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By Robert R. Brookshire

Brush plating has been thought of by many as black magic bordering on alchemy. Actually it is a science that uses both electro-chemical and mechanical engineering skills and technology. We are not sure when brush plating was first used or by whom. I do know that many times when we would put in for patents on things we thought of as new and innovative, we would find that someone had done it many years before. It took World War I1 to get brush plating off and running. Now at this point, someone may be asking just what is brush plating? And why are we plating brushes? One way of describing what brush plating is, is by telling what it is not such as tankless plating. Brush plating-is an electro deposition of an electro-platable element or alloy onto a conductive surface. To do this a source of direct current is required; this can vary widely. I prefer stepless voltage control from 0-35 volts with a capacity depending on the size job to be done. This can vary up to 500 amps for normal applications. In one case we have used 7500 amps.. In the beginning a brush was actually used with a wire in the middle of the bristles and a jelly-like paste made up from tank plating solutions. The bristles were saturated with the gunk and the spot to be plated was muddled with the concoction at a potential which was the same as the applied tank Voltage. Metal was deposited but only thin coats were achieved. Today we use graphite wrapped or covered with cotton to form a Q-tip type anode. By using graphite rather than a specific metal we are able to either plate, de-plate or strip, electro- mill, electropolish, or anodize--all with the same equipment. Only the electrolyte needs to be changed.

Jan 1, 1984

By Robert L. Lagace

A prototype adaptive volume control for the loudspeaker output of mine trolley carrier phones was designed, built, and tested in the laboratory and in a mine. This volume control senses, and adapts to, the ambient acoustic noise environment in such a way as to produce a loud sound output under noisy conditions, and a quieter output under quiet conditions, thereby producing an understandable and unstartling volume level under all noise conditions. The design approach, prototype hardware, and test results are described, and the device is shown to be feasible for in-mine operations. The circuit design principles are easily applicable to currently available mina trolley carrier phones. Recommendations for practical improvements are included. An in-mine experiment to assess the practical feasibility and utility of the dedicated wire technique for overcoming poor trolley carrier phone system performance was designed, performed, and evaluated. The technique involves the use of a single, low-loss, properly terminated auxiliary wire, placed in the rail haulageway, which allows signals to naturally couple to and from the trolley wire/rail transmission line, and thereby significantly decrease the overall signal attenuation rate on the trolley wire/rail line. The in-mine dedicated wire experiment, results, and conclusions are described, and the technique is shown to be a valid and practical one for significantly Improving carrier phone system performance in mines. Guidelines for the installation and use of the dedicated wire are provided. Recommendations are made for obtaining further practical information on its performance and utility. A second in-mine experiment to assess the feasibility and utility of the low-impedance (low-Z) line technique for overcoming poor carrier phone signal transmission in mines was designed, performed and evaluated. The low-Z line technique involves the periodic connection of shunt capacitors between the trolley wire and the rail to artificially lower the line characteristic impedance. This causes the low impedance shunt loads encountered across the trolley wire/rail line to be less mismatched to the line, thereby reducing the overall attenuation of carrier phone signals. The results of in-mine experiments performed along unenergized and fully operational sections of trolley wire/rail line are described. The experiments were designed to measure line parameter such as inductance and capacitance per unit length, characteristic impedance, and propagation phase velocity, in addition to signal strength versus distance behavior under normal and low-Z line conditions. The low-Z line technique is shown to be valid, but not as practical as the dedicated wire technique which is recommended as the most favorable for most coal mine applications.

Jan 1, 1979

By C. Sawmliana

Deep-hole blasting operations in opencast mines are always associated with some annoyance to the surrounding areas in terms of ground vibration, noise, flyrock, etc. These become more severe when underground mines run parallel to them. Blasting in opencast mines may pose danger to the underground mines in terms of roof/side failures, damage of water dams, isolation/ventilation stoppings and other underground installations. The paper discusses a case study in India on the impact of deep-hole blasting in Ramagundam Opencast Project ? III on the stability of various water dams of GDK-6B Incline coal mine operating in close proximity. The stability of underground water dams of GDK-6B Incline mine was endangered due to deep-hole blasting at OCP-III. There were 15 water dams in seam 3 and 16 dams in seam 4 of the underground mine. The physical strength tests using a Schmidt Hammer instrument were carried out in all the 15 water dams of No. 3 seam and 16 water dams of No. 4 seam. The test revealed that there is a decrease in compressive strength values of three dams of seam 3, namely 6A, 6B and 7. Theose three dams were also directly connected to the water source. Water seepage was also observed from the surfaces of the three dams. However, they were found to be stable in accordance with their design parameters and damage point of view while considering a threshold value of ground vibration as 25 mm/s. It was found that the value of tensile stress generated by a vibration of 25 mm/s was much lower (i.e. 0.171N/mm2) than the tensile strength of the two weakest concrete dams (1.85 N/mm2). Ten experimental blasts were conducted at different working benches of the opencast mine and the ground vibration data were recorded in roof and pillars near various underground water dams. The maximum value of vibration data recorded was 5.9 mm/s in roof near dam no. 1 in seam 3 with the dominant peak frequency of 22 Hz. No adverse effect on either of the dams was observed after that blast. During the period of study, no deterioration/adverse impact was found in any dam of the mine. Based on the results of the study and the analyses of the data, optimized blast design parameters and explosives weight per delay were suggested for the opencast mine to maintain the safety of the underground water dams. Keywords: Opencast blasting, damage, water dams, underground mine, ground vibration

Jan 1, 2009

By Met B. E

The increasing pace of modern mining makes constantly greater demands upon the several contributing departments of rock breaking and transport, and rock-drilling, as the spearhead of attack, has received a great deal of attention with respect to both machines and steels. By a series of mechanical improvements, combined with the application of selected heat-treated alloy steels, the rock-drill has now been developed into a machine capable of rapid drilling and long service under severe working conditions. As a factoryproduct made under strict metallurgical control it is as foolproof as, say, the modern automobile, and, like its prototype, it can be kept in efficient operation by a minor amount of attention during use and by periodical adjustments and replacements.The same cannot be said, unfortunately, of the drills with which the machine is supplied; in conventional mine-shop practice these are made of the best tool steel shaped and heat-treated under the poorest of metallurgical conditions.The crudities of steel-shop practice have, in fact, always prevented the full exploitation of the steels available at any time, and even at the present day the general standard of treatment offers a contrast with the quality of the steels which moves the metallurgist to amusement, despondency or outrage, according to his temperament. Nevertheless, the tendency persists to meet the increasing demands of the rock-drill primarily by the use of still better steels, and secondarily by improvement, of the steel-shop practice. Athird type of development is the introduction of factorymade tools in the form of detachable bits and rods. It is proposed in this paper to deal with these three aspects of the recent developments in rock-drilling.*Re-written from a lecturette given during the First Ordinary Meeting, 1936.

Jan 1, 1936

A large-diameter road tunnel will cross beneath the strait in Istanbul and expand the infrastructure bottleneck between Europe and Asia. The technical planning of the tunneling operations poses complex challenges. Therefore, the construction consortium ordered a specially adapted tunnel boring machine (TBM) from Herrenknecht. The 13.6-m (44.6-ft) machine, a Mixshield, was completed in early July 2013 in Schwanau, Germany. To get from the European to the Asian side of Istanbul, people and goods have to cross the Bosporus Straits. So far, two road bridges as well as ferries provide the only transport link between the two parts of the city and the two continents. The tense traffic situation for the nearly 14 million residents of the city and for international transit traffic should be improved considerably thanks to the construction of a new road tunnel under the Bosporus. ?The project is certainly one of the most challenging tunneling operations currently being addressed in the world,? said Herrenknecht project manager Georg Schleer. The route of the ?Istanbul Strait Road Tube Crossing Project? runs around 100 m (330 ft) below sea level at its deepest point. The interior diameter of the tunnel will be 12 m (40 ft) so that two lanes in each direction can be accommodated. They will extend one above the other on two levels. 3.34 km (2.1 miles) of the tunnel with a total length of 5.4 km (3.3 miles) are being created by a 13.6-m- (44.6-ft-) diameter Herrenknecht TBM that will begin its underground mission from a launch shaft on the Asian side.

Sep 1, 2013

By Donald P. Ziegler, James F. Klausner, Srinivas S. Garimella

"By 2015, nearly half the world's population will live in ""water stressed"" areas. Production of fresh water utilizing waste heat from industrial processes has been identified globally as a research priority.About 15% of the electricity required to produce aluminum is lost as waste heat in the off-gas. However, the low temperature (low grade) of the heat limits reuse. The off-gases contain 50-150 ppm SO2 ; tightening regulations coupled with increasing coke sulfur levels are motivating SO2 control, for which seawater scrubbing is attractive for smelters with suitable access.We describe a process that produces fresh water, utilizing the waste heat while scrubbing SO2 . It uses direct contact between seawater and off-gas to humidify the off-gas. The vapor is subsequently condensed. In smelter trials, a unit treating a slip stream produced high quality water in the anticipated quantity, attaining over 95% SO2 scrubbing. Future work involves scaling the process to be economically attractive.BackgroundPopulation growth, coupled with industrialization and urbanization, are increasing demand for water. Water scarcity already affects every continent. Around 1.2 billion people, or almost one-fifth of the world's population, live in areas of water scarcity, and 500 million people are approaching this situation. By 2025, 1.8 billion people will be living in countries or regions with absolute water scarcity, and two-thirds of the world's population could be living under water stressed conditions (< 1,700 m3 per person annually) [1]. An assessment by the U.S. General Accounting Office revealed that under normal conditions, by 2013, water managers in 36 states in the USA anticipate water shortages, and that the number might grow to 46 states under drought conditions [2].The obvious choice to alleviate water scarcity is the 97% of available water in the oceans, which is saline and requires desalination for use in biological, agricultural and industrial applications. Technologies developed for desalination include Thermal Distillation, Reverse Osmosis (RO), Electro-Dialysis, and Vacuum Freezing. Distillation and RO are the most commercially prominent. Thermal distillation technologies include Multiple Effect Distillation (MED) and Multi-Stage Flashing (MSF). The report commissioned by the World Bank [3] is one of the many excellent references on desalination technologies. According to the International Desalination Association working paper [4], there were more than 17,348 industrial scale desalination plants installed or contracted by 2004. The total production from these plants is on the order of 8.3 billion imperial gallons per day. RO provides 47.2% of the total capacity. The leading thermal process, MSF, provides 36.5% of the total capacity. Although MSF and RO technologies currently provide the most cost effective means for desalination, their drawback is that they are very energy intensive, and whether or not they remain cost effective strongly depends on energy prices and energy supply."

Jan 1, 2012

The purpose of this paper is to outline some aspects of the experimental worlr that has been carried out in the mineral dressing laboratory at M&apos;ount. Morgan during recent years.The subject matter has been dealt with under the following headings:1. Comminution of various mill products.2. The application of sulphur dioxide as a flotation reagent.3. Heavy-media separation.4. Bulk flotation of sulphide ores.COMMINUTION OF VARIOUS MILL PRODUCTSThe following data were cbtained by processing fractions of reserve grade ore.Granular TailingIn Table 1 are shown the results of tests on material representative of average grade tailing. In the first test (H1 ) the granular tailing was floated as received and in the second test (Ha) the tailing was ground prior to flotation.

Jan 1, 1952

By G. S. Rice

The Experimental Mine of the United States Bureau of Mines is a unique coal mine that serves as a large-scale testing laboratory. It is used primarily for testing the explosibility of coal-dust and gases but is also the workshop for many other kinds of research work of which the chief object is to increase safety in mining. The mine is situated in Allegheny County, Pa., about 13 miles southwest of Pittsburgh among the high hills of the west bank of the Monongahela River, at the northeastern edge of the gas-coal district of the Pittsburgh coal bed which extends south through the Connellsville coking-coal district into West Virginia. The Pittsburgh bed, of the Upper Carboniferous age, is one of the most extensive continuous coal beds in the United States, if not in the world. Throughout large areas it shows remarkable uniformity of thickness, levelness, and character of coal, which is a coking coal of high-grade bituminous rank. Its thickness in the northern part is 5 to 5 ½ feet and in the central and southern part is 7 to 9 feet.

Jan 1, 1933

By Floyd C. Bossard

In underground mining operations, the over- riding issue has to be protection of worker health and safety. The employees underground, making a living in a dangerous occupation, know these are major issues. These men bargain their lives and health on the presumption that the operating management knows its business, and they, the underground employees, can pursue their occupation with the assurance that management has provided a safe and healthy ambient underground environment. When management assumes the mantle of protection of underground workers, it has to be positive that qualified engineers have designed the project, and that capable operating personnel are in charge and always available. Those persons with these responsibilities must be knowledgeable in the engineering and occupational health aspects of sine ventilation. The ultimate function of a mine ventilation system is to provide a comfortable, healthy and safe ambient environment for the underground workers. The attainment of these objectives has been complicated with the increased application of electrical equipment and diesel-powered mechanized mining equipment underground (discharging toxic diesel emissions); increased production rates with the attendant increased production of airborne dust; and mine development in increasingly hostile mineral formations containing combustible strata gases, radon gas emissions, along with high heat and humidity. In general, the modern mechanization of present mining operations has resulted in a sore complex set of problems for the engineer planning the underground ambient environment.

Jan 1, 1983

By Paul C. Turner

In 1998, approximately 57,000 tons of titanium metal was consumed in the form of mill products (1). Only about 5% of the 4 million tons of titanium minerals consumed each year is used to produce titanium metal, with the remainder primarily used to produce titanium dioxide pigment. Titanium metal production is primarily based on the direct chlorination of rutile to produce titanium tetrachloride, which is then reduced to metal using the Kroll magnesium reduction process. The use of titanium is tied to its high strength-to-weight ratio and corrosion resistance. Aerospace is the largest application for titanium, and titanium cost has prevented its use in non-aerospace applications including the automotive and heavy vehicle industries.

Jan 1, 2001

By Peter F. Weiss, H. Riedler, I. M. Moschitz, A. Olsacher, G. B. Fettweis

CONTENTS : 1. NATURAL FACTORS Geology Petrography and Rock Mechanics Mining System Orientation Rock Bolting System Movability of the Ore Grain Size Distribution Permeability Contamination Value of the Ore Hydrology 2. TECHNICAL FACTORS Height Length and Width Drawing Areas Time Factor Water Predrainage Surf ace Draining Underground Draining Advancing Slitting Sequence of Development Initiation of the Caving Process Drawing Rate 3. SPECIFIC MINING RULES Advancing Development Drawing Rate Interruption of Drawing (Water Distribution, Concentration of Mud, Dilution) Blasting 4. CONTROLS Safety Controls for Operation Computerised Drawing Control Structure of the Computer Program Hard Ware Print Outs 5. SUMMARY 6. ACKNOWLEDGEMENTS 7. REFERENCES Under the heading "Development System for Block Caving under Severe Conditions" a report was presented to this congress regarding a magnesite mine using block caving for several years. On account of the experience gathered in this mine and the results of far reaching exchange of experience, as well as under due consideration of the international literature it is tried to systematically list and briefly discuss the following factors that have to be considered for development and draw control of block caving. 1. NATURAL FACTORS It is self evident that this implies all those circumstances given by nature and which cannot be altered by man. Any mining activity is subjected to those and the success is depending on how far technology can be adjusted to those conditions. Geology Deposits of considerable thickness with rather steeply inclined flat-faced contacts are optimal for block caving. While vertically there is practically no limitation- for the deposit, theoretically, the smallest horizontal basis apt for operating block caving is the minimum area necessary to get the rock to completely cave in by undercutting and drawing. Practically, only consider- ably bigger main dimensions are found, mainly because of technical factors (machinery and equipment) and economic factors (cost ratio of exploration vs. development, danger of contamination).

Jan 1, 1981

By P. D. White, J. T. Moss, J. S. McNiel

Results of experimental work on the in situ combustion process were first published in this country in 1953&apos; when Kuhn and Koch described results of a three-well test in Jefferson County, Okla. Shortly there-after Grant and Szasz2 described field studies in Nowata County, Okla., in which several modifications of the basic combustion process were investigated by injection of various oxidizing gas mixtures other than air. In the past five years speculation concerning this method of oil recovery has continued, with a number of interesting papers on various aspects of in situ combustion appearing in the literature3,4,5,6,7. However, only one of these&apos; provided actual engineering information on pattern-type field experiments. The primary objectives of the Oklahoma three-well test were to check operation of specially designed electrical ignition equipment and evaluate problems associated with initiation of combustion in a natural oil sand reservoir. Immediately following successful completion of this test in the Pontotoc sand, plans were activated for a second field experiment to be conducted in the same sand a short distance away. The objective of this second field test1 as to establish a relationship between field observations and information derived from laboratory experimentation and computations. Secondary objectives of the test were to develop operating tech- niques and define operating problems, and to obtain information that would assist in the economic and engineering appraisals of the process. Careful planning was required since this test was designed with the hope of providing basic information on the characteristics and operation of a combustion drive. It was necessary to include test facilities which would not only permit precise control and measurement of the process variables but would also provide sufficient flexibility of control to insure that variables in the combustion process could be studied during the course of the test under a wide range of conditions. In order to accomplish these objectives elaborate instrumentation and several control wells were included in the design of the test installation. This type installation was felt to be well suited for an experimental study, but was in no respect intended as a counterpart of a commercial-scale operation. PRELIMINARY LABORATORY WORK An important objective of the field experiment, as stated previously, has been to obtain reliable data on operating variables which might be compared with similar data obtained in laboratory combustion tests. The value of successful correlations between quantities that can be measured in the laboratory and those obtained in a full-scale commercial venture has been well established for other industrial processes. The difficulty of following a process underground should make such correlations even more essential here. Also. approaching the field test phase of development of in situ combustion, it was considered desirable to precede design of test equipment with laboratory combustion studies under a variety of conditions to establish likely ranges of variables. These included temperature, air injection rate, frontal advance rate and produced gas composition.

By Daniel G. DiCanio

This report describes a computer-based model for estimating the tangible costs of injuries and deaths from work-related accidents in underground coal mines. The study undertook to identify and quantify the elements of accident costs, including field visits to coal mines, insurance carriers, and public agencies. The mathematical models developed for each tangible element of accident cost are presented in Volume I of the report. A listing of the computer programs which comprise the model and instructions for using the programs are presented in Volume II. Statistical distributions of mining family characteristics, data on 95 miners killed in underground accidents, and other basic data used to develop the model are presented in Volume III. Application of the model to a data base of 9,286 accidents which occured in underground bituminous coal mines during 1974 yielded a total of $56,900,000 in tangible costs to industry, mining families, and public agencies. Loss of income to the families of miners injured or killed in these accidents accounted for 47 percent of the total.

Jan 1, 1976

By José de Camargo

Em janeiro de 2016 a Russula foi contratada pela Dojran Steel (Sidenor) para a reformulação de sua planta de Nikolic / Macedônia. O fornecimento incluiu um novo laminador de barras e perfis com capacidade para atingir 350.000 toneladas por ano, composto de equipamento mecânico, sistema de automação, bem como todo o suporte técnico necessário para a Dojran Steel expandir sua antiga gama de produtos e melhorar sua qualidade de produto acabado. Ao final da reformulação, executada em várias fases, o novo laminador adquiriu capacidade para produzir toda gama de produtos desejada: - Redondos de 8 a 40 mm, - Barras chatas de 16 x 4 a 140 x 20mm, - Quadrados de 8 a 40 mm, - Cantoneiras de abas iguais de 20 x 20 x 2,5 a 120 x 120 x 12mm,- Cantoneiras de abas desiguais de 30 x 20 x 3 a 120 x 80 x 10,- Perfil U (UPN) com altura de 30 a 140 mm,- Perfil I (IPE) de 80 a 120 mm e - Perfil T de 20 a 50 mm.

Oct 30, 2017

By S. Viswanathan, A. S. Sabau

"Dimensional changes between a pattern die and its corresponding investment casting part occur as a result of complex phenomena such as thermal expansion/contraction and hot deformation (elastic, plastic, and creep) during the processing of the pattern material (wax), mold material (shell) and solidifying alloy. Determining the pattern tooling dimensions is crucial to the dimensional control of the investment casting process. To date, computational methodologies have not been applied to the prediction of dimensional changes in investment castings.This paper deals with the evaluation of wax pattern dimensions, which is one important factor in determining pattern tooling dimensions in investment casting. Cerita 29-51, an industrial wax, is considered in this study. The wax pattern dimensions are determined by considering its thermo physical and thermomechanical properties, restraint of geometrical features by the metal die, and process parameters such as dwell time, platen temperature, injection pressure, and injection temperature.IntroductionThe investment casting process involves making a disposable wax pattern by injecting wax into a metal mold, building a ceramic shell mold around the wax pattern by the application of a series of ceramic coatings to the wax pattern, dewaxing the ceramic shell mold, and casting the alloy into the shell mold. Dimensional changes between the pattern tooling and its corresponding cast part occur as a result of thermal expansion, shrinkage, hot deformation, and creep of the pattern .material (wax), mold material (shell), and solidifying alloy during the processing [1]."

Jan 1, 2001

By John P. Turner, Benjamin J. Turner

"Non-destructive testing and evaluation (NDT/NDE) methods have become standard tools as part of the post-construction quality assurance of drilled shaft foundations. In responding to anomalies, foundation designers, owners, and contractors face a number of choices, including: (i) acceptance of a shaft with known anomalies, (ii) further investigations of integrity (e.g., concrete coring), (iii) repair schemes, and (iv) reject and replace. To assist in selecting the best option, analyses are often performed that involve assessing the structural performance of reinforced concrete shafts that may include defective concrete or voids. Currently, the analytical tools for predicting the flexural strength and stiffness of drilled shafts with defective concrete located in discrete regions of the cross section are limited. This paper presents a robust moment-curvature analysis tool for drilled shafts based on the fiber-element discretization method. The tool allows for consideration of anomalous or defective concrete regions in the shape and location that they are believed to exist in the shaft while considering explicitly the nonlinear material behavior of the intact regions based on expected material properties. A case study is used to illustrate the practical application of the analysis to drilled shaft projects.INTRODUCTIONImperfections such as defective concrete or accidental eccentricity of reinforcing cages are an inherent part of the drilled shaft construction process that will occur occasionally even when construction best-practices are followed. Petek et al. (2002), O’Neill and Sarhan (2004), Poulos (2005), and others have described the effects that construction defects can have on the axial and lateral performance of drilled shafts. Our industry has seen rapid progress in recent years in the development and improvement of tools for detecting drilled shaft anomalies, such as gamma-gamma and crosshole-sonic logging, sonic-echo testing, thermal integrity profiling, and even visual inspection with invasive video cameras. Nonetheless, in most cases the wealth of data from these tests is used by foundation engineers to make a fairly “black or white” decision—should the defects be repaired, or should the shaft be rejected? A third option that is not typically considered is to directly analyze the section, including anomalies, and compare the reduced strength and/or ductility to the actual project demands. This option takes full advantage of the data collected during integrity testing, and may provide a justifiable means for avoiding further construction costs and delays, whether for repair or replacement."

Jan 1, 2016

By D. Michael Holloway

The California Department of Transportation (CALTRANS) evaluated several pile foundation schemes for supporting the structures along the realignment of Interstate 880. The project replaces the double-decked (Cypress) viaduct collapsed in Oakland, California during the 1989 Loma Prieta Earthquake. Structural support demands led to the selection of steel pipe piles (16-, 24-, and 42-inch-(406-, 610- and 1067-mm-)diameter), filled with concrete and steel reinforcement. Deep penetrations required through layers of very dense/cemented sands in some locations, caused serious drivability and pile integrity concerns. The need for large pile driving hammers and large diameter steel pipe piles pushed the engineers well beyond local experience. Such questions as the feasibility of driving the pipes closed-ended through dense upper strata and quantifying the effects of installation on the long-term capacities of the piles led Caltrans to develop a comprehensive pile test program to address the design and construction issues effectively. The results were furnished to prospective bidders on the production stages of the ensuing contracts.

Jan 1, 1995

The use of comparative sampling methods during the evaluation of the tin-copper deposits at Cleveland mine yielded closely checking average results from groove, channel, AXT split diamond drill core, and bulk sampling for both tin and copper content of the ore.The weighted mean tin and copper grades and values for the groove, channel, and split core samples showed small percentage differences from bulk sample results, and the F-ratio test for single population origin of the four types of samples was accepted at the 99&#183; 5 per cent level of confidence.These results indicate that grade estimates based on the assays from AXT split diamond drill core and/or groove samples would be reliable within practical limits.

Jan 1, 1968

By H. C. Voges

The concentration of cassiterite at Iscor&apos;s Uis Mine is described, and information is given on aspects of the concentration of iron ore at Thabazimbi and Sishen Mines. At Uis, a very Iow-grade tin ore is concentrated by three-stage jigging, spiral concentration, and tabling to give a high-grade concentrate with a recovery of 80 per cent of the tin. A Iow-grade tantalite-columbite concentrate is also produced. The possibility of recovering mica, the use of sluice boxes instead of spirals, and the recovery of cassiterite from minus 45 µm material are being investigated. At the two iron-ore mines, heavy-medium separation is applied to size fractions larger than 0,5 mm. The types of ferrosilicon and the circuits used for the recovery of ferrosilicon from the various dilute-medium circuits are described. The spiral-concentration plant being installed at Thabazimbi for the treatment of the minus 0,5 mm portion of the ore is described.

Jan 1, 1982

By H. H. Wade, N. F. Schulz

The large quantities of iron-bearing materials, including taconite, semi-taconite,* and other low-grade ferruginous materials occurring in Minnesota and elsewhere, constitute an important potential source of iron. Satisfactory grade and recovery of iron ore concentrate cannot ordinarily be obtained from these ferruginous materials by simple methods of beneficiation. Iron is distinctive in that the free metal and two of its oxides [magnetite (Fe2O3) and maghemite (gamma-Fe2O3) ] are strongly ferromagnetic. The successful magnetic separation of natural magnetite from taconite has already been established on a commercial scale. The iron in semi-taconite, however, occurs largely as goethite (Fe2O3-H4O) and hematite (Fe2O3) which do not respond to ordinary magnetic separation methods. Magnetic roasting converts these iron oxides to magnetite, which can, after liberation, be magnetically concentrated. MAGNETIC ROASTING Hematite undergoes a stepwise reduction when exposed at moderately elevated temperatures to a reducing atmosphere containing hydrogen or carbon monoxide: Fe2O3? Fe3O4 ? FeO ? Fe Since the desirable product in magnetic roasting is Fe3O4, the conversion is halted after the first stage by controlling the reduction potential of the gas mixture with water vapor or carbon dioxide. The reducing gas mixture must be such that the oxygen partial pressure at the solid-gas reaction interface will be maintained intermediately between the oxygen partial pressures in equilibrium with Fe2O3 and Fe3O4 at the prevailing temperature. Because of the rapid increase in decomposition pressure of Fe3O4 with increase in temperature, the practical upper limit of useful reaction temperature is about 1400°F, above which over-reduction usually occurs in atmospheres containing hydrogen or carbon monoxide. On the other hand, useful reaction rates usually occur only above 800°F. Goethite reacts similarly except that the combined water probably has to be driven off thermally before the reduction to magnetite occurs. Iron carbonate must also be decomposed thermally to an oxide before conversion to magnetite. Iron silicates are apparently not amenable to magnetic roasting. The rate of penetration of the reaction toward the interior of a given ore fragment is dependent on the chemical composition and physical structure of the solid. Most ore fragments tested here reduced satisfactorily to 1/4-in. depth in less than 14 min at 1200°F. Some very dense fragments, however, were reduced to less than 1/32-in. depth under the same conditions. Determination of the optimum temperature, gas composition, ore fragment size, or time of exposure

Jan 1, 1961