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By Diego Pacheco Wermuth

Micrometric surgical components typically have high geometric complexity and stringent regulatory specifications. These components need to have excellent mechanical properties and a high demand of products. Besides these factors, it is necessary to maintain a low manufacturing cost, performing essential research on new manufacturing technologies. Metal Injection Molding (MIM) is a process that has been explored , providing an interesting alternative for making medical devices. The research in the production of microcomponents obtained for MIM is gaining momentum and prominence, due to low cost and high productivity of this process. This paper is a study and development of feedstocks with AISI 316L alloy , which is known for its biocompatibility. Four feedstocks with 61%vol. of metal powder were analyzed by capillary rheometry and DSC/TGA.

Aug 16, 2017

By G. R. C. Pacheco, D. M. Fonseca, R. Neuböck, G. E. Gonçalves, W. Moulin-Silva

Degradation by sulfur gases is an important lining wear mechanism in the copper industry. SO2/SO3 gases infiltrate into the pores of the basic refractory bricks, combine with their raw materials through expansive reactions and significantly modify the bricks’ structure. This study presents a comparison of the corrosion resistance against sulfur attack of different magnesia-based refractories using a simple, low-cost and quantitative method. Recipes containing sintered MgO grains showed lower resistance to corrosion by sulfur oxides compared to basic grades containing fused grains. Chromium corundum grades were used as a reference and showed very good resistance to this corrosion mechanism under the test conditions. The novel test provided relevant results that agree with what is commonly observed during operation and in previous post-mortem studies. This tool could be very useful in selecting refractory grades for the copper industry and predicting their performance. INTRODUCTION Oxidation of matte sulfides during copper production leads to the formation of sulfur oxides, which infiltrate into the pores of the refractory lining and react with the basic oxides below 1000°C to form magnesium and calcium sulfates. This reaction is accompanied by an expressive volume increase, consequent densification of the refractory microstructure and weakening of the brick bond (Malfliet et al., 2013). Thus, corrosion by SO2/SO3 is an important wear mechanism in the non-ferrous industry and the resistance to this compound should be considered when defining refractories for this application. Previous studies on this matter include expensive and complex testing methods involving pressurized SO2 gas cylinders in order to investigate the corrosion resistance of MgO-containing materials by sulfur oxides (Gerle & Podwórny et al., 2016; Fotoyi & Eric, 2011; Fotoyi, 2009; Podwórny & Piotrowski et al., 2008). The current study was based on a test developed by Pacheco & Fonseca (2018) to assess alkali infiltration and aims to provide an evaluation method of the corrosion resistance of refractories by SO2/SO3 in a simple and quantitative manner. This novel test is useful to compare the corrosion resistance of different refractory recipes and properly select the grades that should be employed in the non-ferrous industry. A case study is provided to illustrate the damage caused by sulfur oxides in refractory linings.

Jan 1, 2019

By Dale Preece, Stephen Chung, Richard Jensen

DMCBLAST_3D is a three-dimensional extension of the proven two-dimensional rock blast modeling code, DMCBLAST. DMCBLAST has been under development since 1987 and has successfully predicted the physics, mechanisms and results of a number of different types of rock blasting including, coal mine bench blasting, mineral mine choke blasting and underground stope blasting. Substantial effort has gone into the qualification and verification of DMCBLAST by comparing computer code predictions with real blasts in the field. Comparison with field data has also provided significant guidance to the development of the code.

Jan 1, 2001

In this paper a quantitative deterministic risk modelling approach (Quadrim) is introduced. The mathematical framework and equations for quantifying uncertainty within and aggregating across value chain nodes from error propagation techniques is proposed and discussed. A case study and worked examples, based on a hypothetical mine are then presented. This illustrates how uncertainty from the mining and economic value chains can be handled in a typical net cash flow calculation, and how this can be translated to a risk model. It is then illustrated that current valuation techniques do not just result in an information gap for decision makers. Traditional approaches such as discounted cash flow (DCF) analysis and truck and shovel productivity analysis, which do not take into account uncertainty in input values, can result in potential bias in estimates such as net present value (NPV) or equipment hours

Sep 26, 2011

By David R. Kalasky

One of the primary areas of computer application in mine ventilation has been the analysis of mine ventilation networks. A variety of network analyzers that are aimed toward the solution of flows in a given network has been developed. These programs typically use the Hardy Cross or other iterative algorithm for solution of any network, even those that are complex. The computer software has become more efficient and sophisticated over time and has thus been widely adopted for ventilation network analysis. One of the shortcomings of these programs is that they have been developed with the idea of analyzing the ventilation requirements at a single point in the lifetime of a mine. This provides the ventilation engineer with an important tool for analysis but falls somewhat short of providing a convenient means to economically com- pare alternative methods for ventilating a mine. The program described in this paper provides such a tool. The principal concepts that were necessary for the completion of a computer program that analyzes ventilation alternatives is the capability of efficiently determining the ventilation requirements at a variety of times during the lifetime of the ventilation system and some method of analyzing the costs of the alternatives on a realistic comparative basis. To accomplish this task, the authors began using Penn State's mine ventilation simulator designated as PSU/MVS, Didyk et al. (1977a, 1977b) and added the necessary additional software to accommodate the need for multi-period, time-dependent analysis of the net- work. The software was then tested on a coal mine ventilation problem with a 23-year life. The problem points out the value of such a program for ventilation analysis.

Jan 1, 1986

By P Holtham, J Meng, E Tabosa, W Xie

Turbulence and its distribution are of great importance in flotation, and have received considerable attention recently. However, there is no mature technique to measure turbulence in three-phase (liquid-solid-gas) industrial flotation cells due to the opaque, highly aggressive and abrasive nature of the slurry involved. Previous research has shown that the piezoelectric vibration sensor (PVS) is a promising tool for turbulence measurement in industrial flotation cells. The PVS is a robust device that converts mechanical vibration to electrical signal, from which turbulence information can be extracted. An improved calibration method has allowed development of a frequency model to calculate the force applied to the sensor. Experimental results and comparison with laser doppler anemometry (LDA) have shown that the PVS can measure fluid kinetic energy, which is related to turbulent kinetic energy, a parameter used in the literature to represent turbulence in flotation. Laboratory measurement in a two-phase (water and air) 60 L cell and with slurry in a 3.5 L cell gave good stable results and mostly consistent trends between the measured turbulence profile and cell operation. When applied in a 300 m3 industrial cell filled with water, the addition of air or slurry to the cell resulted in a shift in the turbulence profile. This is expected because a change in fluid density will change the force applied to the sensor. It is therefore concluded that the piezoelectric sensor is an easy-to-use and robust technique that is fully capable of measuring turbulence in industrial flotation environments.CITATION:Meng, J, Tabosa, E, Xie, W, Runge, K C and Holtham, P, 2014. Development and application of a piezoelectric sensor for turbulence measurement in industrial flotation cells, in Proceedings 12th AusIMM Mill Operators’ Conference 2014 , pp 457–470 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 1, 2014

By P. Richardson, B. Sceresini

The carbon-in-pulp and the carbon-in leach process for the recovery of gold and silver from cyanide leaching of ores is now widespread in the precious metals mining industry. However the presence of various base metals can have a detrimental effect on the efficiency and the economics of the process due to high cyani,:••? consumption and a reduction in leaching and adsorption rates resulting in poor recovery of the precious metals. Furthermore the presence of fast leaching and adsorbing metals such as copper can significantly reduce carbon loading capacity for the precious metais thereby necessitating a higher carbon inventory, more frequent stripping and poor bullion quality resulting in higher production costs. This paper describes the development and application of a process for the recovery of copper and and the recovery and re-use of the associated cyanide from the leach circuit at the Mt. Gibson Gold Project in the Murchison Goldfield in Western Australia. The process provides a means to counter-act the detrimental effects of the copper which occurs in the ore as various oxide and sulphide minerals including an extremely fine chalcopyrite powder. It has the added benefit of recovering the base metals in this instance copper, in a saleable form. The process is subject to a patent application by Reynolds Australia Metals, Forsayth N.L. and the author.

Jan 1, 1991

By Nobuyoshi Yabuki

Building Information Modeling is a prevailing methodology in the building industry and half (by length) of the world's shield tunnels are in Japan. Accordingly, for shield tunnels from 2005 to 2007, we developed a product model called IFC-ShieldTunnel, which is based on Industry Foundation Classes (IFC), in order to meet the future demand for such a product model. IFC-ShieldTunnel was developed by adding new elements that are specific to shield tunnels and that are not included in the original IFC. The added elements include shafts, segments (A, B, and K types), waterproofing elements, segment joint elements, and ring joint elements. Furthermore, soil layers and void elements were created. Recently, we updated the product model by re-organizing the entities and correcting errors. We deployed the updated IFCShieldTunnel model in the construction of an actual shield tunnel in Tokyo for about a year from August 2010 in order to check its feasibility. In the verification process, first, segments were modeled using Autodesk Revit Structure 2011 and property data were assigned to each segment element. Next, a mapping between the original attributes of the entities of IFC and properties of IFC-ShieldTunnel segments was developed. Using this mapping and IFC?s IfcBuildingElementProxy function, we were able to convert the IFC data from Revit Structure 2011 to IFC-ShieldTunnel automatically. Segment data were also converted from Revit Structure to Google SketchUp by IFC-ShieldTunnel. Furthermore, the construction scheduling and cost data were converted from Revit Structure to EXCEL for 4D and 5D analyses of construction. We interviewed engineers who used IFC-ShieldTunnel and received positive comments about the utilization of the product model. Overall, our test demonstrated the feasibility of IFC-ShieldTunnel. In future work, we plan to apply IFC-ShieldTunnel to more projects and test its practicality.

Aug 1, 2013

By Erico Tabosa

The turbulence characteristics and measurement techniques for agitated tanks are well established for liquid and liquid-gas systems. However, the literature shows that the overall energy dissipation rate (related to turbulence) is affected not only by air addition, but also by the concentration of solids. Unfortunately, there are no reliable measurement techniques for characterizing turbulence in a three phase (liquid-solids-gas) environmental system, which is the case in a flotation cell. Therefore, the effect of turbulence on flotation kinetics is very much one of conjecture. The aim of this work was to develop a sensor to characterize the degree of velocity fluctuation, which is related to turbulence, in a flotation cell operating with slurry and air. This sensor comprises a piezoelectric film transducer that converts mechanical to electrical energy. Hence, when the sensor deflects backwards and forwards an AC voltage is created. Flotation studies carried out using this sensor in a 3m3 Metso RCS cell processing a copper sulphide ore showed a highly turbulent impeller zone with transition to a significantly less turbulent zone in the upper portion of the cell. The transition region moves as the cell operating variables are changed, for instance the impeller speed, impeller size, air rate and feed solids concentration. Keywords: mechanical flotation cell hydrodynamics, turbulence characterization

Sep 1, 2012

By Xiaoming Wang

This paper presents an arcuate magnetic separator to remove the grinding ball fragment directly from the mill discharge, which will cause wear to downstream processing equipment such as pump, hydro cyclones and pebble crusher. Furth more this type separator was applied in Wushan mine under China National Group Corporation in China. After months of operation, the equipment has been a success. It removes majority of ball fragments from mill discharge. Keywords: magnetic separator, sag mill, pebble crusher, grinding ball fragments

Sep 1, 2012

By R. M. Zhao

The process conditions and mineral characters of cleaning separation stage in magnetite concentration plant are studied in the paper, and the affecting factors and the methods to increase the concentrate grade are analysed and given. The BKJ cleaning special drum magnetic separator is developed specially for the cleaning stage according to process conditions and mineral character. The separation mechanism, structure characters, separation process and excellent adaptability of BKJ special magnetic separator are described. The results in Zhangjiawa Concentration Plant show that the BKJ special drum magnetite separators play an important role in increasing the concentrate grade and improving the economic benefit.

Jan 1, 2014

By C. B. Mapes, E. C. Dowling Jr.

"To reduce concentrate dewatering and drying costs, the Concentrator Division at Phelps Dodge Morenci, Inc. investigated available filtration technologies. Numerous methods were explored, including: drum, disk, belt, pressure, hyperbaric, and ceramic media filtration. An economic evaluation of the individual filtration technologies indicated the advantages of ceramic media filtration for Morenci concentrates. This paper discusses the technological development culminating in the first full scale application of ceramic media disk filters in North America. Low moisture contents are obtained at high production rates and greatly reduced operating costs.INTRODUCTIONPhelps Dodge commissioned the Morenci Concentrator Filter Plant in 1942 with four 8'6"" Dorr-Oliver cloth disk filters. That year, the filter plant processed 265,537 tons of concentrate grading 20.5% Cu. The filter cake production averaged 9.3% moisture. In 1944, the Extension Filter Plant commenced operation with three additional 8'6"" Dorr-Oliver cloth disk filters. This coincided with the expansion of the concentrator. Production that year totaled 451,567 tons of concentrate grading 23.8% Cu. Moisture averaged 9.4%.Through the years additional filter units have been added in response to increased concentrate production. An Eimco drum filter was installed on the extension side and an additional Dorr-Oliver disk filter was installed on the original side in the 1950's. In 1961, two 8'6"" Peterson disk filters were installed, one on each side to replace two worn-out DorrOlivers. The installation of four 10xl2 foot Peterson drum filters was completed in 1974, coinciding with the Metcalf Concentrator startup. An Eimco belt filter was installed later.The greatest change to concentrate dewatering at Morenci occurred in 1963 with the addition of a 10x60 foot rotary gas fired dryer. The installation also included a number of conveyors to deliver filter cake from both plants to and from the dryers. Other ancillary systems included dust scrubbers and their slurry pumps. The commencement of drying was undertaken due to the rapid increase in cake moisture as a result of the LPF process and the recycling of acid plant scrubber dust slurry from the smelter. In 1972, a second dryer system was installed to increase capacity."

Jan 1, 1993

By Christopher B. Kapes

To reduce concentrate dewatering and drying costs, the Concentrator Division at Phelps Dodge Morenci, Inc. investigated available filtration technologies. Numerous methods were explored, including: drum, disk, belt, pressure, hyperbaric, and ceramic media filtration. An economic evaluation of the individual filtration technologies indicated the advantages of ceramic media filtration for Morenci concentrates. This paper discusses the technological development culminating in the first full scale application of ceramic media disk filters in North America. Low moisture contents are obtained at high production rates and greatly reduced operating costs.

Jan 1, 1994

By MKS Vel, S. Mukhopadhyay, R. Mishra

Off late, the criteria of selecting the refractory have acquired a trend line aiming to a cleaner environment and the utmost importance is given to the eco-friendly approach. The stainless steel making furnaces normally use mag-chrome refractories for the obvious reasons of changing slag basicity from acidic to basic. Such refractories generate toxic fumes and compounds with hexavalent chrome, which is unhygienic if inhaled. The present paper describes the development of a chrome free alumina magnesia carbon refractory, it's different test properties, simulative testing and microstructures. The optimum quantity and distribution of carbon in the brick restricts the carbon pick-up by the steel. Bricks with the same composition were manufactured in the commercial scale and used in a stainless steel making furnaces in USA. The performance of same refractory in this furnace was quite encouraging and at present the same quality brick has become a normal practice in this furnace. Since no chromite is used in making this brick, so no toxic compounds are generated environment remains pollution free.

Jan 1, 2004

By W. L. Jiang

Reverse-flotation technology is often applied in iron ore dressing plant, in order to enhance the quality of iron concentrate from magnetic separation. However, this technology has disadvantages in operating cost, energy consumption, and environmental protection. Developing innovative equipment to process magnetite ore more-effectively is a way to get rid of these disadvantages of reverse flotation and improve the quality of iron concentrate. This paper describes the development of Complex Flashing-Field Magnetic Cleaner, a new kind of equipment based on the principle of combination of separation in magnetic field and separation in gravity field. This innovative equipment possesses a tailor-made magnetic system and has the characteristics of a magnetic field, which can strengthen the formation of magnetic agglomerations and the dispersion of gangue minerals, improving the quality of separation. The automatic control system developed specifically for this equipment can further increase the accuracy of separation and stabilize the process. Test results showed that this equipment is reliable in operation, economically beneficial, and has large potential of application.

Jan 1, 2014

By Jiang Wenli, Zhang Yimin

In order to enhance the quality of iron concentrate from magnetic separation, reverse-flotation technology is often applied in an iron ore dressing plant.However, this technology has disadvantages in terms of operating cost,energy consumptionand environmental protection(Zhao, Wu& Wang,2005).Developing innovative equipment to process magnetite ore more-effectively is a way to get rid of these disadvantages of reverse flotation and improve the quality of iron concentrate.This paper describes the development of Complex Flashing-Field Magnetic Cleaner,a new kind of equipment based on the principle of combination of separation in magnetic field and separation in gravity field(Hao & Jiang, 2002).This innovative equipment possesses a tailor-made magnetic system and has the characteristics of a magneticfieldwhich can strengthen the formation of magnetic agglomerations and the dispersion of gangue mineralsto improvethe quality of separation.The automatic control system developed specifically for this equipment can further increase the accuracy of separation and stabilize the process.

Jan 1, 2014

By W. W. Wirth

RESEARCH looking toward the reduction of the cost of roof support by substitution of longer-life materials for wooden timber is fully justified by the fact that roof support is an important element of all production costs. Permanent or semipermanent roof support will reduce the expense of timber-maintenance crews during steady operations, but even more markedly during idle periods. The management, therefore, is faced with the important problem of timber renewals, which in times of regular operation are frequently obscured by more urgent problems of production. Increased use of timber in the Anthracite Region of Pennsylvania is caused mainly by increased percentage of coal obtained from robbing areas, which requires more timber for safety than develop-ment work, and maintenance of long haulageways through crushed ground despite the fact that less coal is transported over them. The timber reserve in the immediate vicinity of the mines has been depleted to such an extent that it is necessary to secure 70 per cent of the timber requirements from distant sources. Originally, mine timbering in this region was done by largely utilizing round props or legs with round collars. The whole cross section of the tree from which timber was cut was utilized by forming the joints between the legs and the collars with saw and adze, using plank or round saplings for lagging behind the legs and over the collars to prevent material falling between them. The Mine Inspectors' report of 1898 records an important digression from the use of round timber, when two tunnels at the Babylon colliery, near Pittston, Pa., were timbered with 12 by 12-in. square timber sets with mud sills, through quicksand for distances of 425 and 160 ft., respectively. The timbers were lagged with 3-in. plank to control sand.

Jan 1, 1940

By Dae S. Young

The Disjunctive Kriging (DK) procedure was developed to estimate ore recovery figures within a deposit/ domain from limited diamond drill hole (DDH) core assay data taken at the exploration stage. Local recovery figures include minable ore tonnage and ore grades within relatively small areas such as stopes or small panels on a pit bench, for a given cut-off grade. The grade and tonnage should be computed based on the true selective mining units, that is, the average grade distribution of selective mining units within a panel. Local recovery figures are critical information for economic and engineering feasibility studies before mine development, as well as for short-term mine planning for operating mines. This kind of information can be provided only by non-linear geostatistical methods including DK and the Multivariate Gaussian Approach (MG) (Journel, 2, Parker, et al, 5).

Jan 1, 1982

By S. Seetharaman

In the processing of molten metals, it is extremely important to monitor continuously the concentration levels of various minor elements, In the production of common metals like copper, iron and aluminium electrochemical sensors involving solid, as well as liquid electrolytes are being increasingly used to measure the concentrations of minor elements The present paper deals with the electrochemical principles underlying these measurements and the possible errors involved. One of the major difficulties in the case of the solid electrolytes is to correct for the consequences oldie electronic contribution to the conduction of the electrolyte. The application of the electrochemical sensors for molten metals processing involves designing of these probes to withstand the industrial operating conditions. In this respect, significant achievements have been made with respect to the design of oxygen probes for liquid metals in general and liquid copper in particular. Some of the salient design features are discussed in the paper, The application of auxiliary electrodes for impurities in molten metals like phosphorus in copper and silicon in iron are taken up. The development of oxygen sensors for slags is given special attention. Recent developments' in the field of sensor technology, as applied to metals processing are highlighted.

Jan 1, 1996

By S. Seetharaman, Du Siehen

"In the processing of molten metals, it is extremely important to monitor continuously the concentration levels of various minor elements. In the production of common metals like copper, iron and aluminium electrochemical sensors involving solid as well as liquid electrolytes are being increasingly used to measure the concentrations of minor elements. The present paper deals with the electrochemical principles underlying these measurements and the possible errors involved. One of the major difficulties in the case of the solid electrolytes is to correct for the consequences of the electronic contribution to the conduction of the electrolyte.The application of the electrochemical sensors for molten metals processing involves designing of these probes to withstand the industrial operating conditions. In this respect, significant achievements have been made with respect to the design of oxygen probes for liquid metals in general and liquid copper in particular. Some of the salient design features are discussed in the paper. The application of auxiliary electrodes for impurities in molten metals like phosphorus in copper and silicon in iron are taken up. The development of oxygen sensors for slags is given special attention. Recent developments in the field of sensor technology, as applied to metals processing are highlighted.1. IntroductionThe rapid technological advancement today require precise control of the process parameters and the impurity levels. Most of the molten metals processing in industrialized countries are often steered by suitable computer models, either phenomenological or simulations based on theoretical principles. These models often require that the process parameters are continuously monitored so that the progress is followed and modified suitably as and when required. It is common practice to measure temperatures by incorporating temperature sensors at the various strategic points of the reactor. In the case of monitoring the composition changes in the various phases, the method of sampling followed by routine chemical analysis involves a time lag as well as uncertainties in sampling and analysis. In this respect, electrochemical sensors have the advantage of generating accurate data when properly applied and increasing attention is being paid in the development of electrochemical sensors for various common species in molten metals processing. In the present paper, the developments in this area over the years are outlined and typical process applications are discussed. A greater emphasis will be laid on sensors based on oxygen conducting electrolytes and their application to the production of common metals like iron and copper."

Jan 1, 1996