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By Zhibao Li, Lanmu Zeng

The behavior of dicalcium silicate in NaOH-NaAl(OH)4-Na2CO3 solution is of significance for controlling the silica level in the production of alumina via the sintering process. Dicalcium silicate samples were obtained through a twostep approach: coprecipitation of calcium and silicate from CaCl2-Na2SiO3-NaOH solutions; and calcination of the hydrated precursor at 1200°C for 4 hours. The optimization of the synthesis parameters including temperature, solution concentrations and aging time was also investigated. Xray diffraction (XRD) and chemical analysis show that the calcined solids include dicalcium silicate with trace amounts of wollastonite. The solubility of the synthesized dicalcium silicate in HCl, NaOH, mixed NaOH-NaAl(OH)4 and NaOH-NaAl(OH)4-Na2CO3 solutions was determined. It was found that the solubility increases with increasing HCl and NaOH concentration. The effect of temperature on the solubility in HCl solutions is limited, but the solubility decreases with increasing temperature in NaOH solutions. The solubility of dicalcium silicate in NaOH-NaAl(OH)4 and NaOH-NaAl(OH)4-Na2CO3 solutions was shown to increase with increased temperature, Al(OH)3 and Na2CO3 concentration. The BromleyZemaitis model for the aqueous electrolyte system was selected to predict the solubility of dicalcium silicate. The model’s predictions yielded certain success compared with experimental solubility data.

Jan 1, 2014

By Noko S. Phala

The energetics of CO and CO2 hydrogenation to methanol were studied on a gold surface via periodic and cluster DFT calculations. CO hydrogenation appears to be much easier than CO2 hydrogenation on an Au(111) surface. The use of a cluster model does not seem to improve the energetics of CO2 hydrogenation. It is concluded that an active support (e.g. ZnO) will be required to increase the productivity of a gold surface towards synthesis gas conversion. The energetics of CO and H2 adsorption are improved on the cluster model compared to a slab model of an Au(111) surface, suggesting that nanosized gold particles may be beneficial in CO hydrogenation.

Oct 1, 2003

By N. Maleki

In recent years, research and development of magnesium alloys have been greatly promoted by the lightweight requirements in critical industries. The use of these alloys, however, has been restricted by their limited mechanical properties especially at high temperatures. The disadvantages can be overcome by producing Mg matrix composites. The Mg?Si alloys containing in situ Mg2Si particles have found a great potential as structural materials. Unfortunately, Mg2Si compounds are prone to form undesirable coarse Chinese script morphologies, which would deteriorate the properties of the materials. Refinement of microstructure is performed for improvement of wear and corrosion resistance. This paper investigates the microstructure and corrosion behavior of pure magnesium, unmodified and modified magnesium matrix composites reinforced with Mg2Si particles. The Mg2Si/Mg composite was prepared via a normal cast route, and then various amount of zinc was added to melt in order to modify the Mg2Si reinforcement particle morphologies. The microstrucrures were characterized by optical and scanning electron microscopy followed by EDX analysis. The corrosion behavior of Mg/Mg2Si composite was investigated by using potentiodynamic polarization measurements. The results showed that by addition of zinc, the average size of the primary Mg2Si became significantly decreased from about 100µm to about 20µm, as well as its morphology changed from dendritic to a polyhedral shape. However, by adding extra amount of zinc many primary Mg2Si particles become coarse again. It was also found proper amount Zn addition increased the corrosion resistance of Mg/Mg2Si composite.

Oct 1, 2011

By J. W. Matousek

"Computer modeling of smelting processes requires internally consistent equations for calculating the compositions of mattes and slags. That is, the sum of the calculated assays must total 100%. One set of equations that satisfies this requirement for copper produced under oxidizing conditions (pSO2>one atmosphere pressure) is given by the following:%[Fe] = 62.0 – 0.775%[Cu]%[S] = 28.0 – 0.00125%[Cu]2%[O] = 10.0 – 0.225%[Cu] + 0.00125 %[Cu]2Mattes containing nickel in appreciable quantities do not have the defined “white metal” end point of approximately 80 percent copper and 20 percent sulphur that is found in the copper system during the converting process. The above equations, however, are readily extended to nickel and nickel/copper mattes for any desired end product composition."

Jan 1, 1996

By Muhammad Tawalbeh

The calculated temperature history of a single particle of MgCl2 hydrates when it came in contact with fused salt electrolyte at 650 °C was determined using the measured heat transfer coefficient for the molten salt bath at 650 °C. The calculations revealed that the entire interior of the particle reached the temperature required for the formation of MgOHCI from hydrated MgCl2 in less than 2 seconds. This was much less than the time required for dissolution of the prills as observed in experiments. It is very likely that the formation of MgOHCI during prill dehydration and dissolution is a result of hydrolysis in the interior of the prills.

Jan 1, 2004

By Serena Biella

Gold has received a growing interest as a catalyst for the selective oxidation of organic molecules using oxygen under mild conditions1. In the liquid phase application small gold particles (2.5-7 nm) deposited over different solid supports can be used but, like many other noble metals, their catalytic activity depends upon the nature of the support and the preparation metod2-5. In particular, gold on carbon is the preferred catalyst for the oxidation of the alcoholic 2-7 and the aldehydic7-9 groups and one of the best preparation method is the immobilisation of colloidal particles2-5,8,9. Suggested application of gold catalysis in fine chemicals production, tested on laboratory scale preparations, is reported in table 110. In order to produce more efficient catalysts for the liquid phase oxidation and to derive new insights into the reaction mechanism, we have made a comparison among catalytic systems based on different metals. The first effort was to test the activity, if present, of naked metal particles and then to study the influence of various materials commonly used as a support.

Oct 1, 2003

By Kathy Pomeroy

Sharing?? l Maybe not the first image that comes to mind when we think about the historical corporate mind set and track record of many corporations ? ! A Fundamental Change in Relationships l From a worldview of independence to one of recognized interdependence l Collaborative action with communities for long range mutual goals l Acceptance of greater accountability for the whole l Community and government relationships based on trust, mutuality, respect for human rights, equity, sustainable agreements

May 1, 2002

By Nathalie Gauthier

Bien que le système de ventilation du Puits Penna soit de taille imposante et que plus de $30M y seront engloutis pour son développement, aucun budget spécifique n?avait été préalablement consenti pour refroidir l?air acheminé aux places de travail dans la partie profonde de la mine. Le système de ventilation a été conçu en deux étapes distinctes : le réseau du haut de la mine lequel dessert jusqu?à 1550 m de profondeur et le réseau du bas de la mine (de 1550 m à 2200m) qui a été créé ultérieurement. Le réseau inférieur a été imaginé de façon à acheminer l?air frais directement au gisement et de permettre l?évacuation aux extrémités afin de rejeter l?air chaud immédiatement après l?avoir utilisé. Au total, lorsque le réseau de ventilation sera complété, plus de 670 m3/s d?air sera véhiculé dont jusqu?à 495 m3/s pour la partie inférieure de la mine considérant une capacité totale maximum de 710 m3/s en utilisant la mine adjacente.

May 1, 2003

By Marek Mika

This Paper has been prepared to be presented at the 23rd World Mining Congress & Expo ? Montreal 2013. It presents the idea how to carry out the shaft sinking operation, going through highly water-bearing and very weak rock strata, giving as an example one specific shaft sinking project which is being executed for one of the Polish collieries by our Shaft Sinking Company Content 1. Introduction. 2. Hydrogeological conditions within the area of the shaft. 2.1. Hydrogeological conditions assumed at the stage of designing. 2.2. Hydrogeological conditions encountered in the course of sinking. 3. Designed shaft lining. 4. Procedures for the shaft sinking. 4.1. Designed procedures of the shaft sinking. 4.2. Procedures for preservation and strengthening of the shaft lining and the surrounding rock strata. 5. Technological guidelines for proceeding with the shaft sinking ? selection of special methods. 6. Options for mechanization of work for the selected method. 7. Conclusions.

Aug 1, 2013

By C. Allen, M. Gangal, J. Stachulak

"Most underground diesel equipment is equipped with diesel oxidization catalysts (DOCs) to reduce carbon monoxide and hydrocarbon emissions. DOCs do not alter nitrogen oxides concentrations but can promote the oxidization of nitric oxide (NO) to the more toxic nitrogen dioxide (NO2). Vale and CanmetMINING have been researching how to reduce worker exposure to diesel emissions by testing mining equipment DOCs. Results indicate a > 77% decrease in carbon monoxide concentration but a 46–315% increase in NO2 concentration for 8-mode test cycles. It is recommended that DOCs that increase NO2 emissions be evaluated regarding their continued use in underground operations.RÉSUMÉ La plupart des équipements miniers souterrains sont équipés de catalyseurs d’oxydation diesel (DOC) afin de réduire les émissions de monoxyde de carbone et d’hydrocarbures. Les DOC ne modifient pas les concentrations des oxydes d’azote mais ils peuvent faciliter l’oxydation du monoxide d’azote (NO) en dioxyde d’azote (NO2), plus toxique. Vale et CanmetMINING effectuent des recherches pour réduire l’exposition des travailleurs aux émissions de diesel en analysant les DOC des équipements miniers. Selon les résultats, une diminution > 77 % dans la concentration de monoxyde de carbone est atteinte mais elle est accompagnée d’une augmentation de 46 à 315 % de la concentration en NO2 pour des cycles d’essais à 8 modes. Il est recommandé d’évaluer les DOC qui augmentent les émissions de NO2 pour décider de la poursuite de leur utilisation dans les opérations souterraines."

Jan 1, 2016

By Frands Jensen, Erik Eriksson

"Haldor Topsoe’s Wet gas Sulfuric Acid (WSA) technology has been proven in a number of industries converting sulfurous gasses to concentrated sulfuric acid. In the metallurgical sector plants have been delivered handling SO2 gasses from copper, zinc, molybdenum, and lead ore. WSA has high energy efficiency and allows autothermal operation from feed gas strengths as low as 3.0% (volume). Recent variants of the WSA process have been developed that allow very high SO2 conversion efficiencies of over 99.9%. This paper describes the technology, its advantages and industrial achievements.The WSA technology is well suited for production of concentrated sulfuric acid of commercial quality from the sulfur dioxide (SO2) gas that inevitably emerges from the metallurgical processes. Some of the features that make the WSA technology attractive for this application are:- High SO2 conversion rates (up to 99.99%)- High energy efficiency leading to a low autothermal point (~ 3% SO2)- No need for gas cooling and drying to produce concentrated sulfuric acid- No production of waste- Very low cooling water consumptionThis paper describes the WSA process principles and highlights features that make this process attractive for handling SO2 gases."

Jan 1, 2014

By S. Kamado

Development of new SF6 alternative cover gas with low global warming potential is strongly desired for melting and casting of magnesium alloys. We have tried to apply several kinds of HFC and HFE gases with low potential from 30 to 950 as protection gases to AZ91D alloy melt in the temperature range of 650 to 800°C. As a result, protective film consisted of MgF2 and MgO is formed on the melt surface and ignition-proof effect is sufficiently obtained at all the temperature ranges even when flow rates of mixed gases containing CO2 as a carrier gas are almost the same as those using SF6 gas. Reduction of global warming potential exceeds 98% at 650°C and 89% at 800°C in comparison with a mixed gas of CO2 and SF6.

Jan 1, 2006

By Lauri Gregg

How Can Man Meet the Carbon-Free Energy Challenge ? ? Increases in Energy Efficiency can displace 1/2 to 2/3 of the Carbon-Free Energy required to stabilize at 550 ppmv ? Renewable Energies require too much land and thus can displace 5 to 10 % of the energy requirement ? Large new sources of carbon free energy are needed ? Conservation is desirable but provides only a small and variable contribution ? People will have to adjust to higher levels of CO2 in the atmosphere as energy demand continues to grow

Nov 1, 2002

By A. Yousefpour, M. Hojjati, M. Simard, M. Laramée, M-A. Octeau

The need for effective and reliable joining methods grows as the use of advanced thermoplastic composites becomes widespread in aerospace industry. An experimental investigation of resistance welding of APC-2/AS4 thermoplastic composite laminates is presented. In this method, a heating element is placed between the bond-surfaces then the interface is heated by passing electrical current through the heating element. The polymer at the weld interface is melted due to resistance heating, then diffuses and consolidates under applied pressure, resulting in a weld. APC-2/AS4 prepreg, APC-2/AS4 commingled, and different grades of metal mesh heating elements were considered. A custom made resistance welding rig was designed and developed to perform lap-shear welds. The mechanical performance of the welds was quantified using single lap shear tests. The effects of different heating elements on the mechanical performance of the resistance-welded parts were investigated. Also, quality of the welds was examined under optical microscopy.

Jan 1, 2004

By Y. Mudryk, D. Paudyal, K. A. Gschneidner, V. K. Pecharsky, M. Khan

"Rare earth intermetallic compounds are utilized commercially as magnetic and battery materials, electron gun electrodes, etc. Several of these intermetallics will be briefly discussed. There are many other rare earth intermetallic compounds which are not utilized industrially but have unusual properties which are of fundamental interest and may have future technological applications. Several of these materials are discussed as well.INTRODUCTIONTens of thousands of rare earth intermetallic compounds exist, but physical properties (primarily their magnetic behaviors), other than their crystal structures have been measured for only a small percentage of these materials. Among these are the commercially important compounds: Nd2Fe14B, and the SmCo5 – Sm2Co17 family – well known high strength permanent magnets; (Tb0.3Dy0.7)Fe2, Terfenol-D, a giant magnetostrictive material; LaNi5Hx a critical component of the rechargeable Ni metal hydride batteries; and LaB6 an electron emitter. There are, however, many other intermetallic compounds which are not utilized industrially, but none-the-less, exhibit interesting, and sometimes, exotic physical properties which are of fundamental interest and may have some future technological significance. These include: the giant magnetocaloric effect compounds Gd5Si2Ge2 and La(Fe13-xSix)Hy; the RCu and RAg families of ductile intermetallics; the mixed intra-lanthanide (R,R')Al2 compounds in which magnetic transitions disappear and reappear as one R is substituted for by R'; and GdNi which exhibits large dilations along two crystallographic directions and a larger contraction in the third direction at the Curie temperature resulting in zero volume change as GdNi orders magnetically via a second order phase transition.COMMERCIALLY IMPORTANT INTERMETALLICSNdFeB Permanent MagnetsThe Nd2Fe14B permanent magnets were discovered in 1984 independently in the USA and Japan. It is a ferromagnet and with proper heat treatment and processing Nd2Fe14B is the strongest near room temperature permanent magnetic material known today. This intermetallic compound is utilized as a permanent magnet in many applications, such as electric motors (e.g. the modern automobile contains up to 35 electric motors), spindles for computer hard disc drives, microphones and speaker magnets for cell phones and other audio equipment, direct drive wind turbines, actuators, and Magnetic Resonance Imaging (MRI) units. There are two kinds of NdFeB permanent magnets – bonded and sintered. The bonded magnets have a lower magnetic strength than the sintered magnet. The highest strength magnets are obtained by small substitutions of Dy (up to a maximum of 10%) for Nd, because Dy can significantly increase the coercivity and thus the energy product (a measure of the magnetic strength or hardness). The bonded magnets account for about 12% of the NdFeB market (~82 metric kt per year, containing ~20 kt/a of Nd). The NdFeB permanent magnet market is growing at a rate of about 15% per year. (Burzo & Kirchmayr, 1989; Kobayashi & Hirosawa, 2001; Coey, 2011)."

Jan 1, 2012

By Avi Nanda, Robert Brandt, Alex Piatkiewicz, David M. Jones

In 2010 the United States Environmental Protection Agency (UESPA) revised the National Ambient Air Quality Standards (NAAQS) by lowering the permissible value to a 1-hour average SO2 concentration of 75 ppb. In 2012, the USEPA designated the Miami area as non-attaining for the new SO2 NAAQS. A number of options were studied to assist in bringing the Miami smelter into attainment with the new standard. The chosen solution included: Installation of a large tertiary hooding system over the converter aisle; Hooding of the anode vessels and treatment of the anode gas in a baghouse; Installation of a large 2,325,212 Nm3/hr caustic scrubber to treat the captured converter fugitives and anode off-gases; Installation of a secondary ESP for the tapping fugitive off-gas treatment system; and the continuous scrubbing of all acid plant tail stack gases. The modifications have reduced smelter SO2 emissions by 85%, achieving a world class SO2 stack emissions rate of 0.45 kg of SO2/tonne Cu. INTRODUCTION The Freeport McMoRan Miami smelter has been previously described in literature (Steinborn, Pasca, Sallee, Binegar, Bhappu). For the sake of brevity a brief description is given here. The Miami smelter is located 129 km east of Phoenix, Arizona near the town of Miami, Arizona. The smelter was established in 1915 and has undergone a number of process upgrades and modernizations over the years. The present smelter consists of an Isasmelt furnace, an electric settling furnace, four Hoboken converters, two anode refining vessels & one casting wheel; and one double contact sulfuric acid plant. Concentrates are railed & trucked to Miami from four Freeport McMoRan mines located in Arizona & New Mexico. The wet concentrates, typically containing 10% H2O with a Cu/S ratio of 0.85, are smelted in an Isasmelt furnace to a matte grade of 58%. The entire output from the Isasmelt is laundered into an Elkem electric furnace (originally installed in 1972 as the primary smelting furnace) for separation into matte and slag. Slag containing 0.85% Cu is skimmed from the electric furnace and discarded. Molten matte, containing 60% Cu, is tapped from the electric furnace and processed in one of four Hoboken converters to produce blister copper. Two anode refining vessels further refine the blister copper before the final product is cast on a single, 30 mold, casting wheel. All of the anodes produced at Miami are shipped to the Freeport McMoRan electrolytic refinery in El Paso Texas for refining into cathode copper. Smelter off-gases from the Isasmelt, electric furnace and Hoboken converters are combined and treated in a double contact acid plant to produce sulfuric acid. Acid produced at Miami is internally consumed at Freeport McMoRan mines in the region.

Jan 1, 2019

By Wencheng Gao

An attractive way to beneficiate magnesium chloride and aluminum chloride is to prepare Mg-Al spinel, an excellent refractory material. Mg4Al2(OH)14?3H2O, the precursor of spinel, can be prepared using a co-precipitate method from aqueous MgCl2-AlCl3 solutions. The co-precipitation process of magnesium-aluminum from acidified chloride solutions by using NaOH or NH4OH as base neutralization agent was studied. Co-precipitation was conducted from different mixed solutions ? at initial CAl=0.0625M and Mg/Al molar ratio from 0.5 to 10, the temperature range from 30 to 90 °C. The effect of other parameters, including base type, method of base addition, base addition rate, aging time, background electrolyte and concentration were also investigated. The co-precipitation process was monitored by potentionmetric(pH) measurements. The experimental pH curves were characterized by two platforms separated by a steep jump in pH at Mg/Al molar ratio 0.5~6. The first platform was centered at about a pH of 3.8 and the pH of second platform was varied with different conditions. When the Mg/Al molar ratio was up to 6~10, the first platform in pH was almost disappeared. Furthermore, the shapes of pH curves were also affected by base type, base addition rate and method of base addition. Experimental results showed that the first platform in pH was connected with Al precipitation, and the second platform was involved with Mg. The final co-precipitates were characterized by XRD, TGA-DTA, particle size analysis, SEM and TEM. We found both Mg/Al molar ratio and temperature proved to be the key parameters controlling the formation of Mg4Al2(OH)14?3H2O phase. At solution Mg/Al ratio=0.5~4, the main precipitate phase was Bayerite (Al(OH)3) admixed with Mg4Al2(OH)14?3H2O; at Mg/Al ratio=4~6, the main phase was Mg4Al2(OH)14?3H2O admixed with some Mg(OH)2; while from Mg/Al ratio=6~10, the systems were mixtures of Mg(OH)2 and Mg4Al2(OH)14?3H2O.

Oct 1, 2011

By Robin Belley

Outline Introduction Wabush Mines HistoricalBackground Mine and Concentrator at WabushMines High Intensity Magnetic Separators (HIMS) Development of the Manganese Removal Process Pilot Plant Testing Phase Manganese Removal Line 1 Coming Phase: Manganese Removal Line 2 Manganese Concentration Process Development Historical Background 1847: Creation of the Cleveland Iron Company1850: Opening of its first iron ore mine in the Upper Peninsula of Michigan 1965: Beginning of Wabush Mines at Scully Mines, Wabush, Labrador. 1980-1990: Questions raised about how to exploit Scully high Mn Ore (> 2%)Part of the available ore is not saleable due to too high a level of pyrolusite (MnO2) Adding this ore to the resources would be valuable (longer mine life and lower stripping ratio) 1990s: Testwork for Manganese removal Many different processes are studied over more than a decade High Intensity Magnetic Separators (HIMS) are identified as the best technology for Mn removal 2007: Pilot Mn removal line installed Testing carried out through 2007-2008 First Production Line is ordered (2008) 2009: Cleveland Cliffs (now Cliffs Natural Resources)acquire the remaining part of Wabush Mines 2010: Mn Removal Line 1 construction & commissioning Summer 2011: Mn Line 2 Construction

May 1, 2011

By Jean-Francois Magnan

"The old conventional process to produce lithium raw material dates from 1954 (CA patent #504477A). This process produces low purity lithium carbonate (Li2CO3) only. To obtain battery-grade carbonate, another polishing process is needed. To further obtain lithium hydroxide, another chemical conversion process is needed. That is why historically, the value of lithium hydroxide has always been higher than that of the lithium carbonate precursor. With the old conventional process, the low quality lithium carbonate is precipitated from a lithium sulfate solution (Li2SO4) by adding soda ash (sodium carbonate and its impurities). The resulting reaction produces significant quantities of sodium sulfate (salt cake) as a by-product with amounts larger than the impure Li2CO3 recovered with part of the soda impurities. When this conventional process was invented, the salt cake by-product was not an issue: it was discarded in a river near the plant. This practice cannot be done today in North America. While looking to find a solution for salt cake, electrolytic salt splitting of Na2SO4 into NaOH and dilute sulfuric acid appears as a technically feasible solution to get a rid of the salt cake. However, the sodium sulfate salt splitting process has difficulties to economically compete with the chlor-alkali process, which produces millions of tons of NaOH from sodium chloride (NaCl) every year.In contrast, the process developed by Nemaska to directly produce LiOH by Li2SO4 salt splitting not only solves the environmental problems related to the conventional process to produce lithium carbonate raw material, it also produces very high purity lithium hydroxide monohydrate directly at very competitive OPEX cost in comparison with industry peers (Figure 1). It also drastically reduces the amount of reagent and the direct greenhouse gas emissions."

Jan 1, 2016

By R. A. L. Drew, C. A. Rodríguez González, Caleym W. F.

This work addresses the need of new refractories for copper converters. Technological improvements and environmental regulations for chromium containing refractories have generated this need. Chemical interactions, mechanism of penetration and the effect of oxygen potential and temperature in the system Cu2S-FeS-SiO2-O2 are presented for two refractories: a burned magnesite chrome brick (typically used by the copper industry) and a chrome-free spinel direct bonded brick. The main difference determined in the refractory performance was the blister copper penetration resistance; burned magnesite chrome brick is penetrated while direct bonded brick is not. These results are very promising since blister copper penetration has been reported as the major cause of refractory wear. The results are explained in terms of refractory porosity and wetting characteristics.

Jan 1, 2004