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By G. Titichoca

Modification of the blasting process considers that any increase in the energy consumption generates greater benefits if done in the later stages (associated with a larger decrease in energy consumption). Therefore, although the blasting cost is doubled, generating a greater proportion of fines in addition to a weaker ore (because with greater loads and appropriate distribution of explosives a greater number of internal cracks is generated), the reduction of the unit cost that occurs in the grinding stages (SAG and ball mills) generates a positive balance in the overall size reduction process. Codelco Chile, Division Andina, has developed an extensive experimental plan to evaluate the concept of blasting modification applying greater energy. This was implemented in two stages, each including a specific mine sector: La Union and Don Luis. This paper reviews the experience of implementing such blasting modifications at the La Union mine and its impact on the design concepts and the operation of the SAG mill plant

Jan 1, 2007

By Rennie Kaunda, David Streeter, John Kemeny

This paper describes a field/laboratory study that was conducted in cooperation with a mine in Arizona. The primary purpose of the study was to investigate the effect of blasting energy on the crushability and grindability of the post-blast rock fragments. The crushability and grindability of the rock fragments were evaluated through laboratory comminution tests. A secondary purpose of the study was to investigate different laboratory methods for estimating the comminution properties of the rock fragments. In particular, a number of standard rock mechanics tests were conducted and compared with the comminution test results. Finally, the study was used to evaluate new technologies for estimating insitu rock mass strength and for assessing post-blast fragmentation. To estimate in-situ rock mass strength, the specific energy of drilling (SE) was calculated during blast hole drilling utilizing a continuous drill monitoring system. Post-blast fragmentation was estimated using the Split image processing system. Results from the study support the idea that increases in blast energy can enhance crushing and grinding. Also, several simple rock mechanics tests were found to correlate well with the results from standard comminution tests, which could prove to be useful in practice.

Jan 1, 2003

By \/eena Sahajwalla, Alexander Blagus

This paper reports the effect of using High Density Poly-Ethylene (HDPE)/coke blends on the reduction behaviour of Mn3O4 to MnO at 1000°C. The results suggest that CH4 release increases with increasing HDPE addition. The results show that the rapid release of methane, over only the initial five minutes, limited the interaction of Mn3O4/MnO with CH4. With the devolatilisation of HDPE there was increased porosity in samples containing HDPE, assumed to be the major factor in differences of reduction rates.

Jan 1, 2011

By S. J. Laskowski

In potash ore flotation, carried out in NaCI-KCI saturated brine (about 6-7 molar KC1 and NaCI solution), long-chain primary amines are used as flotation collectors. Long-chain primary amines are poorly soluble in water and their solubility further decreases at high electrolyte concentration. For ionic surfactants there is a characteristic temperature (Krafft Point, KP) below which their solubility is too low for micellization. In a previous study, the effect of pH on the KP of dodecylammonium chloride in water was determined [Q. Dai and J.S. Laskowski, Langmuir, 7, 1361-1365 (1991)]. This paper deals with the effect of electrolyte concentration on the KP of dodecylammonium chloride. The derived theoretical relationship between the KP and the critical micelle concentration (CMC) for dodecylamine can be used to calculate the KP for electrolyte concentrations of up to 0.5 mol/L (about 8% NaCI-KCI brine). A simple experimental procedure for the determination of the KP for higher electrolyte concentrations is also described. The results show that the Krafft point of dodecylamine increases from about 17-18°C (in distilled water) to about 80°C at 16% brine saturation.

Jan 1, 2006

By R. Wensel

A composite material consists of two or more dissimilar components. These dissimilar components retain their identities when mixed together and contribute to the properties of the composite. A composite usually consists of two parts, the matrix and the reinforcing material, or extender that is added to the matrix. Typical materials used as the matrix in composites are metals, polymers, and ceramics. The reinforcing material can be added for any number of reasons. For instance, if the matrix is expensive, an inexpensive filler may be added to the matrix to lower the cost of the product without sacrificing properties. An example of this is calcite (CaC03) which is added to systems such as polyvinyl chloride (PVC), to lower the cost. Reinforcements may also serve as a means to enhance the properties of the matrix material. For example, carbon fibers are frequently added to plastics to increase their strength, and glass spheres may be added to plastics to improve flexural strength. Mg(OH)z is added to polymers to give the property of fire retardancy. The latter is the focus of this paper.

Jan 1, 1995

By Atta Ur Rehman, Kwame Awuah-Offei

This paper examines the effect of bucket geometry (cutting-blade profile, floor profile and blade thickness), speed, motor power output and muckpile particle sizes on bucket penetration and draft for rubber tire loaders. The work uses a 1:16 scale model of a load-haul-dump (LHD) in full-factorial experiments to examine the effect of the variables on penetration and maximum draft. The results show that speed and motor output are positively correlated with penetration and draft, and muckpile particle size is positively correlated with penetration and negatively correlated with draft (p < 0.0014).

By Atta Ur Rehman, Kwame Awuah‑Offei

This paper examines the effect of bucket geometry (cutting blade profile, floor profile, and blade thickness), speed, motor power output, and muckpile particle sizes on bucket penetration and draft for rubber tire loaders. The work uses a 1:16 scaled model of a load-haul-dump in full factorial experiments to examine the effect of the variables on penetration and maximum draft. The results show that speed and motor output are positively correlated to penetration and draft; muckpile particle size is positively correlated to penetration and negatively correlated to draft (p < 0.0014). The results show that buckets with a semi-spade cutting nose profile yield the highest penetration (mean 118.30 mm) followed by those with the spade (mean 108.88 mm), which also yield higher penetration than those straight blades (mean 95.19 mm). Bucket floor profile and blade thickness had no significant effect on penetration or draft. Also, we determined that increasing the speed and motor power output, simultaneously, can reduce bucket penetration. Thus, operators should not waste energy for no additional gain or even loss in bucket penetration. Also, the work finds speed and motor power output each combine with muckpile particle sizes to affect bucket penetration. This research furthers our understanding of the effectiveness of different bucket geometries in improving penetration and reducing draft for rubber tire loaders.

Oct 29, 2021

By A Nigam, K Biswas, R Sarkar

Because of the problems with 1st and 2nd generations of Advanced High-Strength Steels (AHSS), a 3rd generation of AHSS steels has become prominent and these steels have properties in between the 1st and 2nd generations of AHSS. However, although the 3rd generation of AHSS is a promising candidate as a replacement for its predecessors, there remain some challenges in processing these steels which are essentially medium Mn (Mn content ~ 5–7 wt per cent) and high Al (Al content ~ 1– 3 wt per cent) steels. The use of conventional casting powders based on the CaO-SiO2 system is unsuitable for high and medium Mn/Al steels. This work investigates the development of CaO-Al2O3- based mold fluxes for casting third-generation AHSS steel. Mold fluxes, with otherwise similar compositions but different C/A ratios, are tested and their crystallisation behaviour is examined using differential scanning calorimetry (DSC). A calcium aluminate phase having a composition Ca12Al14O33 was found to be the main crystalline phase in the mold fluxes. A decrease in crystallisation temperature was observed as the CaO/Al2O3 ratio increased from 1.00 to 1.33. The effective crystallisation rate constant exhibited an increase with decreasing crystallisation temperature, indicating a potential influence of nucleation rate on the overall crystallisation rate and suggesting an anti-Arrhenius behaviour in the crystallisation process of these mold fluxes.

Aug 21, 2024

By CHENCHEN SUN, GUOPING LUO, GUOCHENG ZHANG

Preparation of briquettes by adding CaF2 reagent into the Australian iron ore powder. The structure and morphology of iron ore briquettes during various reduction stages (i.e., Fe2O3→Fe3O4, Fe3O4→FeO, and FeO→Fe) were observed via an ore microscope and scanning electron microscopy. The results showed that CaF2 reacted with SiO2 to form CaO and SiF4 gas during the roasting process. The reduction swelling index decreased from 12.36 to 8.83% when the CaF2 content in the briquettes increased due to CaF2-mediated refinement of the hematite grains during the first stage of the reduction process. Lattice distortion resulting from the presence of Ca2+ in the FeO lattice during the second stage of the reduction process, coupled with an increase in the porosity of the iron ore briquettes and the formation of a low-melting-point slag phase, promoted the anisotropic growth of FeO lamellar crystals, which resulted in an increase in the reduction swelling index from 4.27 to 7.36%. During the third stage of the reduction process, the growth of iron whiskers was promoted by wüstite (FeO) lattice distortion caused by a solid solution of Ca2+ in the FeO lattice; the reduction swelling index increased from 15.61 to 24.72%, resulting in the catastrophic swelling of the iron ore briquettes.

May 27, 2021

By S Hapugoda, H Han, L Lu

Charcoal produced from Syzygium Zeylanicum trees was widely used in ancient Sri Lankan iron smelting practices. Charcoal made from Syzygium Zeylanicum tree trunks, branches and leaves were analysed by optical mineralogy and SEM and found to contain unusually high concentrations of calcium oxalate (CaC2O4.H2O – CaOx) crystals in plant cells. Partial and full reduction tests of a high-P Brockman ore were conducted at several temperatures with coke and coke doped with CaOx and CaCO3. It was observed that CaOx promoted reduction and generated comparatively more metallic iron in reduced samples. Furthermore, CaOx encouraged phosphorous partition into slag phases than into the metallic iron, suggesting CaOx can a potential alternative fluxing material to calcium carbonate for treating high-P iron ores in ironmaking processes.

Sep 18, 2023

By Peter Hayes, Evgueni Jak, Taufiq Hidayat, David Grimsey, Denis Shishin

"An integrated nickel flash smelter is operated with Peirce-Smith converters at the Kalgoorlie Nickel Smelter. To improve the partitioning of arsenic between slag waste and matte product, an option to modify the slag–matte chemistry by addition of CaO was analysed. A combination of plant sample analysis, high-temperature laboratory experiments and thermodynamic modeling was carried out to evaluate the process options. The high-temperature experiments involved the re-equilibration of industrial matte-slag samples at 1225 °C and P(SO2) = 0.12 atm, rapid quenching in water, and direct measurement of phase compositions using electron probe X-ray microanalysis (EPMA) and Laser Ablation Inductively Coupled Plasma Mass Spectrometry (LAICPMS). A private thermodynamic database for nickel sulfide smelting and converting was used together with the FactSage thermochemical software package to assist in the analysis of the distribution of elements between slag and matte as a function of CaO addition. The thermodynamic predictions combined with experimental data obtained in this study can be used to characterise the effect of CaO fluxing on the slag–matte thermochemistry during the nickel sulfide converting.INTRODUCTION At the Kalgoorlie Nickel Smelter (KNS), nickel sulfide concentrate is processed in an Outotec-type flash furnace to produce nickel matte containing +47 wt% Ni. Separation of nickel matte and waste slag from the flash smelting is enhanced through settling in the electric arc -heated zone attached to the flash furnace. The flash furnace matte is further processed in a Peirce-Smith converter to produce Ni-rich matte containing +66 wt% Ni (Crundwell, Moats, Ramachandran, Robinson, & Davenport, 2011). Iron silicate-based slag is used in the converting process at KNS. Most of the arsenic is contained in the final matte and very little of the arsenic partitions into the slag. Previous work by Font et al (Font, Hino, & Itagaki, 2003) shows that the distribution ratio of arsenic between calcium ferrite slag and nickel-matte (LAsslag/matte) is significantly higher than that between iron silicate slag and nickel-matte, where LAsslag/matte = (wt pct As in slag)/{wt pct As in matte} (1)"

Jan 1, 2017

By García B., Wolff E.

The pellet qualities primarily depend upon the thermal profile and gaseous environment during induration. During the induration of the pellet, it undergoes physical as well as chemical changes. Physical changes are mostly due to sintering and chemical changes are due to carbon burning inside the pellet. The effect of carbon on sintering is investigated on a single pellet scale using an optical dilatometer. Sintering is a complex process that involves transportation through various mechanisms. Sintering is quantified in terms of sintering ratio and the kinetic parameter, exponent ‘n’, under isothermal conditions is deduced using the power law equation. The value of n can be used to estimate the sintering mechanism at different isothermal temperatures. Also, the activation energy is calculated using the empirical Arrhenius equation. The activation energy of 0 per cent coke and 1 per cent coke-containing pellets are 531.0 kJ/mole and 552.6 kJ/mole respectively. The order of magnitude of activation energy suggests the same mechanism in both cases. Although the mechanism of sintering is the same, 1 per cent coke-containing pellet sinters more at any isothermal temperature.

Jun 17, 2024

By S Lakemond, L I. Ku, J Vaughan

Conventional processing of poly-metallic gold containing flotation concentrates are challenging for a number of reasons. One reason is that substantial copper and zinc in the cyanide leach solution compete with gold and silver for carbon adsorption sites. In this study, metal-cyanide adsorption kinetics and equilibrium are measured on three samples of coconut derived activated carbon and one sample of synthetic carbon. Loading selectivity was confirmed to be in the order gold&gt;silver&gt;copper&gt;zinc for all carbon samples. The synthetic carbon tested showed promising results in terms of loading kinetics and capacity for precious metals.CITATION:Lakemond, S, Ku, L I and Vaughan, J, 2013. Effect of carbon type on adsorption of Cu, Zn, Ag and Au from mixed cyanide solution, in Proceedings World Gold 2013 , pp 411-418 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 26, 2013

By F. H. Samuel, A. M. Samuel, H. R. Ammar

Casting imperfections, such as porosity, in cast aluminum components greatly influence their fatigue properties. The effect of porosity on the fatigue life of 319-F and A356-T6 aluminum alloys was studied, where the porosity characteristics on the fracture surfaces of fatigue-tested samples were examined using SEM and image analysis. The results show that porosity has the most detrimental effect on the fatigue life: 92 % of all tested samples fractured due to porosity acting as the main crack initiation site. In the absence of casting imperfections, other microstructural aspects such as slip bands can be responsible ( 4 % ). The porosity was investigated in terms of the pore size at the sample fracture surface and its location i.e. near the edge or close to the interior. It was found that porosity located far from the sample surface (edge) has less influence on the fatigue crack initiation, and the fatigue life decreases as the size of the pore located at the sample surface increases. Aluminium

Jan 1, 2006

By Xiang-ning Meng, Miao-yong Zhu

"A three-dimensional finite-element heat-transfer model is conducted to predict temperature of hot copper plate in a slab continuous casting mold and the effect of casting speed on temperature difference between copper plate and solidifying shell is simulated in combination with process data. The results show that centre temperature of hot copper surface at casting speed 1.8 m·min-1 and 2.0 m·min-1 are higher than that of 1.6 m·min-1 casting speed 4.7-5.2 °C and 11.2-12.2 °C respectively and temperature is not increased linearly with casting speed. Temperature difference in meniscus between mold and shell is influenced obviously by casting speed and increased 4.0- 6.0 °C with increment of casting speed 0.2 m·min-1• Fluctuation of temperature difference in meniscus is a main reason to deteriorate casting quality as increasing casting speed.IntroductionIn conventional continuous casting of steel, a large amount of sensible and latent heat of molten steel dissipates in primary cooling zone and mold becomes a critical component of caster to govern steel quality, meanwhile, thermal load on mold is increased constantly and environment is also more abominable since high productivity and quality are required and high-effective technologies are applied. So, an in-depth understanding of thermal behavior of mold at high casting speed is essential to design cooling structure and maintain casting stability. Many studies have been carried out to shed light on thermal behavior in mold. Chow et al. [l] applied a mathematical model to heat transfer in billet mold at a high casting speed to give a new taper in order to minimize mold-strand interaction. Thomas et al. [2] researched relation between mold geometry and temperature distribution based on a finite-element heat-transfer model. Lu et al. [3] indicated that slab mold temperature are mainly affected by thickness of copper plate and nickel layer by a heat transfer model. Samarasekera et al. [4, 5] researched temperature of copper plates for both billet and slab molds and effect of a large number of factors ranging from water quality to casting speed. Park and Thomas et al. [6, 7] developed a finite-element thermal-stress model to determine temperature and thermal distortion and stress in both thin and slab molds and O'Connor et al. [8] applied an elastic-plastic-creep finite-element model in a funnel shaped mold to achieve same goals. Cicutti et al. [9] evaluated heat transfer and temperature fluctuation in a slab mold and proposed an expression to predict global heat flux as a function of process parameters and an index to quantify thermal instability. All mentioned above shown that thermal behavior is not only important to casting stability, it is also premise to further understand mechanical behavior in mold."

Jan 1, 2011

By S. K. Kawatra, S. J. Ripke

Bentonite clay is used as a binder for iron ore concentrate pelletization. Bentonites are sensitive to cations such as calcium, magnesium, sodium, and potassium that are known to be dissolved in the moisture remaining in the iron ore concentrate. These cations affect the ability of bentonite to absorb water, as measured by the plate water absorbance (PWA) test. This paper addresses the relationships between plant water chemistry and pellet strength for a wide PWA range of bentonites. Experiments were conducted to determine the effect of concentrate moisture solute chemistry and bentonite PWA value on the wet knock and wet and dry compressive strengths of iron ore pellets. Experiments used seven different types of bentonite that had PWA values ranging from 564 to 1033. Flushing plant concentrate with distilled water to remove the dissolved cations resulted in increased pellet strengths, to a widely varying degree, for each bentonite tested; wet knock values increased an average of 92% and dry compressive strength increased an average of 46%. In addition, pellet strengths were not found to be directly related to the ability of bentonite to absorb distilled water, measured by the PWA test.

Jan 1, 2002

By A. K. Tripathy, P. K. Pattnayak, H. S. Ray

The effects of water addition on the solid-state reaction between Cr2O3 and Na2CO3 at low temperatures (up to 873 K) were investigated to determine its possible influence on the reaction rate and the degree of conversion to soluble chromate. Experiments at high temperatures were conducted for comparison. It was found that adding water to the mixture before roasting enhanced both reaction rate and yield significantly. The reactions followed the Lesokhin-Tempelman equation at low temperature and the Ginstling-Brounshtein equation at above 973 K; the respective activation energies were 95 and 22 kJ/mol

Jun 19, 1905

By Mohammad Reza Khalesi, Ruhollah Rezazadeh, Mohsen Izadi Yazdan Abadi, Mahmoud Abdollahy

"The rotary vacuum drum filter (RVDF) is widely used for dewatering in mining industrial. In general, different parameters have influence in the solid-liquid separation such as: solid percent, level of vacuum, particle size distribution, filter cloth and chemical additives. These parameters can influence on some variables such as cake moisture, throughput and filter cloth life time. The aim of this study is to propose some chemical additives to improve the rate of filtration and decrease cake moisture of Gol-E Gohar iron ore concentrate by using laboratory scale bottom feed vacuum filter and suggest a filter cloth with long life time (more than 400 hours). Effect of particle size distribution on filtration investigated in large scale by measuring the thickness of cake and cake moisture.Increasing molecular weight of anionic flocculant lead to increases throughput but cake moisture increases too; While the filter aid increases throughput and decreases cake moisture simultaneously; the combination of them show different behavior. TSS and filter cloth life time have directly relation with material and type of filter cloth weave. Depending to type of feed, two polyester and polypropylene filter cloth are suggested. More over twill and satin weave have the best results. To prove the laboratory results some industrial tests performed in Gol-E Gohar hematite iron ore concentrate plant.INTRODUCTION“The process of grinding and classification involves the use of large quantities of water. The separation of solids from liquids is usually achieved by gravity sedimentation in thickeners. For fine particles this is a slow process. In general, 75–80% of the water can be separated and removed by thickeners. For further water removal, filters are used where in excess of 90% of the water can be removed” (Gupta, 2006).“Many types of filters are available, which are broadly classified here as vacuum, pressure, precoat and depth filters. Each classification contains a number of sub-processes. A category of filter that uses vacuum induced driving forces and semipermeable media to facilitate the separation of solids from suspension. While pressure differences across the filter are limited to less than 85 KPa (usually 75 KPa), most units are capable of processing a wide range of feed materials in a continuous manner” (Rushton, 2008)."

Jan 1, 2016

By A. Danaei, A. McLean, M. Barati, C. Ravindran

"The aluminum industry generates about 90 million tonnes of red mud each year. Previous research shows it could be utilized as a refining flux with a high capacity to absorb phosphorus and sulphur from hot metal in the steel industry. The present study was undertaken to evaluate the melting properties of such fluxes, as it affects the effectiveness of the flux. The results show that the melting behavior of red mud is strongly affected by lime addition and the characteristic melting/softening temperatures reach minimum VALUES (at 32.7 wt% CaO. From these findings, a correlation was established between melting behavior and optical basicity. This allows one to adjust the composition of the flux based on the process requirements. INTRODUCTIONThe aluminum industry generates about 90 million tonnes of bauxite residues each year. This residue is usually red in color because it contains a substantial amount of iron oxide. The red mud, as it is called, is a solid waste with a high concentration of sodium oxide, high pH (10 to 13), and high alkalinity, and thus is harmful to many forms of life. Traditionally, the material is stored in large tailings ponds within the plant’s vicinity (Power, Grafe, & Klauber, 2009). Development of solutions for safe disposal or preferably using this residue for other industrial processes or applications could help restore polluted locations and eliminate a negative impact on the environment (Haake, 1988; Power et al., 2009; Yan & Xuegong, 2010).The mineralogy and chemical composition of red mud depends on the quality of the bauxite and refining process parameters. In general, it consists of iron oxide (Fe2O3), aluminum oxide (Al2O3), titanium oxide (TiO2), sodium oxide (Na2O), silicon oxide (SiO2), and calcium oxide (CaO) (Power et al., 2009). Like most ores and soils, bauxite can contain trace quantities of metals such as arsenic, beryllium, cadmium, chromium, lead, manganese, mercury, nickel, and naturally-occurring radioactive materials, such as thorium and uranium. Most of these trace elements stay in the residue (Power et al., 2009)."

Jan 1, 2012

By R. Uwaoma, A. Goosen, R. Matjie, K. Mphahlele, J. Bunt

Coal properties that are associated with wear and damage of grinding equipment during pulverization prior to combustion were investigated. A South African Highveld feed coal and its beneficiated fractions were crushed to <1 >0.25 mm particles for the grindability tests. These particles were milled and screened into <75 μm and >75 μm fractions, which were analysed by different techniques to establish a correlation with the conventional Hardgrove Grindability Index (HGI). The <1.5 g.cm-3 float fraction, which contained 93 vol.% (mineral matter free) total -macerals,9% kaolinite, and had the lowest HGI (57) (hardest to grind) was pulverized for 15, 30, 60, and 120 minutes for particle size distribution analysis. This analysis indicated that the content of <75 μm particles increases with increased grinding time. The >1.9 g.cm-3 sink fraction, with the highest HGI (76), 44% kaolinite, and 20 vol.% total macerals, was ground easily to generate the highest proportion of <75 μm particles. Based on higher correlation coefficients (R2 = 0.77–0.91), the ash yield, mineral matter, petrographic composition, and fixed-carbon have significant effects on the HGI. Conversely, the inherent moisture and total sulphur (R2 = 0.48–0.62) have only minor effects on the HGI. Results from this investigation could be implemented in the preparation of a suitable pulverized fuel with little equipment wear, as well as utilizing mineralogical and petrographic compositions. Finally, the effect of microlithotypes and maceral types in South African feed coals on the HGI should be investigated in further pulverization and grindability studies.

Jul 5, 2023