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By NRMR Bhargava

With the increasing use of lead-free solder alloys, low melting point alloy is often required due to the heat- sensitive parts or substrates in modern electronic devices. For such demand of low melting point, the nanostructure lead- free solder alloy, having excellent metallurgical characteristics and a melting point of <215oC, were developed by mechanical attrition of conventional lead free solder alloys (Sn-Ag-Cu, Sn-Ag and Sn-Cu). The decrease in melting point due to nanosize effect was calculated theoretically as function of particle size and the theoretical results were compared with experimental values measured by differential scanning calorimetry. The newly developed alloys have eutectic composition of Sn-3.5Ag-0.7Cu, Sn-3.5Ag and Sn-0.7Cu and the melting point depression found to be 5.10C, 4.10C and 6.20C when the bulk alloys reduced to 80 nm, 92nm and 96nm sizes respectively.

Jan 1, 2009

By Fanke Meng

Electrolyzing oxides of titanium, aluminum and niobium could prepare high-Nb bearing TiAl alloy (Ti-45Al-9Nb) at 1500°C. The chosen electrolysis voltage is 3.5V, which is lower than reducing voltage (~4.7V) of electrolyte CaF2, but higher than that of titanium, aluminum and niobium oxides. The investigation shows that compared with traditional methods, this method for preparing high-Nb bearing TiAl alloy is of many advantages such as few steps, friendly environment, low energy consumption, low cost and high current efficiency.

Jan 1, 2009

By Ö. Kaya

The removal of gangue minerals from three different graphite ores (Inebolu, Akdag?madeni and Çoraklidere) from Turkey by acid leaching was studied. Acid leaching experiments were applied to the flotation bulk concentrates, which were obtained in determined optimum conditions after preliminary flotation tests. The effects of acid type, acid concentration, leaching temperature and leaching time on the dissolution of gangue minerals were studied. The most suitable leaching conditions were determined to be 20% HCl + 4% HF for acid type and concentration, 85 ºC for leaching temperature and 4 hours for leaching time. After removing the gangue minerals at these optimum conditions, the total carbon contents of the samples from Inebolu, Akdag?madeni and Çoraklidere increased from 23.51% to 40.07%, from 37.93 to 60.47% and from 42.28 to 59.47%, respectively.

Jan 1, 2009

By Hamid Maleki

A geotechnical monitoring program has been implemented at Energy West Mining Company for enhancing site-specific evaluation of longwall stress conditions. This program consists of underground measurements at five locations in two neighboring mining districts located in the Hiawatha and Blind Canyon Coal Seams under moderate to deep cover. Within the last five years, additional measurements, including data on recorded seismic events and face conditions, have been incorporated into the data collection program together with detailed geologic mapping of longwall gateroads. In conjunction with the measurement program, the authors have completed detailed boundary-element stress analyses of the mine plans. Models have been calibrated using the data from in-mine instrumentations and then routinely used for evaluation of mine plans at depths approaching 2,600-ft. The work has improved our understanding of load transfer, seismicity and yield pillar performance. It has identified areas of potential increased stress levels at certain longwall face positions and provided guidance to measures that could be considered to mitigate the potential for these increased stress levels.

Jan 1, 2009

By Jinhui Li

Silver is a very important metal used in a wide range of applications. It is necessary to recovery of Ag from electronic wastes for increasing of Ag price and circumstance protection. For separating and recycling Ag from Ag-Cu composite materials, thermodynamic data of reaction is calculated and some experiments have been proceeded with Ag-Cu composite material scraps, time, temperature, nitric-sulfuric mixed acid volume ratio and the volume ration of mixed acid vs. water have been discussed. The results show that the optimization conditions is that nitric-sulfuric mixed acid volume ratio 5:95, volume ratio of mixed acid vs. water 10:1, temperature 55?, time 25min. In the conditions, Ag can be selectively leached from Cu-based composite material, Cu base is not eroded nearly.

Jan 1, 2009

By H. K. Lin

Deepwater discharges of sulfide flotation tailings have been practiced for several decades. Oxygen penetration and organic matter content in such environments are the two major factors that determine their reduction-oxidation condition and hence the rate of sulfide mineral dissolution under such discharge environments. In this study, the effects of solution redox potential and pH on the dissolution of some heavy metals from sulfide flotation tailings were examined. Zn, Pb and Cu concentrations in solution were all higher at a higher redox potential and lower pH. Dissolved Zn concentrations reached 100 ppm even at a low redox potential of 105 mV and near neutral pH after 33 days. Pb concentrations were below 2 ppm at 105 mV and near neutral pH after 165 days. At 105 mV, the Cu concentrations were below 0.2 ppm at near neutral pH after 165 days. At pH 2.3, the Fe concentrations were higher at 420 mV than at 105 mV. But at pH 6.8, the Fe concentrations were lower at 420 mV than at 105 mV, due to the oxidation of Fe2+ to Fe3+ and the subsequent precipitation of ferric hydroxide. Arsenic concentrations in solution were all less than 0.002 ppm. For Zn, Cu and Fe, no significant differences were observed between the tests in solutions prepared using seawater and those using distilled water. However, Pb concentrations reached higher levels in solutions prepared using seawater.

Jan 1, 2009

By Sutham Niyomwas

Silicon-Silicon Carbide (Si-SiC) composites were synthesized by self-propagating high temperature synthesis (SHS) from a powder mixture of SiO2-C-Mg. The reaction was carried out in a SHS reactor under static argon gas at a pressure of 0.5 MPa. The standard Gibbs energy minimization method was used to calculate the equilibrium composition of the reacting species. The effects of silica sources and carbon mole ratio in precursor mixture on the Si-SiC conversion were investigated using X-ray diffraction and scanning electron microscope technique. The as-synthesized products of Si-SiC-MgO powders were leached with 0.1M HCl acid solution to obtain the Si-SiC composite powders.

Jan 1, 2009

By T. C. Souza Pinto

Because shape is an assessment of the three-dimensional form of a particle, it may be described in terms of sphericity (?), which is a measure of how closely a particle approaches a spherical configuration. In this study, Darcy?s law and the Kozeny-Carman model for fluid flow through porous media were applied to packed beds to determine the sphericity (?) of apatite particles. The beds were composed of glass spheres or particles of apatite (igneous from Brazil and sedimentary from the United States) of three classes of size (Class 1: -297 +210 µm; Class 2: -210 +149 µm; Class 3: -149 +105 µm). Glass spheres were used to validate the model because of its known sphericity (? = 1.00). Apatite particles, either igneous or sedimentary, showed very close values for particle sphericity (? ? 0.6). Observations on particle images conducted by scanning electron microscopy illustrated that igneous (? = 0.623) and sedimentary (? = 0.644) particles of apatite of Class 2 predominantly exhibit elongated shape. The close value of particle sphericity (? ? 0.6) showed by either igneous or sedimentary apatite may be justified by the similarity in particle shape.

Jan 1, 2009

By M Wortley, R Morrison, T Rivett

The tracking of ore through process hold-ups such as stockpiles has been traditionally been difficult to achieve. The inability to pinpoint the exact source in the mine of material that is feeding a processing plant has led to inefficient mine-mill reconciliation processes. In addition, a lack of understanding of the behaviour of ore in process hold-ups such as bins and stockpiles often leads to poor predictions of plant performance and to poor reconciliation of this to the orebody.This paper reports on two short case studies. One case study addresses tracking ore from various parts of two mines to the concentrator. The other follows synthetic particles through the coarse ore stockpile. Both studies use radio-frequency identification (RFID) tracer technology. The paper concludes by discussing general strategies for implementation of such concepts into mine-mill metal accounting and reconciliation systems. As shown in this paper, reliable ore tracking systems will allow much more effective mine-mill reconciliations as well as the ability to model process hold-ups with regard to size by residence time distributions. This should, in turn, allow metallurgists to have a better understanding of the size and grade of material that will report to the plant at different process hold-up (eg stockpile) conditions.

Jan 1, 2009

By Maya Kamenetsky, Khoi Nguyen, Natalee Bonnici, Steve Walters, Claire McMahon, Julie Hunt, Ron Berry

"The analysis of meso- and micro-scale textural attributes has been undertaken on ore samples from the Ernest Henry iron oxide-copper-gold (IOCG) deposit in NW QLD. Quantified textural data including grain size, shape and mineral association have been extracted from classified images of core with the aim to better predict potential mineral processing behaviours such as comminution, liberation and flotation. Data have been extracted from images of intact core at meso- and micro-scales using high resolution continuous images collected using automated core-logger technology, SEM-based and optical microscopy platforms.The results of this study will show examples of quantified size, shape and mineral association data from meso- and micro-scale classified images. Analysis of the data shows that there are domains of variable grain size and mineral association that can potentially be related to crushing and liberation behaviour. The trends that are observed at the drill-core (meso-) scale are consistent with those at the micro-scale. The results from the micro-scale analysis show that the domains defined at the core-scale have clearly different chalcopyrite sizes and shapes as well as variable bulk mineralogy.INTRODUCTIONInnovations in technology have allowed automated extraction of information about mineral shape, grain size and mineral association, i.e., texture, from meso- and micro-scale images of intact rocks. The overall aim of this research is to investigate trends in quantified textural data that can potentially give an early view of processing parameters such as predicted grind size and liberation behaviour."

Jan 1, 2009

By J. E. Nesset, J. A. Finch, Rosenblum. F., S. Somot

"In a previous presentation at the CMP, evidence was shown for the formation of hydrogen sulphide (H2S) in self-heating experiments on pyrrhotite-rich samples (Somot and Finch, 2006). Oxidation of H2S is strongly exothermic leading to the proposition that H2S is playing a key role in the self-heating process. Subsequently, tests in two weathering apparatus (I and II) were run under varying oxygen levels to further examine conditions leading to self-heating. To characterise their resulting self-heating capacity the samples from the weathering tests were subjected to a modified Stage B test using the self-heating apparatus developed by Rosenblum and co-workers (Rosenblum and Spira, 1995; Rosenblum et al., 2001). Results showed highest self-heating after weathering occurs under low oxygen conditions, supporting the H2S hypothesis. It was observed that highest heating rates are not directly related to highest weight gains of samples.INTRODUCTION“Sulphides” refer to several types of minerals containing sulphur in its lowest oxidation state of - 2. Self-heating is the spontaneous heating of a material without external heat input. It is well established that some sulphides will self-heat on exposure to moisture and oxygen (Farnsworth, 1977; Good, 1977; Rosenblum et al., 2001; Wu and Li, 2005). This process is highly exothermic and if the heat generated is not dissipated, combustion may occur when the temperature reaches the ignition point of the sulphide (typically 350-400 °C). The hazards of sulphide self-heating range from handling hot material, to sulphur dioxide release, to fires. The literature documents self-heating incidents underground, on ships and trucks transporting sulphide concentrates, and in mine waste (tailing) disposal areas (Stachulak, 1990; Lukaszewski, 1969; Headley et al., 1977). Lukaszewski (1969), Farnsworth (1977), and Good (1977) note that sulphide minerals can act as fuel to promote underground mine fires. Based on such findings, sulphide minerals could become classified as hazardous materials, making transport of concentrates and storage of mine waste subject to stricter and more costly regulation. The problem is one the industry is keen to avoid."

Jan 1, 2009

By A. Gibson

Most methods for the treatment of scrap printed circuit boards do not reclaim the components in working order as the boards are either fed to a copper smelter, to recover the valuable elements, or, simply landfilled. This work reports the dissolution of the solder in fluoroboric acid containing Ti4+ ions which was particularly selective for solder, allowing the components to be recovered. The solder was subsequently electrowon from the leachant. The boards were then shredded and the copper dissolved in ammonium sulfate and, then treated via solvent extraction to give an electrolyte suitable for electrowinning. The remainder of the metals were dissolved aqua regia, silver remained unattacked by the aqua regia, palladium precipitated as Pd(NH4)Cl6 in the presence of zinc and nickel, the gold was removed by solvent extraction and precipitated as nanoparticles. The aqua regia was then diluted and the zinc and nickel separated by solvent extraction.

Jan 1, 2009

By D. S. van Vuuren

Over the last 60 years many different processes were conceived to reduce the cost of titanium produced by the Kroll process. However, success eluded all previous efforts, which were consequently terminated in periods of economic downturn. Recently, the grow thin demand for titanium and the high cost of producing the metal again sparked renewed attempts in various parts of the world to replace the antiquated Kroll process with a more efficient route. The different options to produce titanium are reviewed, classified and evaluated in terms of the fundamentals underlying the technologies, and it is shown that the options considered to be the most likely to replace the Kroll process, are continuous processes to reduce TiCl4 metallo-thermically to titanium powder. Of these, continuous magnesio-thermic reduction of TiCl4 would conceptually result in the lowest-cost and highest-value product. However, when considering by-product salt removal from the titanium product and recycling of the salt as well, sodio-thermic reduction of TiCl4 is better.

Jan 1, 2009

By Sanjiv Dhanjal

"Often mineralogy dictates the physical properties of a material rather than chemistry. This in turn affects how that material behaves in a process plant, and whether optimum conditions for refining one mineral are different to those for refining another. For example how does refining copper from chalcopyrite differ to refining copper from bornite?Minerals are naturally occurring inorganic solids that have a definite chemical composition and an ordered atomic (crystalline) structure. X-ray diffraction is a common and highly developed method to identify and quantify minerals. X-rays are fired onto a material and the mineral is identified by the angles where the diffracted X-rays are in phase.Most X-ray analyzers are laboratory based. A sample is prepared and analyzed by a detector that travels in an arc to collect the diffraction pattern. COSMA has a curved detector which picks up the complete x-ray pattern instantaneously. Therefore, material is collected and transported through the machine where is it is analyzed continuously.COSMA measures about 0.5 tons of material per day, while laboratory analyzers measure a few grams at a time. Real time data trends are produced allowing for improved process evaluation and automatic control. The COSMA on-line system has taken X-ray diffraction out of the laboratory into the field.There are a number of systems in operation in cement production. It is recognized that on-line mineral analysis has a role in many other processes. This paper presents the technology and invites further discussion should the technology be beneficial to members of the audience.INTRODUCTIONThis article describes COSMA, a system that provides direct and continuous on-line mineral analysis using X-ray diffraction in the field. While X-ray diffraction is a common technique used in mineral analysis, the time from sampling to analysis can be hours and plant operators typically do not get the data in time to control a process or respond to an upset. COSMA provides rapid measurement, analysis and feedback of data, in real time. This provides powerful information that can be used to optimize operation, thereby reducing costs and increasing quality."

Jan 1, 2009

By Xiaodong Wang

A liquid metal flow generated by a magnetic field whose traveling direction is periodically reversed, the Reversed Traveling Magnetic Field (R-TMF) is studied. The modulation frequency ranges from 0 to 6 Hz. Ultrasonic Doppler velocimetry probes the generated fluid flow. Depending on the modulation frequency, a number of characteristic flow features are exhibited. A transition frequency (approximately 4 Hz) exists, above which the flow is no longer sensitive to the force modulation. Below this transition point, the amplitude of the velocity oscillation increases, and then below fm = 0.05 Hz, it saturates around a value close to that observed without any modulation. A theoretical model to obtain an analytical solution of electromagnetic force and to predict flow motion is developed, which is fairly in agreement with the experiments.

Jan 1, 2009

By Lance A. Roberts

Micropiles are commonly utilized for applications other than foundation retrofit. In bridges, for example, micropiles can serve as the permanent foundation elements or can be used in temporary support applications. In this paper, a case study on the use of micropiles for the 18th Street Expressway Bridge rehabilitation/repair project in Kansas City, Kansas is presented. In the project, micropiles were utilized for support of six temporary jacking structures, which allowed the bridge to be lifted while repairs were completed. A group of six micropiles was required to support each jacking structure. The required compressive service load per micropile was approximately 300 kips (1300 kN) and the settlement of the micropiles under the service load was to be limited to 0.5 in. (12.7 mm). Two field compression tests were conducted as part of the project. The field load test data was integrated within a soil-structure interaction capacity approach in order to analyze and permit the shortening of the design bond length for the production micropiles.

Jan 1, 2009

By C. E. M. Meskers

Electronic and Electric Equipment contains a range of components made of a wide variation of metals, plastics and other substances. Up to 60 elements can be found in complex electronic equipment: base metals, precious metals and special metals in circuit boards and batteries. Because of its amount WEEE represents a considerable metal resource with a higher special and precious metal content than found in ores. The Umicore integrated smelter and refinery recovers and supplies back to the market 17 different metals from EEE. Pre-treated materials enter state of the art, material and energy efficient metallurgical processes for environmentally sound recovery of metals and treatment of off gasses and hazardous substances. The organics in the feed function as reducing agent and alternative energy source during smelting for precious metal recovery. Lithium-ion batteries are treated using a dedicated process. As a result the environmental footprint of metals produced from EEE is much smaller than primary production.

Jan 1, 2009

By Cem Colakoglu

In this study, nickel containing iron alloys were produced by carbothermal reduction of lateritic nickel ores obtained from Manisa - Caldag region of Turkiye in order to investigate the reaction mechanism of nickel and cobalt. In the experiments, the lateritic ore containing 1.58 wt.% Ni and 0.12 wt.% Co was calcined in a semi-pilot scale rotary furnace at 1100°C for 1 hour. Then, a mixture of calcined ore and metallurgical coke was reacted in sintered alumina crucibles using a graphite resistance tube furnace at different time (0- 60 min) and temperature (1500-1600°C).

Jan 1, 2009

Compagnie Miniere Esperance (CME), a mining company based in French Guyana, operates a gold primary ore body in open pit. The ore is processed through crushing, grinding and gravity separation. Tailings are stored in a ?fine? pond. Analyses of the fine ponds proved a residual gold grade sufficient for a chemical treatment. However, direct cyanidation would require a too large installation, regarding the local conditions (accessibility, supplying and rainforest meteorological conditions). It has been then decided to test the feasibility of a pre-concentration using flotation. Lab tests have been carried out by SGS Lakefield (Canada) in March 2007, which proves the technical feasibility. Therefore, CME asked Caspeo to: ? Carry out an on-site flotation pilot campaign. ? Design an industrial flotation circuit. The tailings reprocessing will contribute to a better tailings management and a dry up of the gold resource, limiting the risk of illegal mining after remediation of the CME site. CME MINE The Esperance gold mine is located in French Guyana, in the vicinity of several gold deposits as Omaï, Rosebel or Camp Caïman, holded by Iamgold and Newmont. These main gold deposits are located on the figure 1. Esperance was put into operation in the early 90?s. The first years were devoted to the mining of alluvial gold in the gravel of the Esperance Creek. Since then, operation was led in the primary gold deposit. Annual production is on average 254kg for a total production in fifteen years of 4300kg. Geology Esperance deposit is located in the greenstone belt of the Guyana Shield. Mineralization is in tectonic contact between sedimentary basin of Maroni and a granitic massif. Clastic series, composed of conglomerate and lamina sandstone, overlie a volcano-sedimentary basement (series called "Paramaca"). The area is strongly folded by shear movements, resulting from granite deposit. Gold is in interlacing quartz veins intersecting the clastic series. Gold is present in association with pyrite. Other elements, as silver or arsenic, are in negligible quantity. Exploitation The Maroni River is the only access to the Esperance mine. Only the saprolite and a part of the transition rock are extracted in the open pit. Excavation works are done using shovels Hyundai 450 (4 units) and haulage works using articulated dumpers Terex TA35 (4 units). These two sorts of equipments are presented figure 2. Mill The mill is composed of crushing and grinding processing plants. After gravity concentration, both plants produce tailings that are stored in two ponds: the first pond contains coarse product which segregates the particles crushed to 2mm upstream and settled clays downstream; the second pond contains the fine product made of particles ground to 200µm. These two ponds, bordered by dams and diversion canals, are located on former alluvial sites of Esperance Creek (see figure 3). [ ] The CME mill is currently producing gold concentrate, with a global recovery of about 67%. The ore is crushed by one jaw crusher and two hammer crushers. The ore then passes through a Knelson KC 48 gravity concentrator, producing a first gold concentrate. The

Jan 1, 2009

By D. E. Pollock

Recent NIOSH published information has shown an increase of rapidly progressive coal workers? pneumoconiosis (CWP) in the southern Appalachian coal region (SAR) of the U.S., despite the fact that compliance data indicates that most coal miners have been exposed to coal mine dust concentrations below the statutory limit of 2.0 mg/m³. While the exact cause of these elevated CWP levels in the SAR has not been established, several factors may be contributing to the increase in occupational lung disease among coal miners. The mining of high rank coal is known to lead to higher CWP rates, and this type of coal is mined in a portion of this region. Also, a high percentage of the mines in the region are on reduced dust standards because of the high silica content of the airborne dust resulting in miners possibly being exposed to excessive amounts of respirable silica dust. Exposure to excessive amounts of respirable silica dust can lead to silicosis, a disabling and potentially fatal lung disease. NIOSH&apos;s Respiratory Hazards Control Branch has been investigating the possible causes that would account for the observed higher trends in disease progression through literature review, data analysis, and in-mine surveying. The investigation to date has revealed that underground mines are faced with cutting large amounts of rock in order to maintain haulage clearances. Cutting rock not only increases the potential for silica exposure, it increases the requirement for machine maintenance which was a concern observed during dust surveys conducted by NIOSH. Over half of the mines operating in the SAR are on reduced standards due to high silica content. Adequate face ventilation of the continuous miner and roof bolter and limited down-wind operations from the miner are also issues of concern and items which require the constant attention of miners operating in these conditions. Disclaimer: Mention of any company or product does not constitute endorsement by the National Institute for Occupational Safety and Health.

Jan 1, 2009