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By Jesus Gonzalez

Peirce-Smith converters (PSC) are long cylindrical chemical reactors where copper matte reacts with air. Traditionally, air is injected laterally through submerged tuyeres at different subsonic velocities. However, the accumulated experience in steelmaking, particularly in the basic oxygen furnace (BOF) process, shows that the gas bottom injection may improve the mixing efficiency of a liquid pool. The aim of bottom injection is to maximize the copper kinetic energy meanwhile avoiding excessive reactor splashing. When gas is injected from a single orifice at the bottom of a liquid pool, two main gas flow regimes can be identified, bubbling and jetting. In this work, a PSC with bottom air injection is studied by means of multiphase 3D CFD numerical simulations considering multiple air velocities. Special attention is paid to the bubbles and jet formation mechanism. The mixing efficiency is measured by calculating the turbulent kinetic energy of the copper matte.

Jan 1, 2008

By María Eugenia Castro, Silvia Galasso, Jorge Duca, Claudia Osuna, Ernesto Esparza

"We present a procedure for treatment of non-active solutions equivalent to the solutions obtained from dissolution of ionic exchange resins used in purification of a nuclear reactor primary cooling system containing Co, Ni, Cs and its isotropic varieties as main radioactivity source. Finally it is immobilized into a ferritic matrix by calcination which avoids its future leaching into environment.In order to achieve the objective of this treatment, a bivalent and a trivalent iron salt is added to the solution. Then, either a base or an acid is added, depending on the initial pH of the treated solution, with a Cs precipitating additive in order to reduce Co and Cs by precipitation, flocculation and adsorption. Controlling the amount of precipitating reactives it is possible to modify the activity/volume rate becoming a medium into a low radioactivity waste.The leaching test result applied over the ferritic sample is lower than the minimum limit established by law. Therefore, it can be kept safely in a interim storage."

Jan 1, 2008

By Scott G. Britton

Mine exploitation is a broad subject whose focus is the technical skills or efforts needed for the extraction of mineral from a known ore body. Mine exploitation can be considered the very core of the mining engineering discipline. It begins at the conclusion of the exploration and development stages of mining and ends when the ore body is exhausted and the mine (or mines)closes and is reclaimed. Section 8 on mine exploitation is comprised of seven chapters: (1) classification of mining methods, (2) mine surveying and mapping, 3) systems engineering, (4) computer methods, (5) labor relations and training, (6) management and administration, and (7) mine closure, sealing, and abandonment. Each chapter focuses its efforts towards providing detailed and useful information for the engineer on basic mine exploitation principles. The information can be applied to a broad range of mining problems without regard to mineral type or mining method.

Jan 1, 2008

The fluorspar deposits at Okorusu, Namibia are closely related to an alkaline igneous ring complex of late Cretaceous age (125¦7 Ma). The fluorite ores consist of relatively fine-grained purple replacement fluorite and subsequent coarser-grained purple and green vug-filling fluorite crystals. Homogenisation temperature measurements for 38 primary fluid inclusions shows that main stage purple to green fluorite crystals were deposited over a temperature range from 166¦C to 144¦C, and minor late yellow fluorite was deposited at lower temperatures from 132¦C to 128¦C. Homogenisation and freezing temperatures measured for 18 primary fluid inclusions shows that the fluorite-depositing fluids were less saline than Mississippi Valley-Type (MVT) ore fluids and overlap the lower temperature range of fluids that deposited epithermal ore deposits. Mining in three open pits (A, B and C) at Okorusu has gradually provided exposures which reveal that the fluorite orebodies have been emplaced primarily by the preferential replacement of carbonatites. Evidence for the replacement of carbonatite includes: replacement remnants of carbonatite within the fluorite ores; goethite pseudomorphs after the carbonatite minerals, pyroxene, pyrrhotite and magnetite, which are disseminated in the fluorite ores; andpartial replacement by fluorite of a large sill-like carbonatite body in the A pit. Electron microprobe analyses of minerals in unreplaced portions of the carbonatites show that their mineralogy consists of titaniferous magnetite, diopside pyroxene, apatite, biotite and calcite. Magnetite contains 6.97 per cent to 10.46 per cent TiO2, averages 8.44 per cent TiO2, and has an average V2O3 content of 0.35 per cent. At high magnifications under the scanning electron microscope (SEM), the magnetite shows abundant fine ulv÷spinel exsolution lamellae arranged in a cloth texture. Apatite contains moderately high fluorine contents that range from 3.21 to 5.0 per cent and average 4.2 per cent, and apatite crystals range in total rare earth oxides from 1.7 per cent to 2.61 per cent. Pyroxenes in the carbonatites are iron-rich diopside, and they contrast to pyroxenes in the fenites that are aegirine-augite. All of the microprobe analyses for mica crystals in the carbonatites give biotite compositions. Microscopic examination of fluorite concentrates from Okorusu provides mineralogical information important to the resolution of beneficiation problems. Fluorite ores that are related to carbonatites are typically accompanied by phosphorus benefication problems. The cause for the presence of phosphate in some of the Okorusu fluorite concentrates is a function of the presence of binary locked fluorite-apatite particles. The fluorite ores have also replaced marble locally in the A pit, especially along the A band in the B pit, and dominantly in the orebody proposed for the new C pit. Those ores are characterised by fine grain sizes, faint remnant bedding, lack of carbonatite mineral pseudomorphs and local presence of remnants of unreplaced marble. Concentrates derived from those fluorite ores are devoid of phosphorus, but commonly have elevated silica contents due the presence of free quartz. Carbonatite and marble were preferentially replaced by fluorite because the calcite was readily soluble in the presence of the fluorite-depositing fluids and the dissolution of calcite provided calcium for the formation of fluorite. 

Jan 1, 2008

By K Friese, H P÷llmann

Clinoptilolites, modified with sodium, produced a material which has been tested for the ability to remove Hg (II) from aqueous nitric acid. The amount of adsorption depends on contact time, acid concentration of aqueous solution and initial mercury concentration. The study of the kinetics of mercury uptake revealed that all sorbents exhibit a fast rate of sorption. The highest sorption capacities were observed for sodium forms, and were up to five times higher than for the unmodified zeolite. The maximum sorption capacity toward mercury is determined as 0.093 ¦g/g at an initial concentration of 10.0 ¦g/L for a clinoptilolite from Tsagaantsav deposit (Mongolia). The sorption of Hg (II) has an ion-exchange nature and consists of three stages, ie the adsorption on the surface of microcrystals, the inversion stage and the ion exchange in the interior of the microcrystal. Sorption capacity decreases with the increase of mercury concentration. The presence of other metal ions such as Cd (II), Cu (II), Ni (II) and Zn (II) increases Hg (II) uptake capacity. Finally, sorption for Hg (II) was investigated in batch systems to evaluate the short-term stability of the sorption properties.

Jan 1, 2008

Knowledge of the crystal chemistry of carbonate apatites is very important for the development of the concept of biomineralisation and the creation of a scientific base for new biocompatible materials for medical purposes. The present work is devoted to research results on various synthetic and biological carbonate apatites obtained at Saint Petersburg University over many years. All-important problems will be considered such as the location of CO32- ions in the apatite structure, the ionic substitutions in various biological apatites and the development of synthesis methods for their analogues. Syntheses of apatites were realised by precipitation methods and under hydrothermal conditions (from solid compounds and by calcite treatment). Biological samples used in this study were physiogenic and pathogenic apatites formed in the human organism, eg in teeth and in renal and salivary stones and dental calculi as well as apatites from fossils of different taxonomic families (brachiopods, conodonts, fishes, reptiles, mammal) with different geological ages and burial conditions. The study of the crystal chemistry of carbonate apatites has been carried out by powder (including high-temperature measurements) and single-crystal X-ray diffraction methods, IR-spectroscopy, thermal analysis and various chemical analytical techniques.

Jan 1, 2008

By Taegong Ryu

The thermal plasma process has been applied to the preparation of nanosized tungsten carbide (WC1-x). The reduction and carburization of the vaporized chloride by methane-hydrogen mixtures produced nanosized WC1-x powder, with a small amount of WC or W2C phase. The products were characterized using XRD, carbon analyzer, and TEM. The effects of plasma torch power, the flow rate of primary plasma gas (Ar) to generate plasma flame, and the addition of secondary plasma gas (H2) on the product composition were investigated. The tungsten carbide (WC1-x) powder had a particle size less than 30 nm. The powder was treated under hydrogen atmosphere to fully carburize the WC1-x, and W2C phases to WC as well as remove excess carbon in the product. Finally, WC powder with a grain size less than 40 nm was obtained.

Jan 1, 2008

By Wenbin Liu

A novel route for rapid synthesis of ultrafine WC-Co cemented carbides with homogeneous binder phase distribution is reported. The composite powder is produced by in situ reduction-carbonization reactions by using WO2.9, Co3O4 and carbon black as raw powders. The reaction equilibrium and phase stability are studied by thermodynamic calculations. The WC-Co composite powder is condensed by spark plasma sintering (SPS) to obtain the cemented carbides bulk. The sintering temperature is lower than that in the conventional sintering methods by 1500C, while the sintering time is remarkably reduced by 3-5 times. The high performances of the hardness and the fracture toughness are obtained. The experimental results confirm that the present processing scheme of in situ reduction-carbonization reactions and subsequent SPS sintering is an efficient way to prepare WC-Co cemented carbides, and is apparently superior to the conventional long-period techniques of preparing composite powder and cemented carbides bulk.

Jan 1, 2008

By H. Palkowski

Recent trends in the automotive industry lead to increasing interest in advanced high strength steels (AHSS). Those steels often have a high bake hardening potential (BH), giving additional contribution to the strength of structural parts, subjected to the paint baking process. For hot rolled AHSS, namely dual phase and martensitic steels, the effect of process conditions on mechanical properties had been investigated. However, the influence of chemical composition within the range in industrial production has not been investigated sufficiently yet. In the current research, samples with different chemical compositions within the characteristic interval for industrial production are under investigation under different preload conditions and simulating the thermo-mechanical production process. The samples were then subjected to BH process. Tensile tests were performed to study the influence of varying chemical composition on the BH effect. The results of investigations on dual phase steels will be presented in this paper.

Jan 1, 2008

By Filiz Sahin

This paper presents a synthesis of TiB2 via carbothermal reduction method using a mixture of TiO2, B4C and C prepared in molar ratio of 2:1:3. Reduction experiments were carried out in a high temperature graphite furnace in a graphite crucible under argon atmosphere at different time (0, 15, 30 and 60 min.) and temperatures (1400, 1500 and 1600 °C). The products obtained were investigated using XRD technique.

Jan 1, 2008

By P Joyce, A S. Ray, P S. Thomas, J Haggman

Climate change and global warming present a significant challenge as unsustainable levels of greenhouse gas emissions arising from human activities continue to be emitted. The cement industry is responsible for between five and ten per cent of annual world carbon dioxide emissions; most arising from the manufacture of Portland cement (PC). An effective way of reducing emissions is by incorporating supplementary cementitious materials (SCMs) as partial PC replacements. SCMs are silicate or aluminosilicate based pozzolanic materials which, in finely divided form, combine with water and calcium hydroxide (lime), liberated by cement hydration, to form compounds exhibiting cementitious properties. Pitchstone is such an aluminosilicate and has the potential to act as an effective pozzolan for partial replacement of PC. In North Queensland, Australia, a vast deposit of pitchstone is mined and processed for expandable perlite aggregate. During the classification stage of the excavated natural material, waste pitchstone fines (PF) less than 0.5 mm in size are generated. This study evaluates the waste PF as a viable, eco-friendly pozzolan for the partial replacement of PC. The reactivity of the PF is compared to fly ash (FA), using the pozzolanic compressive strength activity index (SAI) after seven, 28, and 91 days ageing at 20 per cent and 40 per cent PC substitutions. PF was found to be comparable to FA as a pozzolan at 20 per cent PC substitution at all ages tested. However, for the 40 per cent substitution blends significant strength was only achieved at 91 days ageing for the FA blend. The pozzolanic reactivity was also investigated using thermogravimetric analysis to determine the degree of free lime present after 91 days. In all cases where an SCM was added, the free lime was observed to be consumed with increasing age.

Jan 1, 2008

By Mingming Zhang, Ramana G. Reddy

"Carbon dioxide (CO2) is one of the most common by-products produced during light metals production. It is considered to be the cause of greenhouse effects. Efficient reduction of CO2 can help minimize the rate of global warming and improving energy sufficiency. In this paper, a novel light metal production process was developed using ionic liquid electrolytes. This process has significant advantages compared to the traditional high temperature processes such as zero CO2 and CF4 emission, low energy consumption due to the low temperature operation and nonconsumable electrodes. Two types of anode materials (graphite, extruded carbon) were tested in electrolysis experiment. The results showed that both anode materials were stable (negligible weight loss). However, the extruded carbon was found to be superior to graphite in terms of current density and current efficiency. The calculated energy consumption for aluminum production was less than 10 kWh/kg at current densities up to 300 A/m2.IntroductionGlobal demand for ultra-light, ultra-strong, recyclable metals is growing as the world switches to low-emission vehicles, energy-saving devices and sustainable products. Aluminum demand is forecast to climb by 30 percent; magnesium demand by 200 percent, while for the emerging industrial light metal, titanium, the demand is expected to be at least double in the next decade. However smelting of light metals is the most energy intensive among all the steps of light metals production. For example, on an average it takes about 15.7 kWh of electricity to produce one kilogram of aluminum from alumina [1, 2, 3]. Advancements in energy efficiency have been steady, but slow, and most U.S. aluminum smelting production operates at 95% current efficiency. Besides high energy consumption, another major concern of the light metals smelting process is the emissions of greenhouse gases (GHG). Electrolysis green house gas emissions in the Hall-Héroult process can be split into three groups: 1) reduction reaction emissions, carbon dioxide (CO2) and carbon monoxide (CO); 2) process upset perfluorocarbons emissions; and 3) hydrogen fluoride (HF) formed from the moisture (H2O) present in the raw materials [2, 3]. Hydrogen fluoride gas can be captured and returned to the cells by the alumina dry scrubbing system used in modern facilities. A total of 5.31 kilograms of CO2 is generated from the reduction process for each kilogram of aluminum produced in the average U.S. primary facility. The perfluorocarbon emissions are related to the “anode effect.” If the concentration of alumina in the bath becomes too low, other reactions between the carbon anode and the bath occur and tetrafluoromethane (CF4) and hexafluoroethane (C2F6) are generated. These gases have high global warming potentials (GWP), which is a ratio developed to compare the ability of each greenhouse gas to trap heat in the atmosphere relative to carbon dioxide"

Jan 1, 2008

By M. Schafer

The 6-m- (20-ft-) diameter cast-in-place tunnel lining for Phase 3 of the Mill Creek Tunnel (MCT3) has been completed. This article summarizes aspects of liner design and ad-dresses the construction approach in placing the liner in areas of tunnel that experienced crown overbreak. Tunnel lining production rates, installation procedures and form buoyancies experienced during concrete placement will also be presented. The Mill Creek Phase 3 tunnel (MCT-3) is expected to be completed this year. It is one of the largest tunneling projects undertaken by the Northeast Ohio Regional Sewer District (NEORSD) to date. The tunnel horizon is situated within the Devonian Chagrin Shale rock formation at an average depth of 85 m (280 ft). The tunnel was excavated using a two-pass method. A full face, fully shielded, Robbins 7.2-m- (23.8-ft-) diameter tunnel boring machine (TBM) was used to excavate approximately 4,500 m (15,000 ft) of tunnel and facilitate installation of initial supports (first pass). The final lining (second pass) consists of 305-mm- (12-in.-) thick cast-in-place reinforced concrete and integral low flow channel. Seven shafts were constructed on the project. The excavation of the tunnel commenced at Shaft 14 and proceeded down grade to Shaft 9, the terminus shaft. Because of the presence of overbreak in the tunnel crown, measures were required to support the form and counteract the effects of buoyancy during concrete placement.

Jan 1, 2008

By N. Y. Ma

Solid wastes produced in ironmaking and steelmaking off-gas cleaning systems often contain zinc. The zinc level in these solid wastes is generally too high to recycle the wastes for iron through blast furnaces, but too low to economically treat the wastes for zinc through zincrecovery facilities. The behavior, status, and distribution of zinc in the ironmaking and steelmaking off-gas cleaning systems have been analyzed from three aspects: thermodynamics of zinc condensation, oxidation and deposition, correlation of zinc concentration with particle size and density, and aerodynamics of dust particles in the off-gas cleaning systems. Theory and supporting data show that spontaneous separation of zinc from iron-bearing dust occurs in the ironmaking and steelmaking off-gas cleaning systems. Dry off-gas cleaning systems provide the most favorable conditions and environments for zinc to separate from the dust. If highefficiency dry separators were applied and appropriately arranged in the off-gas cleaning systems, zinc would be concentrated, and the majority of the solid wastes could be recycled for iron recovery through blast furnaces.

Jan 1, 2008

By Frank R. Field, Randolph E. Kirchain, Elisa Alonso

"There are a number of environmental incentives for increasing recycling, including the reduction of waste, energy and resource use. Recycling can also be advantageous for manufacturing firms in both the short and long term. Secondary material can substitute for primary material, potentially dampening primary material price increases and reducing the pressure for greater primary extraction. This paper examines the potential for and dynamics of recycling for the case of platinum using a dynamic, behavioral simulation model of the primary and secondary markets. Since the secondary supply of platinum depends on a supply chain separate from primary extraction, recycling can diversify the risks of primary supply instabilities. Over time, recycling can cut primary consumption, reduce overall costs to firms, and possibly reduce the impact of price fluctuations upon firms.IntroductionThe benefits of recycling, from the perspective of the environment, are many, and the environmental benefits of increased recycling are considered a step towards increased sustainability [1, 2]. Life cycle assessments indicate that obtaining materials from secondary sources generally requires less energy and has fewer environmental impacts than extraction and refining of primary materials [3]. Analyses of materials flows show that, in addition to landfill volume reduction, recycling reduces primary material consumption, affecting long term materials scarcity [4, 5].The benefits of recycling are not limited to the environmental. Firms can benefit from the lower energy costs of recycling, especially that of metals whose primary extraction and refining are particularly energy-intensive (e.g., aluminum). The routine participation by firms in secondary materials markets (e.g., www.recycle.net) shows that this advantage has not gone unnoticed.Recycling can also benefit firms whose costs can be significantly affected by changes in material prices resulting from material shortages and material scarcity, with potentially permanent effects upon firms [6-8]. This paper focuses on the impact of recycling in the face of platinum scarcity for supply chain downstream firms."

Jan 1, 2008

By Mike Tracy

This section of the Handbook deals with general principles to be evaluated in the development of a mining operation. It addresses the major issues that must be examined to fully evaluate a mining venture. Of course, one of the main topics to be evaluated is mine planning, which is covered in more detail in other sections (13, 17) of the Handbook and should be referenced in mine development projects. The topics to be discussed in this introduction include equipment and supplies, infrastructure, utilities, and project management. In any of the aspects mentioned, the current existing conditions at or near the mine site must be evaluated. This will include assessment of current use of utilities, infrastructure, housing, equipment suppliers, etc., as well as anticipated growth, both in the supply aspect of these systems as well as projected usage on these systems. After full assessment of both these aspects, an evaluation must be made as to the requirements the project will place on these items. Assessment must be made as to any up-grades required to bring the project on line, what impact the project will have on existing or expanded systems, and anticipated future growth impacts on support systems not only of the project but of other surrounding industry and urban devel-opment

Jan 1, 2008

By Soobhankar Pati

Solid oxide membrane (SOM) technology has been successfully employed for the production of high energy metals such magnesium, titanium and tantalum by directly reducing their oxides. This paper reports on the recent investigation done for calcium production by SOM process from calcium oxide, dissolved in fluoride and chloride based fluxes. This process employs an inert oxygen-ion-conducting stabilized zirconia membrane to separate the inert cathode in the flux from the anode. When the applied electrical potential between the electrodes exceeds the dissociation potential of calcium oxide, oxygen ions are driven out of the melt and through the zirconia membrane to the anode where they are oxidized. Reduced calcium metal deposits or evolves at the cathode depending on the operating temperature. The SOM cell has been electrochemically characterized, and key concepts related to CaO dissociation, leakage current, solubility of Ca in the flux, and hygroscopic nature of the flux relevant to the SOM process are explained.

Jan 1, 2008

Copper-Cobalt hydrometallurgy has seen a resurgence in recent years with the development of projects in Zambia and the DRC. Many of the flow sheets are unique in their use of hydrometallurgical techniques to improve performance compared to the older types in current use. The emphasis has moved from direct copper electrowinning/stripping, with multiple stages of precipitation for removal of impurities and concentration of cobalt, to innovative use of solvent extraction and ion exchange with higher cobalt recoveries to final product. The poor quality direct electro-won copper has been supplanted with solvent extraction-electrowinning; with consequent production of LME 'A' quality metal. Many of the precipitation steps in cobalt recovery and concentration, have been replaced with solvent extraction; while the remaining precipitation stages have been enhanced with use of oxidants to improve impurity removal. Operating experience from two of these circuits has shown the benefits of the new technologies and the improved overall recovery of both copper and cobalt into higher quality products.

Jan 1, 2008

By Adolfo Pillihuaman Zambrano

Fe-Cr-C production is a very high electrical energy consuming process. Decrease up to 10% of this electrical energy is expected when self-reducing agglomerates are used. This research aims to understand how the synergetic effects are when stronger reductant, like Fe-Si, is substituted for coke in self reducing pellets. Brazilian chromites containing 41.2%Cr2O3 were mixed with petroleum coke and agglomerated with cement as the binder. Small amounts of 1%, 2% and 4% of Fe-75%Si were substituted for the equivalent petroleum coke, and pure silica plus hydrated lime were added for adjusting the slag composition. The mixture was pelletized, dried and submitted at 1773K up to complete the reactions. The results showed that the reduction reactions were 1.4 and 2 times faster with 1% and 2%Fe-Si addition, respectively, than with no addition. The microscopic analysis showed that it was formed a liquid phase, but the pellet did not collapse what indicates that the coalescence of the metallic phase depends on the dissolution of the pre-reduced particles of the chromites into slag.

Jan 1, 2008

By K. Morsi

Titanium-titanium boride whisker (TiBw) composites are emerging as strong candidate materials for advanced applications within the automotive, aerospace and defense industries. Although increasing TiBw volume fraction improves the specific stiffness and wear resistance of titanium, it is usually on the expense of fracture toughness and ductility especially at increased volume fractions of reinforcements where whiskers interlock. This research addresses strategies for microstructural design that may overcome these shortcomings, by generating titanium composites that are locally reinforced with TiBw through in-situ reaction in segregated regions of the microstructure and separated by ductile Ti matrix. The effect of varying composite reinforcement particle sizes (i.e. size of the reinforced regions) on the pressure-less sintering of these dual matrix composites is discussed. Electric current activation was also used to generate high density dual matrix composites and a new simultaneous imaging and modulus mapping technique was used to characterize these unique microstructures.

Jan 1, 2008