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By Fu-Shen Zhang, Mengjun Chen, Jianxin Zhu

"A novel approach for foam glass preparation, namely vacuum-aided powder sintering technique, was preliminarily investigated in the present communication. The key point of which was to prepare foam glass at a negative pressure. Compared to normal powder sintering process, the new approach could benefit the foaming process by shorting the holding time, reducing the amount of foaming agent and especially decreasing relative density of the product. Optimum conditions were 750 °C, 1000 Pa, 5 min and 1 wt.% foaming agent, respectively.IntroductionFoam glass represents a highly valuable solution for thermal and acoustic insulation, since it possesses a generally higher mechanical, chemical and thermal stability than other foams'1'. The first industrial processing for foam glass production, the direct introduction of gases (""blowing"") into the special molten glass, can be dated back to the end of 1930s'2'. At present, almost all foam glasses is prepared by powder sintering technique instead of blowing,3 since it reduces the temperature by several hundred degrees. Moreover, as fine glass powders or similar powders can be used to substitute corresponding glasses by this technique, considerable attention has been focused on the production of foam glass by considering fully recycled glasses, coal fly ash, or other solid wastes as raw materials,4 especially CRT glasses'3' 5', on the point of environmental protection.In a previous report'6', when discussing the lead removal and recovery from CRT funnel glass by a pyrovacuum process, we found that foam glass could be prepared at a negative pressure. Therefore, in this communication, the similarities and differences between the powder sintering process for foam glass at normal and negative pressure was preliminarily discussed."

Jan 1, 2011

By Russell C. Frith

Risk-based roadway roof support design is now a critical part of the Australian Coal Industry. Safe and efficient mining demands that roof support be tailored to the prevailing geotechnical conditions and coal mining legislation in New South Wales, Queensland, and Tasmania is clear in requiring that formalized roof support design be undertaken. The assumption of dead-load suspension of an otherwise unstable roof has been used in roadway roof support design for many years. However longevity does not necessarily translate into either a best or even reasonable practice in the current industry, particularly when pro-active strata management systems are now routinely used and reinforcing support design methods are available. The paper discusses why the assumption of dead-load suspension is fundamentally incorrect in almost all instances when pro-active or reinforcing roof support is applied and how it can easily result in misleading and potentially under-designed roof support systems under various circumstances. The commonly used design methodology of balancing the installed axial capacity of long tendons with the assumed ?weight? of a future roof fall is summarized, and several fundamental flaws are identified. The critical area of selecting the design Factor of Safety is also discussed in detail. Accepting that under certain circumstances the roof of a roadway will require it to be ?suspended?, suggestions are given for how a robust support system can be developed, designed and applied.

Jan 1, 2011

By V. E. May

Has your organization adopted Six Sigma as part of their Performance Improvement strategy? What about Lean manufacturing or Lean Six Sigma? If you already have any of these business process improvements in place where will you go next? In this article we will focus on transforming your organization beyond Lean Six Sigma to the next level of performance. In the future companies can take another quantum step forward by combining Lean Six Sigma with advanced Root Cause Analysis (RCA). The value of taking this natural progression on the way to achieving new levels of organizational excellence is presented.

Jan 1, 2011

By James Weaver

During the past 16 years, the authors have successfully used high-capacity rock anchors installed inside open-ended pipe piles, driven to bedrock, to provide uplift and overturning resistance for various structures including piers, bridges, power plant components and commercial buildings. These systems were ultimately used on the projects due to a combination of high uplift forces or overturning moments on the structures and the relatively poor subsurface conditions present at the sites. Other, foundation systems such as rock-socketed drilled shafts and spin fin piles were considered but were found to be economically prohibitive or not technically feasible.

Jan 1, 2011

By K. T. Aye

An investigation into the leaching of chalcocite and covellite in cyanide solutions at concentrations typically encountered daring gold cyanidation has been conducted. The results indicate that, for both minerals, the extent of leaching is greater under anoxic conditions, but is still incomplete even in the presence of free cyanide ions, with undissolved copper solids remaining in equilibrium with solution species. The speciation of the sulfur and cyanide reaction products in solution are interpreted in terms of the fast formation of a copper(I)- cyanide complexes in solution and a sulfur-rich copper(I) polysulfide solid phase, which then reacts more slowly to produce thiocyanate ions.

Jan 1, 2011

By Thomas C. Mowatt

Preliminary Bureau of Mines studies of mafic igneous rocks collected from the Rabbit Creek area, northwestern Alaska, indicated concentrations of platinum (412 to 1,406 ppb) and palladium (343 to 892 ppb) in five of eight samples analyzed. The samples represent boulders and cobbles of mafic/ultramafic rocks from this locality. They are not from outcrop. Petrologically, (on the hand specimen scale) the samples are crudely to well-layered and are troctolitic ± gabbroie in character, with primary igneous mafic minerals strongly altered. Small patches of interstitial sulfide minerals, including chalcopyrite, bornite, pyrrhotite, pyrite, and covellite are associated with these altered zones and elsewhere through the specimens. Copper values ranged from 0.1 to 0.3 pct in samples analyzed semiquantitatively; nickel, cobalt, and chromium contents are low. Chemical, mine alogic, and petrographic relationships suggest that the rocks of similar character outcropping in northwestern Alaska could also be considered as prospective for- concentrations or platinum, palladium, and copper.

Jan 1, 2011

By Chao Du, Xiaohui Ning, Hongmin Zhu, Qiuyu Wang, Shuqiang Jiao

"TiCxOl-x solid solutions were synthesized by sintering a mixture of titanium carbide and titanium monoxide at 1600 °C. The corresponding structures and morphologies of the TiCxOl-x solid solutions were characterized by XRD and SEM. A series of tests has been performed on the electrochemical dissolution behavior of TiCxOl-x solid solutions in NaCl-KCl molten salt. The influences of synthesis time and electrokinetic parameters on the anodic dissolution behavior were also investigated. The results showed that TiCxOl-x solid solutions can dissolve as Tin+ into alkali chloride melt. Titanium ion species dissolved from TiCxOl-x solid solutions changes between Ti2+ and Ti3+ depending on the applied potential. The tail gas on the anode was monitored by a mass spectrometer. It was found the synthesis time significantly affects the components of the anodic gas.IntroductionTitanium and titanium alloys have been desired greatly because of their many uses. The critical factor that restricts the range of uses for Ti is its high cost of extraction. The primary titanium metal, sponge titanium, is still produced industrially worldwide by a process invented by Dr. Kroll in the 1940s[1] •Since the early 1970s, the research focus of the titanium industry has been directed towards developing a continuous process to produce high purity titanium at low cost. [2-10] Of the many alternative methods that have previously been investigated, the electrolytic process has been considered a promising method for titanium metallurgy [4-10]. Recently, several electrolysis and related methods such as the PFC-Cambridge process[11-15], calciothermic reduction[16-18], USTB [19,20] and MER[21] process were extensively investigated.The USTB process is a new approach where the pure titanium can be directly obtained by the electrolysis with an anode of titanium oxycarbide in molten salts[19, 20]. The titanium oxycarbide was produced by carbothermal reduction of titanium dioxide under vacuum at a temperature"

Jan 1, 2011

By M. Sukhram

This paper presents a technique to determine the direction of velocity in liquid aluminum (Al) by measuring the temperature distribution within a cylindrical rod while it is inserted into the flow. The heating pattern of the rod is a result of the interaction of the thermal fields of the rod with the liquid Al. This interaction freezes aluminum onto the cylinder in a characteristic pattern and as a result the temperature response within the rod also follows a distinctive heating pattern. Monitoring the temperature within the cylindrical rod as a function of spatial and temporal coordinates, the direction of velocity can be inferred. Experimental research work involving liquid Al was conducted at the University of Toronto using the Revolving Liquid Metal Tank (RLMT). The RLMT is a resistance furnace which can hold up to 50kg of liquid Al. In this RLMT tangential velocities up to 0.35m1s can be generated. Experimental data for different superheat and magnitude of velocity demonstrate that the sensor records different heating patterns under different fluid flow conditions. Using the transient temperature information, the direction of velocity of the molten Al flow field can be detected.

Jan 1, 2011

By I. J. Barker

This paper argues that the scale up of furnaces and the supply of electricity are going to be two major issues that will affect the ferro-alloy industry in the near future, and that economic factors will drive this development. The most common type of furnace for producing ferroalloys at present is the submerged-arc furnace with three electrodes, fed from a three-phase AC electrical supply. The scale up of this technology has now reached a fundamental constraint, which is caused by the electrical reactance of the secondary circuit. If the economy of any further scale up is to be achieved in the future then a different technology will have to be used. The supply of electrical power in future is likely to become amore complex issue than it is at present. Existing submerged-arc furnaces tend to run at fairly steady loads, but the ability to swing the load under demand-side management may offer advantages, and may allow a furnace to obtain cheaper power from the organizations that supply this power. This will have to be counterbalanced against the nuisance factors incurred by having a varying load in the operation of the furnace. Various options are therefore discussed in this paper. The possibility of scale up of Søderberg electrodes is discussed, as well as the use of DC power and multiple electrodes. Some of the issues with load swinging are also examined. A particular scenario is also briefly presented to show that considerable further scale up of ferro-alloy furnaces is still possible.

Jan 1, 2011

The schlieren technique describes an optical analysis method designed to enhance light distortions caused by air movement. The ability to visualize air flow has significant implications for analyzing underground mine ventilation systems, including the enhancement of surveys and models. Currently, traditional schlieren methods are impractical underground. Background oriented schlieren (BOS) provides a solution to this problem. BOS requires two primary components, a professional quality digital camera and a schlieren background. A schlieren background is composed of a varying contrast repetitive pattern, such as black and white stripes. This background allows the camera?s sensor to capture minor light diffractions, such as those caused by air flow. Although BOS shows great potential for ventilation analysis, sensitivity is an issue. This paper seeks to validate the BOS technique for imaging flow through a regulator by comparing BOS images with traditional schlieren images. This paper also outlines initial experimental efforts used for the validation.

Jan 1, 2011

By M. Barati

A collaborative research between University of Toronto and Hatch was conducted to understand and optimize the process conditions pertaining to a novel steelmaking technology. In this technology, known as CRISP, direct reduced iron is continuously melted and refined in a stationary electric arc furnace. The major challenge against continuous operation of the electric furnace was identified to be minimizing the corrosion of the refractory in order to achieve uninterrupted operation for a minimum of one year. Theoretical analysis and bench scale experiments together with two pilot runs resulted in defining an operating window for slag chemistry that would minimize chemical attack to the refractory while satisfying the oxidizing conditions required for sufficient decarburization. An analysis of the process in terms of energy consumption and emission of greenhouse gases revealed that it is superior to the current batch DRI-based steelmaking technologies.

Jan 1, 2011

By R. P. van Hille, A. W. van Zyl

The BIOX® culture, aiding liberation of arsenopyrite/pyrite occluded gold, is inhibited by thiocyanate (SCN > 1 mg/L); precluding the recycling of tailings water up-stream of the bioleaching circuit. The activated sludge tailings effluent remediation (ASTERTM) process is a biological process that was developed to facilitate water recovery and treat waste water on-site (to achieve a SCN concentration < 1 mg/L) to be recycled or disposed of. The aim of this study was to investigate the effects of changing temperature and SCN loading on the SCN degradation ability of the mixed microbial population clue to seasonal temperature changes and fluctuations of SCN concentration in the waste water.

Jan 1, 2011

By Steven R. Lowe

Construction of a pump station, consisting of an inlet chamber, wet well and pump chamber, required excavation to a depth of 9.7 m (32 ft) below ground surface and more than 7.6 m (25 ft) below the ground water table in a rural, but rapidly developing part of southern New Jersey. Private houses are located [ ] within a few hundred feet of the pump station that use shallow wells for water supply. The pump station design anticipated support of the entire pump station on shallow foundations bearing directly on the underlying natural soils. However, during construction, uncontrolled ground water flow caused ground loss and damage to the bearing qualities of foundation soils. As a result, remedial repairs were required including support of the pump station on drilled pile foundations and releveling of the pump chamber that had settled. This case study is an example of where a poor understanding of the significance of upward flowing ground water had a major impact on the cost of construction. Anticipated subsurface conditions The pump station layout is shown in Fig. 1 with the locations of two borings made prior to construction superimposed. One of the borings was located within the footprint of the deep wet well excavation. Generally, this is not advisable where a deep excavation is required below the ground water table. This is because there is a history of projects where ground water seepage, or pressure, has broken out into an excavation through an ungrouted borehole and compromised the integrity of foundation soils. Logs of the borings did not indicate that the borings [ ] were grouted upon completion.

Jan 1, 2011

By I. A. Kunasz

This paper is not intended to review and re-state general information on lithium, but rather to analyze the paradigm that has caused such a rapid rise in lithium production and the development of new lithium producing centers. Details on pegmatites, brines, concentrate and chemicals are amply covered in a number of publications ? SME?s Industrial Minerals and Rocks, Industrial Minerals, Roskill and a host of other publications. There is no question that the latest interest in lithium has been driven by the potential development of the electric car. This stimulus prompts one to recall two symposia: 1. ?Lithium Resources and Requirements be the year 2000?, organized in 1976 by the U.S.G.S. in Denver (1) and the sequel 2. ?Lithium ? Needs and Resources? at Corning, N.Y. (2).

Jan 1, 2011

By John Noakes

Marine scientists at the University of Georgia, have in the past few years, designed, developed and refined two geochemical survelliance systems for the exploration of hard mineral resources on the seafloor. The one first developed is an underwater sled which contains a nuclear radiation detector for measuring naturally occurring gamma radiation that is associated either with marine phosphorites containing uranium and its decay daughters or thorium decay products that are indicative of monzanite. The latter can, in most instances, be used as a pathfinder mineral for placer deposits that may contain other heavy minerals of interest such as rutile, ilmenite, chromite, gold, etc. This sled is operational in continental shelf depths. The second system is capable of more definitive measurements in the form of direct elemental analyses of the silt and clay fractions within the surficial sediments. It consists of a towed sled containing a submersible pump which, upon agitating the sediments, transfers the finer fraction up a hose to a shipboard centrifugal cone then to an automated sample processor. The resultant samples are rendered into sediment wafers, suitable for non-destructive XRF analysis. The system is capable of shipboard analysis for specific elements within minutes after sampling, allowing a cursory look upon which an exploration grid can be formulated while on site. A much wider spectrum of up to 40 elements can be evaluated when the wafers are returned to the land based laboratory.

Jan 1, 2011

By D. Kwietnewski

With all of the unknowns associated with tunnel construction, how does a contractor choose a roadheader? This paper presents a review of several models of roadheaders being used in today?s tunnel projects. The features of different models of roadheaders are presented and compared. Roadheader size and cutter power generally determine which roadheader is best for a particular job. We will also present a model for matching features of the roadheader to the anticipated ground conditions such that the most efficient machine is selected for the project.

Jan 1, 2011

By V. I. Lakshmanan, R. Roy

"TiO2 is used in paints, plastics, rubber, paper, inks, textiles and other miscellaneous applications. The demand for the pigment grade Ti02 is growing at 3.0%/year on average and this invites the development of innovative and cost effective processes. The current processes are not designed to recycle the reagents and thereby discharge the effluents into the environment, causing an environmental concern.During this study, synthesis of TiO2 from an ilmenite concentrate was investigated using an innovative atmospheric mixed-chloride leach process. The solution purification was carried out using solvent extraction in two stages. In the first stage iron removal was carried out and in the second stage titanium was extracted. The strip solution obtained from the second stage solvent extraction contained the purified titanium and from this stream pigment grade Ti02 was recovered. The barren solution was used for reagent recovery and the regenerated leach liquor was recycled."

Jan 1, 2011

By M. Nzotta, L. Teng, S. Seetharaman, A. Chychko

The objective of the present work is to optimize the EAF practice towards Mo alloying with maximum retention of the alloying element in molten steel. During Mo additions, there were significant losses to the dust (ca 7 %) and to the slag phase (ca 2 %), which had serious economic and environmental impacts. The present work was aimed at designing a suitable Mo precursor, an alternative to ferromolybdenum, as the Mo source and a process sequence for optimal retention of Mo in the steel. The design of the Mo source should be in such a way that low cost raw materials such as MoO3 concentrate have to be used, stable during the addition so that the vapour phase losses as MoO3 are kept minimum and the dissolution of the precursor in molten steel is easy without loss to the slag phase. After thermodynamic considerations, three precursor materials were chosen, viz. CaMoO4, MgMoO4 and Fe2MoO4. Synthetic mixtures of the component oxides in each case as well as pure MoO3 were investigated by TGA and high temperature XRD in order to find out the temperature range in which the compounds were formed. Experiments were also conducted separately where the evolved gases were analyzed. All the three precursors were formed easily and the loss of MoO3 to the vapour phase was found to be extremely low. Addition of the oxide mixtures to steel melts were conducted in three different scales, viz. 16 g, 500 g and 3 tons (induction furnacle). Initial experiments showed that MgMoO4 was not suitable since the Mo yield in the steel melt was not very high. Fe2MoO4 was found to perform best, the Mo yield reaching 98 %. Further trials were conducted in the 65 ton Electric Arc Furnace (EAF) at Uddeholms AB in Hagfors. Mixtures of mill scale, MoO3 and carbon in suitable proportions were added in a pre-determined addition sequence. It was found that, in the actual practice, the Mo yield reached 99 %, equaling in performance the addition of ferromolybdenum. The process offers an effective use of cheaper raw materials and very high Mo yield avoiding a pre-treatment step like the production of ferromolybdenum. This is both cost effective and environmentally advantageous. The process has been patented and is being currently implemented at Uddeholms AB, Hagfors, Sweden.

Jan 1, 2011

By G. Hamel

The LCL&L process (Low Caustic Leaching & Liming) is a patented hydrometallurgical route developed by Rio Tinto Alcan (RTA) to economically process spent pot lining (SPL) generated by aluminum cells. The three resulting end-products (carbonaceous, fluorinated and caustic liquor) are inert and have valorization possibilities. An industrial size pilot plant located in Saguenay (Quebec) was inaugurated in mid-2008 to demonstrate and optimize the technology. This paper describes characteristics of the LCL&L process and the experience acquired by RTA since the plant&apos;s start-up, including ramp-up capacity and technology challenges that were overcome. Possible end-products valorization methods are also presented. The carbonaceous end-product can be separated into carbon and brick rich fractions and used as either alternative fuel, reducing agents, or as raw material for third party processes. The development of a conversion process for the fluorinated end-product would allow its reuse as a substitute to fluorspar mineral for aluminum fluoride production. Finally concentrated caustic liquor is already valorized at the nearby RTA Vaudreuil alumina refinery.

Jan 1, 2011

By N. Ward

The Gualcamayo Mine is located in the Andes Mountains north of San Juan, Argentina (Figure 1). A property of Yamana Gold Inc, it declared commercial production in July 2009 and has a total mineral reserve and resource base of approximately 88,000 kg of gold. Crushing operations for the open-pit mine are located in a 13,500 m3 underground cavern with a ceiling height of 22 m. More than 3,600 m of tunnels are used to access the cavern and convey the ore. The Project as described in this paper relates to the design and construction of the Main Cavern, Conveyor System Exit Tunnel, the Mechanical System Access Tunnels, and two 4.20 m diameter shafts (Ore Pass #1 and Ore Pass #2) as shown in Figure 2. [ ] Preliminary engineering for the Project was performed by Hatch Chile. Rizzo Associates Argentina, S.A., a division of Paul C. Rizzo Associates, Inc (Rizzo) was contracted to provide geomechanical and geotechnical support for the construction of the access tunnel system and geomechanical design and construction supervision for the cavern and shafts.

Jan 1, 2011