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By I. Filzwieser, A. Filzwieser

The Peirce Smith converter is the key metallurgical vessel in the majority of copper smelters. During the two step process, oxygen enriched air is injected through a row of tuyeres into the matte received from a primary smelting unit. Additionally, in the first step the iron content is oxidized into a fayalite slag by the addition of silica. During the second step, the remaining copper sulphide is converted into blister copper with a final sulphur content of approximately 200 ppm. The overall efficiency of this process is determined by the total reaction time, the slag quality and quantity, and the chemistry of the final blister copper. To increase the reaction kinetics during both stages, the METTOP Process Control and Regulation (MPCR) system was developed, which consists of four elements: OPC - Optical product control ACR - Automatic computer regulation GCU - Gas control unit GIS - Gas injection system The OPC system from SEMTECH records the optical spectrum emitted by the off gas flame providing immediate, detailed process information. Using this online data, additional gas can be automatically injected into the converter through a gas injection system opposite the tuyere zone. An improved oxygen distribution in the melt and the accurate determination of the process end point results in a significant reduction in the process cycle time. Furthermore, by maintaining the reaction closer to the equilibrium the final sulphur and oxygen content can be reduced compared to the conventional process. In particular, the final sulphur content can be lower than 70 ppm, eliminating the need for an oxidation step in the anode furnace.

Jan 1, 2007

By Adrian Moore, Bryan Goodwin, David Fales, David Lam

This paper describes the development of blasting protocols used to successfully create a 450m long blast fractured permeable trench in a basalt aquifer up to 20m thick, at a petrochemical facility in Australia, to enable the remediation of contaminated groundwater.

Jan 1, 2011

This paper presents the results of research aimed at proposing new solutions in the area of belt conveyor elements. Many factors, such as energy consumption costs, and operating costs of belt conveyor elements, including belts, idlers and drives have an impact on the operational costs of conveyors. The paper presents special tests of new materials for the bottom cover of an energy-saving belt conveyor, which decrease rolling resistance. It also presents large-scale in-situ tests of a high-output belt conveyor for the purpose of simultaneous measurements of various types of conveyor belts (standard vs several energysaving types) under typical operating conditions of a lignite surface mine. Improvements in materials used for the bottom belt covers, supported by specially developed comprehensive tests of the new types of belts have provided valuable results of various proposed solutions. Since the tests of belts were done at exactly the same time and in the same operating conditions, direct comparison of the results is valid and should lead to a substantial decrease in the conveyors? drives? energy consumption, which will improve the effectiveness of belt transport and minimize its negative influence on the environment.

Aug 1, 2013

By P. R. Hervey

Quartz is the second most widely used electronic material, with approximately 3,000 tons of single crystals used each year. Virtually all of this material is synthetic; grown with a technique called hydrothermal growth. We will review the basics of hydrothermal growth, the feedstocks for these crystals, and the challenges to improving the growth process. We will also review the processing of these crystals, the markets and applications where they are used, and the global outlook for these markets.

Jan 1, 1999

By Bradford H. Miller

Separation and Recovery Systems, Inc. (SRS) provides on-site waste minimization and resource recovery using its state-of-the-art MX-1500 centrifuge and MX-2000 thermal desorber. The MX-1500 can process over 450 feed tons of material per day, resulting in centrifuged cake containing 20% to 60% by weight. The MX-2000 is a hollow-flite thermal processor indirectly heated by either steam or hot oil. SRS has dewatered and/or deoiled over 1,000,000 feed tons of material in the refining, chemical, and energy industries using the MX-1500. SRS estimates that over 300,000 barrels of reusable oil have been recovered from that material. Additionally, SRS has dried and/or detoxified over 150,000 wet tons of solids or soil to regulatory or customer-specified limits using the MX-2000.

Jan 1, 1994

Proper water and thermal management is essential for obtaining high performance of Proton Exchange Membrane Fuel Cells (PEMFCs). A steady, two-dimensional water and thermal management model was developed, aiming at considering pressure drop, open circuit voltage variation with stack temperature, water vapor effects on membrane conductivity, which made the model physically more reasonable and more suitable for various operating conditions. The model could predict the distributions of a series of important parameters along the flow channel, and thus the effects of various operating and design parameters on the fuel cell performance could be investigated easily by numerical trial-and-error method. The modeling results compared well with the available experimental results from the literatures. The results also showed that the humidification is crucial for the performance of PEMFCs. The model could be a very useful engineering tool for the optimization of PEMFCs.

Jan 1, 2005

By Juliano Villanueva

La concentradora Antapaccay comenzó sus operaciones en noviembre del 2012. Como parte del proceso de puesta en marcha, se desarrolló la subetapa de este comisionamiento de los IsaMills, fundamentales en el circuito de remolienda. El circuito de remolienda consiste en dos IsaMills, uno para el concentrado rougher y otro para el concentrado scavenger. En ese sentido, el presente texto describe las ventajas encontradas en este equipo como el nivel de carga de medio de molienda, que es reflejado en el consumo de energía.

Oct 1, 2014

By Patzen Wu

Taiwan is located in the orogenic belt of island arcs on the western rim of the Pacific Ocean. The structure of the Taiwan coal fields is much complicated as a result of active Cenozoic orogenic disturbance in Plio-Pleistocene time. The abundant faults and folds have created poor structural conditions of the coal seams and some peculiar safety problems in mining however, the domestic coal still played an important role in the economic development of Taiwan for the years before 1968. Because of increasing mining depth and a decreasing number of miners, the coal production dropped from nearly 5.1 million metric tons in 1968 to 2.45 million metric tons in 1981. There were 173 small active coal mines and about 22 thousand miners in 1981. The coal mining in Taiwan has a history of more than one century. Specific efforts have been undertaken in solving major coal mine safety problems such as gas outbursts, bad roofs and weak floors, difficulty in ventilation due to deep underground mining, spontaneous combustion etc. We have thus acquired much helpful experience which, we deem, is worth reporting at this meaningful meeting.

Jan 1, 1982

By Jennifer Williams, Donald J. Berger

Originally built between 1913 and 1916, the Ashton Dam & Hydroelectric Facility has experienced various seepage and piping incidents since completion. Ashton Dam is located within 15 miles (24 km) of the historical Teton Dam failure site and about 2.3 miles (3.7 km) west of Ashton, Idaho. Numerous repairs conducted over the years ranged from filling sinkholes on the crest of the dam to placement of rockfill on the upstream slope to improve seismic stability. In addition, the existing low level outlet works was grouted full and abandoned in 1991 due to significant vibrations induced on the dam during its operation.

Jan 1, 2014

By J. Hamada, K. Yamashita, Y. Shigeno, T. Tanikawa

"This paper offers a case history of piled raft foundation in soft ground supporting a twelve-story building in Tokyo. To increase bearing capacity of the soft soil as well as a countermeasure of liquefaction, grid-form deep cement mixing walls (DMWs) were employed with the piled raft. Based on the long-term monitoring results, the ratio of the load carried by the DMWs to the effective structure load after the construction of the raft was estimated to be 0.3 while that carried by the piles was 0.7. In order to clarify the contribution of the DMWs to bearing the structure load, numerical simulation of the settlement and the load sharing among the piles, the DMWs and the unstabilized soil was performed using a three-dimensional finite element model. The results of the numerical simulation agreed well with the measured values, when the Young’s modulus of the DMWs obtained from the unconfined compressive tests was adopted and the shear modulus of the soft soil was reduced to 50% of that at small strains.INTRODUCTIONIn recent years, piled raft foundations have been used in many countries as building foundations. The effectiveness of piled rafts in reducing average and differential settlements has been confirmed not only on favorable ground conditions as shown by Katzenbach et al. (2000), Poulos (2001) and Mandolini et al. (2005), but also on unfavorable ground conditions such as soft clay and/or liquefiable sand using ground improvement technique (Yamashita et al., 2011a; Yamashita et al., 2011b; Yamashita et al. 2013). Grid type ground improvement using the Deep Mixing Method has been applied to sandy ground as a countermeasure of liquefaction to increase liquefaction resistance of unstabilized soil left in the grid walls where its shear deformation during seismic motion is reduced by the confinement effect of the grid walls (Kitazume, 2013). The high applicability of the method was demonstrated in the 1995 Hyogoken-Nambu earthquake and the 2011 off the Pacific coast of Tohoku Earthquake (Tokimatsu et al., 1996; Uchida et al., 2012a; Uchida et al., 2012b).This paper offers a case history of piled raft foundation in soft ground supporting a twelve-story building in Tokyo. To increase bearing capacity of the soft soil as well as a countermeasure of liquefaction, grid-form deep cement mixing walls (DMWs) were employed with the piled raft. First, the results of long-term field monitoring on the settlement and the load sharing among the piles, the DMWs and the unstabilized soil are briefly described. Next, to clarify the contribution of the DMWs to bearing the structure load, the foundation behavior is simulated using a three-dimensional finite element model, and then the results of the numerical simulation are discussed."

Jan 1, 2015

By C Bie, S Li, P Xiao, P Zhao, H Lin

"Based on solid simulation material research, the simulation conditions for methane and coal solid-gas coupling were obtained using solid-fluid coupling theory. Using sand as the aggregate and paraffin and oil as the cementing agents, a material suitable for solid-gas coupling simulation was developed. A permeability testing instrument was also developed, and the compressive strength, brittleness parameters and seepage velocity of material were tested with different aggregates. The results showed that as the paraffin content increased, the compressive strength of the material increased but the permeability decreased. The oil removed the drawback of intensely changing material compressive strength. By setting a different ratio of aggregate to cementing agent, it can simulate rocks with different strengths and permeability. Applying the material to a mining simulation experiment revealed a relationship between methane seepage velocity and overlying strata movement. By extracting pressure relief gas from Shanxi Tianchi coalmine drainage, the authors found that the mining fissure zone was a storage area of pressure relief gas, and a gas drainage system can be placed to achieve good results. CITATION: Li, S, Zhao, P, Lin, H, Bie, C, Pan, H and Xiao, P, 2015. Character of simulation material of coal – rock and gas solid-gas coupling and engineering application, in Proceedings The Australian Mine Ventilation Conference, pp 105–110 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Aug 31, 2015

By J. E. Garlanger

Each year, Florida mines approximately 40 million tons of phosphorite, most of which is ultimately converted to various commercial fertilizers. The phosphorite is mined from within the bottom portion of the 40-to 60-ft. thick surficial aquifer, using open pit mining techniques. The ore zone or "matrix" is generally overlain by relatively permeable fine sand to silty and slightly clayey fine sand. The ore itself is highly variable in nature but, in Central Florida, typically consists of less permeable clayey phosphatic sands and sandy clays with stringers of permeable sand. The ore is much more sandy in the north Florida mining area.

Jan 1, 1990

By S. Lu

The particle-bubble attachment and the rupture of formed aggregates in flotation cell were investigated in terms of turbulent regime. It was found that the particle-bubble collision rate is closely correlated to the energy barrier between particles and bubbles, and no adhesion takes place for the hydrophilic particle-bubble system due to the introduced ?capture efficiency? f(a) being zero. The values of an especially defined Weber number, i.e. the ratios of turbulent stress to aggregate strength in the inertial subrange of turbulence were estimated, the results showed that the detachment of a particle from a bubble involved in an aggregate is mainly caused by the turbulent stress only in the impeller zone, no bubble splitting occurs both in the impeller zone and in the bulk zone.

Jan 1, 1993

By E. P. Wiechmann, J. A. Henríquez, P. E. Aqueveque, L. G. Muñoz, G. A. Vidal

"The original segmented intercell Optibar succeeded in reducing the magnitude and occurrence of short circuits. It also improved the specific energy consumption of the process. This paper expands the load current source concept introducing a triple segmented bar. This new bar adds immunity to dirt contacts and open circuits. Moreover, it further improves the standard deviation of current densities. As compared with industrial practices this development should accomplish an 8% specific energy reduction. Also, a plant implemented with BBS should be able to work with 12.5% higher process currents than Walker without compromising the operation.INTRODUCTIONIn 2011 the technology based on current mode was implemented at industrial scale. The success of this technology moved CIM Magazine (Lanktree, 2011) to write in the Jan 2012 issue an upfront story of this technological innovation. To cover the story, the technical reporter Graham Langtree was appointed by Peter Braul Editor of the upfront section. The article tells that “More than 40,000 tonnes of copper have been refined in a year-long test run of Optibar Inc.’s new technology at Barrick Gold’s Zaldívar copper plant in northern Chile. The new segmented intercell bars being used in the Compañía Minera Zaldívar refinery have slashed energy costs, reduced short circuits during refining and allowed the production of heftier, purer sheets of copper – gains that all promise to boost the plant’s margins. A copper refining tank house containing the cell circuits typically consumes 2,000 kWh of electricity to produce a single tonne of grade-A copper. Yet, monitoring the energy efficiency of the Optibar technology after increasing the weight of harvested copper sheets, the project’s engineers recorded a 92 kWh-per-tonne cut in energy consumption, a savings of 4.6 per cent. “Today, with the power prices we have, Optibar technology represents a potential savings for the whole plant of US$1.5 million per year,” says Robert Mayne- Nicholls, executive general manager of Barrick Gold’s Chilean operations.”"

Jan 1, 2012

By M. Kermani

This paper presents and compares the physical properties of Gelfill and cemented hydraulic fill (CHF) obtained by lab experiments. Gelfill has an alkali activator such as sodium silicate in its materials in addition to primary materials of cemented mine backfill which are deslimed tailings, water and binders. The CHF and Gelfill samples with various mixture designs were cast and cured for 28 days. Initially, the influence of sodium silicate concentration on the mechanical properties of samples was evaluated using the unconfined compressive strength (UCS) test. Consequently, the effect of curing temperature on CHF and Gelfill samples cured in various curing temperatures ranging from 5?50 °C was studied using the UCS test. Microstructure of selected samples was studied wirth the mercury intrusion porosimetry (MIP) technique. This study concludes that: (i) The mechanical properties of CHF can be improved by the addition of appropriate amount of sodium silicate. (ii) The rate of strength acquisition in Gelfill samples is faster than CHF samples over 28 days of curing period. (iii) Curing temperature strongly influences the mechanical and microstructural properties of CHF and Gelfill samples. (iv) The microstructure analysis revealed that the addition of sodium silicate can modify the pore size distribution and total porosity of Gelfill which can contribute to the better mechanical properties of Gelfill. (v) The MIP tests suggested the microstructure of specimens were changed by adding sodium silicate in a way that the Gelfill samples had a higher percentage of fine pores than CHF samples.

Aug 1, 2013

An EAF dust generated in a Swedish steel mill has been leached in hydrochloric acid at The solution obtained has been subjected to purification by cementation followed by precipitation of zinc with sodium carbonate. The thermal decomposition of the precipitate was studied using thermal analysis and X-ray diffraction. The results show that during the calcination of the precipitate three different reactions occur. The decomposition of the solid phases Zn5(CO3) (OH)6, CaZn(CO3)2 and CaCO3 occur completely at 370°C, 560°C and 940°C respectively, yielding a final product containing 61.9% ZnO and 38.1% CaO. Methods to minimize calcium and manganese in the final product are discussed.

Jan 1, 2003

By Seher Ata

This paper is concerned with the coalescence behaviour of two bubbles in dilute solutions of cetyltrimethylammonium bromide, methyl isobutyl carbonil and triton x-100. Two bubbles were produced at the tips of adjacent capillaries and the time elapsed between the first contact of the bubbles and film rupture was determined by means of a high speed camera. It was found that the amount of surfactant required to stabilise the bubbles increased in order of CTAB>TX-100>MIBC. The probability of coalescence decreased sharply with increasing surfactant concentration in CTAB and TX-100 solutions while with MIBC each bubble pairs resulted in coalescence, giving hundred per-cent coalescence probability.

Jan 1, 2014

By M. A. Vasina, I. A. Matveeva, E. A. Naumova, V. V. Doroshenko, N. A. Belov

"Using the calculated (Thermo-Calc software) and experimental methods (SEM, TEM, EMPA, DSC, XRD, etc.) the phase composition, structure and hardening of aluminium alloys of the Al-Ca-Zn-Mg system were studied in the following range: 2. 5%Mg, up to 10% Ca, and up to 14% Zn (wt%). Fragments of this quaternary phase diagram in the aluminium corner were constructed, including the liquidus surface, as well as some vertical sections. It was shown that the relatively large amount of zinc enters in the Ca-containing phase, which formula can be described as (Al,Zn)4Ca. An increase of Zn content leads to formation of Al4Ca primary crystals at lower concentrations of calcium. The eutectic (Al)+(Al,Zn)4Ca has a fine structure and aluminide particles are capable to spheroidization during the heat treatment at temperature 500 C. The maximal level of hardness observed on calcium containing alloys was higher than 200 HV, what gives the reason to expect good strength properties. With an example of an Al-9% Zn-2,5%Mg-3,5% Ca model experimental alloy based on the (Al)+(Al,Zn)4Ca eutectic, a principal possibility of manufacturing thin rolled sheets was demonstrated.INTRODUCTION Aluminum alloyed with calcium was first studied in 1970-80s by such authors as Piatti (1976), Moore (1978, 1980), Il'enko (1985), Swaminathan (1990), and Perez-Prado (1997) as superplastic materials. In particular, the alloy systems Al-Ca-Zn were studied (Il'enko, 1985, Swaminathan, 1990, Perez-Prado, 1997). For some time there was no new published works concerning the aluminum-calcium alloys. During the last years many works were published dedicated to the calcium alloying of magnesium alloys (Kim, 2011; Xu, 2011; Aljarrah, 2008; Bakhsheshi, 2014). This urged the authors (Belov, Naumova & Akopyan, 2016) to start studying cast and wrought aluminum-calcium alloys for construction (2008–2014). There is almost no information in the literature concerning triple and more complex diagrams of the aluminum-based system states with calcium and other elements. In recent work, parts of the state diagrams are plotted for the aluminum angle zone: Al-Ca-Mg-Sc (Belov, Naumova & Bazlova, 2016), Al-Ca-Ni-Sc (Belov, Naumova & Bazlova, 2017), Al-Ca-Si-Sc (Belov, Naumova & Akopyan, 2017) and others. Special attention was paid to the study of the system Al-Ca-Zn-Mg (Naumova, 2017). Based on this system creation of advanced extra-high tensile alloys is planned. Wrought extra-high tensile alloys series 7??? based on the system Al-Zn-Mg-Cu are well studied."

Jan 1, 2018

By Edmund H. Warner

Any city dweller who has walked alone along a remote mine passageway has to be impressed by the eerie silence - the total absence of noise except for ones own breathing and scuffing of boots on the bottom. An underground mine can have tremendous contrasts, from complete silence to the ear piercing clatter of percussion drills working on the mine roof. Noise in underground mining machines is both useful and detrimental. Without characteristic noises that are recognizable to miners, operators would have a more difficult job operating their machines. Noise serves as a warning of approaching machinery, and changes in noise give indication that breakdowns may occur. But excessive noise is a health hazard. In recognition of this fact, our Congress included noise exposure as a part of the "Coal Mine Health and Safety Act of 1969". As Fig. 1 indicates, allowable noise exposure is established by specifying a time duration permitted at different noise levels. This is the well known "Walsh-Healey" criteria which governs noise exposure in many industries.

Jan 1, 1977

By S. Z. El-Tawil, K. A. El-Barawy, M. B. Morsi, M. M. Nasr, Z. I. Zaki

"Tue sulphatization of zinc concentrate produced from heated zinc concentrate of Um Ghieg area, eastern desert by ammonium sulphate as sulphatizing agent is carried out at different conditions to achieve the appreciable formation of soluble sulphates. The maximum zinc recovery as soluble sulphate equfils to 95% upon using 1.5 stoichiometry ammonium sulphate at 600 °C for one hour. Tue obtained leached zinc sulphate solution is subjected· to purification process to prepare high pure zinc metal and zmc compounds such as pure zinc sulphate, zinc caibonate and zinc oxide. The products obtained are analyzed chemically and identified by X-ray analysisTue mechanism and kinetics of the sulphatization process of zinc concentrate are considered where the activation energy is calculated and equals to 33.3 K.J.mol""1 A process flowsheet for the overall sulphatization process of zinc concentrate by ammonium sulphate is proposed.IntroductionConsiderable reserves of zinc ores are present in Um Ghieg area eastern desert, Egypt. The possibility of extraction zinc from these ores and preparing its valuable compounds by choosing a more feasible technology become of vital importance. An attention is focused on the sulphatizing roasting processes (1-9) to achieve the appreciable formation of soluble sulphates. Previous publications are reported in our division by El. Tawil and others (10-16) using ammonium sulphate as sulphatizing agent for the successful treatment of nonferrous bearing materials.Therefore, the present work aims to study the different factors affecting the sulphatizing roasting process of local zinc coocentrate by anunonium sulphate to extract completely zinc and preparing its main compounds. Tue mechanism and kinetics of the different chemical reactloos that 1ake place in the process are considered."

Jan 1, 2000