from hardrock blasting combined with creative experimentation to overcome.

Jan 1, 1994

The types of risk to mining projects using environmental protection as justification are examined. In Australia, Governments, whether Federal or State, enforce environmental legislation. The way they do This has an impact on the risk to a project. This is discussed and examples are taken from the Northern Territory uranium industry. Special reference is made to mine closures where the roles are not yet entrenched.

Jan 1, 1994