Search Documents

By Anne Caroline Costacurta Polli, Jose Rojas Cáceres, Roberto Mahler de Morais, Thais Costa Silva

The technology and the knowledge about the behavior of explosives and detonation accessories allowed to create new products for different situations by the restrictions imposed by the market. In a Brazilian underground copper mine the restriction occurred in the use of high grammage Det Cord in the development heading blasts perimeter holes. Enaex Brazil has developed Densiex UG™ (Low-Density Bulk Emulsion), a water-resistant bulk gassing emulsion with a density ranging from 0.60 to 0.90 g/cm³ to replace the high grammage Det Cord in blasts. That product is pumped in the same Mobile Manufacturing Unit (MMU) as Enaex Brazil's standard underground (UG) bulk emulsion. This product has a Lower Velocity of Detonation (VOD), vibration, and detonation pressure, which contributes to a better finishing of the drift, lower impact in the support structures, and lower generation on unstable rocks in the perimeter of the drift. This case aims to summarize the results of the work on the application of the Low-Density Bulk Emulsion in perimeter holes in an underground development gallery at an underground copper mine in Brazil. During this work, 10 horizontal drift blasts were performed using the Low-Density Bulk Emulsion, which presented an average density of 0.64 g/cm³, increasing safety, a 25% reduction in overbreak, a 23% reduction in scaling time, elimination of rework, and a saving of $135,000 per year for this business partner that immediately implemented this new product in all blasts at this mine.

Jan 21, 2025

The basic make-up of the majority of currently produced bulk explosives has changed little in the last 20 years. These explosives would be described as mature in a life cycle analysis. Therefore these explosive products and the practical rules for their use are well understood and well established. In recent years there has been interest in low density explosives, predominantly due to ammonium nitrate shortages and the associated increase in the cost of explosives. In the use of low density explosives some of the practical rules for the more commonly used bulk explosives do not apply. Therefore a shift in the thinking among users is required. At a number of mines low density explosives have been trialled or are being used, utilising the practical rules that apply to bulk explosive products. This has led to poor blast results in many situations. These poor blast results have often then led to a reduction in the use of low density explosives at the mine. This reduction does not acknowledge the advantages that can be gained from this product in the area of reduced cost of mining. This paper looks at low density explosives and discusses how and why these products work. Included in the paper are some practical ideas and examples of how low density explosives can be effectively used at the mine site.

Jan 1, 2007

By H. Aaltonen, T. G. Robinson, M. Morimitsu

"The energy required to plate pure zinc can be the most significant operating cost for an operator in the production of electrolytic zinc. This paper reports on developments on low energy Outotec coated titanium anode process technology with fully amorphous coatings, MSA®, and its application to brownfield zinc electrowinning operations around the world. This technology aims to reduce the operating cost and increase productivity for zinc producers.INTRODUCTIONZinc electrowinning is an energy-intensive process using more than 3,000 kWh/t of electric energy [1-4], and the reduction of the energy consumption is one of the key issues. The high energy consumption is due to a high cell voltage during electrolysis, which is mainly caused by a high overpotential of oxygen evolution reaction on lead alloy anodes which have been widely used in commercial zinc electrowinning processes. The overpotential of oxygen evolution is 0.6 V or more and which is approximately 4 times higher on average than that of the cathodic reaction (zinc deposition) [3,4]. Therefore, the reduction of oxygen overpotential is significant to reduce the electric energy consumption, and this will become more significant with increasing demand in metal production and rising energy costs.Oxide coated titanium anodes have been widely investigated for the oxygen evolution anodes in order to replace the lead alloy anodes [5-9], because it is known that the oxygen overpotential strongly depends on the material and structure of the anode. The most typical example of such anodes is an IrO2-Ta2O5 coated titanium anode, which is usually prepared at thermal decomposition of a precursor solution containing metal salts at 450 oC or more and obtained mixed oxide coating consists of crystalline IrO2 and amorphous Ta2O5. On the other hand, one of the authors of this paper, Professor Morimitsu, Doshisha University in Japan, has developed a novel oxide coated titanium anode, MSA® [10-25]. The most specialized point of MSA® is that the catalytic coatings are prepared at low thermal decomposition temperature and amorphous IrO2 or RuO2 is contained as the components in the coatings. Such amorphous coatings have high catalytic activity for oxygen evolution compared to lead alloy or crystalline coatings. Outotec acquired the international specialized MSA® patent licensing rights from Doshisha University and has produced and commercialized the amorphous oxide coated titanium anodes. These anodes have already been utilized mainly in copper electrowinning plants worldwide and have demonstrated a significant voltage reduction, a cost-efficiency, and a long lifetime. This novel technology is also effective to zinc electrowinning process, thus this paper presents the characterization and performance of amorphous IrO2-Ta2O5 coated titanium anodes and amorphous RuO2-Ta2O5 coated titanium anodes for oxygen evolution in zinc electrowinning."

Jan 1, 2016

Physical and chemical properties of the salt flux phase play a significant role in the recycling of UBC in Aluminum melting processes. Particularly knowledge of several properties such as salt vapor pressure, melting temperature, loss of aluminum, corrosion of refractories are useful for the process control decisions in order to attain a good quality of aluminum produced. A literature review and analysis of several salt flux systems for the selection of a flux for the Aluminum melter (low temperature natural gas bath melting) process were made. Based on these analysis two salt flux systems are recommended for further studies. These are NaCl?KCl?LiF system and NaF?LiF?KCl system with small amounts of other salt additives. Application of these fluxes to Al industrial processes are discussed.

Jan 1, 1996

By Takefumi Takuma, Hiroyuki Nishimura, Shigeru Kambe

"In order to achieve tubular pile driving with low noise and low vibration, the Press-in Piling Method has been adopted on many projects. The method utilizes reaction force derived primarily from previously driven piles to push in the next pile into ground. With attachments, the Press-in piling equipment can deal with hard soil as well as difficult site conditions. At West Toronto Diamond Rail Grade Separation Project in Toronto, Canada, the Press-in piling equipment drove more than 500 of 914 mm (36 inches) diameter tube piles in length of 12 to 25 meters (39 to 82 feet) to construct earth-retaining walls for railway grade separation. Myoshoji River Restoration Project in Tokyo, Japan drove some 600 of 1,000mm (39.4 inches) diameter tube pipe sections in length of 11 to 22 meters (36 to 72 feet) by the rotary Press-in piling equipment to increase the flood drainage capacity of an existing river in highly populated area of the city. Both projects exemplify the advantages of the method in urban settings.1. BACKGROUNDThe Press-in Piling Method was invented some forty years ago in Japan, where a very large number of construction projects were causing widespread construction pollution, especially by pile driving work in densely populated areas. The method has been providing solutions for piling projects which could not have been built otherwise due to the noise and vibration impact to the surrounding communities. The method can be used with various types of piles including sheet piles, tubular piles, concrete sheet piles and so on. With high pressure water jet and continuous flight auger attachments, the Press-in piling equipment can deal with dense sand, stiff clay, gravels, boulders and even soft rock without employing a different set of equipment."

Jan 1, 2015

By R. F. Favreau, Patrice Favreau

In many quarries and construction sites visited by the authors over the last 50 years, the latter have observed muck piles from blasting with explosives, which included numerous large blocks, in some cases of dimensions larger than the input to the crusher. The names of these sites cannot be given in the article because the owners insist that data obtained on such visits be kept confidential. Often the blasters felt that the natural fissures in the rock would compensate for the use of a low powder factor, and they asked the authors to explain why such blocks were present. A detailed analysis of the situation often indicated that the cause of the blocks is that explained by figures such as 6 and 7 below in the article.

Jan 1, 2018

By A. Niedbalska

A technique was developed for low pressure diamond synthesis using a specially prepared glassy carbon. The glassy carbon is produced in the form of solid plates by slow carbonization process of phenol formaldehyde resin interrupted at temperatures of 1273° K, 1073° K, and 923° K. The diamond synthesis is performed using cobalt plates as a catalyst-solvent. Synthesis was carried out at applied pressures of 6.0 and 3.8 GPa and a temperature of 1970° K and 2170° K. The products were analyzed by the x-ray powder dyffraction method and by microprobe to identify the diamond crystallites. The samples were taken from the place of contact between the glassy carbon and the cobalt catalyst. They were separated from the charge by a chemical method. Diamonds of the best form and the largest size were obtained at pressures that were much lower than those used in the traditional graphite method of diamond synthesis.

Jan 1, 1989

By Ray Y. Lin

Chemical vapor deposition of tungsten carbide on the surface of steel has been investigated at temperatures between 400 and 550C in an atmosphere containing tungsten hexafluoride, hydrogen and benzene. The tungsten fluoride flow rate was maintained at 20 ml/min. The hydrogen flow rate was at 100 ml/min. The benzene concentration varied from 1.15 to 5.56% in the reaction gas. It was observed that the higher the temperature, the faster the deposition rate for tungsten carbide. But the dependence of the deposition rate on the benzene concentration was not systematic. From the x-ray diffraction analysis, it was observed that W, W2C and WC are all presented in the coating. The amount of each phase presented in the coating depends on the temperature and, to a less extent, on the benzene concentration. The microhardness measurement has also been done for all CVD carbide coatings obtained in this study.

Jan 1, 1992

By Nick A. Hasenack

A full survey of the laboratory and blast-furnace tests on 2 types of acid pellets is given. From the laboratory tests, carried out in an atmosphere containing hydrogen, it appears that type B, produced out of 100% magnetitic ores, has a far better low temperature disintegration index and a lower reducibility index than type A, produced from a hematite/magnetite mixture. The swelling index, chemical composition and mechanical properties of both types of pellets do not differ significantly. From the blast-furnace test, carried out with a burden consisting of 45% of pellets and 45% of sinter with basicsty ratio about 2.2, and at constant driving rate, it follows that there is no significant relationship between the disintegration value of the pellets and the blast-furnace permeability. If also is concluded that the lower reducibility of the type B pellets leads to a significantly higher coke consumption.

Jan 1, 1975

By F. C. Miller

The briquetting of fuel is an industry centuries old and has followed the hammer and tongs method of making use of any by-product fuel by the simple process of sticking the mass together with anything that will stick. If fuel briquetting, as an industry, once in the lead over coal mining, had kept pace by introducing science, there would not at this time be the mad scramble to look up the fuel briquette family tree and accept every new method as fruit without the cultivation that makes fruit worth while. Cultivation of industry is a mass of evidence showing a tremendous expenditure of money for mistakes paving the way to success. Cultivation of the mining industry is practiced by nations and low temperature distillation and fuel briquetting will in the near future receive the same consideration. Fuel briquettes were used as a winter fuel in Ireland and Scotland before the discovery of America' or the introduction of coal as a fuel to replace briquettes in Ireland. This industry was practiced by the peasants who collected peat from the bogs and cut it into brick-shaped blocks, which were set up to dry in the sun and stored under cover for use or for sale. Demand for peat briquettes led to competition that resulted in a highly refined fuel. In some localities the peat was ground and purified from the earth by washing before placing in presses to squeeze out the excess moisture and form a block of peat about four inches thick. These blocks, after standing in the sun for a few weeks, were cut into briquettes about four inches square by twelve inches long and moved under cover where they remained until thoroughly dry. In this form peat makes an excellent fuel with considerable heat, small amount of smoke while burning, and tough enough to stand hauling in carts and boats without breakage. Slack from domestic coal, non-coking and anthracite, has until recently commanded a very low price and the attention of briquette men has centered on ways and means of preparing this class of fuel for the market in the form of briquettes. Industrial plants with automatic stokers have taken kindly to cheap slack or slack that was cheap because the price has been boosted to a figure where the cost of slack plus the cost of binder and operation makes fuel briquettes somewhat expensive. However, fuel briquettes are being turned out in commercial quantities to compete with prepared lump coal and the demand is in favor of the briquette man. Science has been called to aid the briquette and it is possible to purchase a complete coal briquetting plant that will turn out between four tons per hour and thirty tons per hour of briquettes at a calculated cost per ton to cover material and every item down to insurance on the plant. A few briquettes are being ' made with a mixture of- Portland cement and pulverized coal, where this class of briquette is cheap in the making, there is the increased amount of ash due to the cement to contend with and the briquette is not one that can compete with lump coal. Most binders have a fuel value, such as coal tar, pitch, asphalt residium, flour, glue and secret binders. Most briquettes are of an egg shape, weighing between one and one-half ounces and five ounces, pressed to form with a pressure varying between 1,000 pounds and 2,500 pounds per square inch. This' pressure, together with the binder, make a lump of fuel harder than most grades of soft coal. Most of the briquettes are free from pitch odor, and any tendency to leave a trace of the binder on the fingers, easy to handle, quick to, ignite, high in heat value and capable of indefinite storage without any change. Evaporative efficiency of briquetted fuel in stationary, marine and locomotive boilers has proved that a great many low-grade coals can be fired successfully in the briquetted form, where the same fuel without briquetting failed to give boiler rating.

Jan 1, 1923

By C. Moreland

Fluidized low-temperature carbonization of coal, a recent development, offers a possibility of reducing fuel costs of coal-burning electric ?generating plants. The Research Council of Alberta have built a pilot plant and are conducting a programme to -develop a carbomzation plant for Alberta sub-bituminous coals which will produce char suitable for use as a .boiler fuel, and tar of a potentially high value as a ?chemical raw material. The economies of the process as a whole, and the value of the tar, have yet to be assessed.

Jan 1, 1958

By R. G. Reddy

Reduction of different chromite ores with carbon was studied as a function of C/FeO ratio and temperature in the range 700 °C to 1100 °C by thermogravimetry (TGA) analysis. Powders of chromite ore(-150 mesh) and carbon(-150 mesh) were thoroughly mixed in a desired proportions and were placed in the reaction crucible. The reduction rates of reactions were determined by continuously monitoring the weight loss as a function of time at constant temperature using TGA set up. The analysis of results suggest that FeO present in the chromite ores is reduced to Fe involving gaseous intermediates CO and CO2. The overall rate of FeO reduction is controlled by the oxidation of carbon. A kinetic equation, that of random nucleation, was proposed. The activation energies for the reduction of FeO, present in Roast Movat and Transvaal ores, with carbon were determined to be 55800 and 23000 J/mole, respectively. The results of the present study are compared with the data available in literature. The low activation energy values as determined in this study suggest that the carbon oxidation reaction is catalyzed. It is concluded from the present investigation that the low grade chromite ores can be significantly upgraded to higher value added chromite that can be used as a feed source for economical smelting.

Jan 1, 1998

By Djona M. Gaballah I.

Selective chlorination of unroasted and roasted spent hydrorefming catalysts was studied between 300 and 600°C using the following gas mixtures : C12+CO, C12+N2 and CI2+air. Such materials contain Co, Ni and Mo compounds supported by alumina and/ or silica. They also contain variable amounts of V compounds, C, S, etc., accumulated during the life time of the catalyst. Direct oxychlorination of the C+S rich sample allows higher extraction rates than those obtained by the carbochlorination of the same roasted one. It seems that the roasting step doesn't favor the economic metals' recovery. Results of the chlorination of C+S poor spent catalysts, in the presence of CO, in the chlorinating gas mixture, or of carbon added to the sample, were comparable. Cobalt and nickel chlorides were .extracted from the chlorination residues by their dissolution with acidified water, whereas molybdenum and vanadium chlorinated compounds were recovered by selective condensation from the vapor phase. The recovery rates of valuable metals as well as the selectivity were higher for the chlorination of spent catalysts than results obtained by the hydrometallurgical processing of the same sample. Results of the scale-up of the oxychlorination of the unroasted sample confirmed those of the laboratory scale. The global recovery rates were about 88 pct of cobalt, 93 pct of molybdenum and 76 pct of vanadium. The carbochlorination was applied to the recovery of W and Ti from Denox catalyst that is a carbon and sulfur free one. Recovery rates higher than 99 pct at temperatures lower than 500 °C could be obtained. This may indicate that the chlorination process can be applied to the treatment of various industrial wastes or by-product containing transition and/or refractory metal compounds A flow - sheet for the pretreatment of these materials is proposed.

Jan 1, 1995

By C. S. Barrett, O. R. Trautz

PREVIOUS investigations have shown that lithium is body-centered cubic from near its melting point to the temperature of liquid air1,2,3 Nevertheless there was an incentive to search again for a transformation at low temperatures: C. Zener4,5 has remarked that the low value of the elastic modulus (11 - C12)/2 of body-centered cubic metals and alloys implies a rapid increase in free energy with decreasing temperature, which would favor the occurrence of a transformation; also the shear movement to which this modulus applies is one that can transform a body-centered cubic structure into a slightly distorted face-centered cubic structure. It was confirmed that lithium does not transform spontaneously at liquid nitrogen temperature, but it was found that a transformation can be induced at this temperature by cold working the metal,6 and at slightly lower temperatures a different transformation occurs spontaneously. Transformations were also found in solid solutions of magnesium in lithium. THE NATURE OF THE TRANSFORMATIONS Before presenting a detailed treatment of the technique used and the specific data obtained, it would be well to give a brief survey of the general characteristics of the transformations. A new crystal structure begins to form spontaneously in a specimen when it is cooled below a critical temperature. In lithium the structure appears to be close-packed hexagonal; in the Li-Mg alloys most of the diffraction lines (but not all) are near those for hexagonal lithium. The transformation proceeds as the temperature is lowered and soon stops if the temperature is held constant or raised. The course of the transformation on cooling is indicated by the curve at the lower left of Fig I. This curve is drawn in stepped fashion because the transformation goes by discrete steps with audible clicks. Because of the similarity to the decomposition of austenite into martensite in steels, it seems appropriate to designate the beginning of the spontaneous transformation on cooling as the Ms point. On heating to room temperature after the low temperature treatment only the usual BCC structure is found. On heating, the low temperature modification begins to disappear at a temperature which will be designated as Ac. The transformation on heating is halted when the rise in temperature is halted. The temperature must be raised 40 to 50°C above Ac before the reversion is complete-an interval which is sensitive to the rate of heating and to the time of holding at temperatures above Ac. This behavior on heating thus has similarities also to the formation of martensite in the cooling of steels.

Jan 1, 1948

By D. Tsweleng

In the Evraz Highveld production process, iron ore is prereduced in rotary kilns prior to charging into submerged arc furnaces (SAFs). Owing to the highly aggressive slags that are formed within the combustion zones of these kilns, chrome-oxide-containing lowcement castables have been used for some years in the kiln lining. Due to concerns around the potentially harmful effects should Cr(V1) be present in the spent linings, Highveld and its suppliers of kiln castables devoted time to developing alternative chrome-free lining materials. Such materials needed to be cost-effective and ensure good performance and improved kiln availability. This paper discusses all the parameters surrounding this development. Keywords Low-cement castable, chrome-oxide free, chrome (VI), titaniferous magnetite ore, rotary kiln, submerged arc furnace, open slag bath furnace, Evraz Highveld Steel & Vanadium Limited.

Aug 1, 2013

By D. A. Sloan

THE Young Davidson mine is of particular interest because of the extremely low costs and also because of the novel method devised for pillar recovery. The outstanding feature of the mining system is its simplicity and regularity. The successful operation of this property was de-finitely assured by the rise in price of gold in 1934. The mine is situated in the southeastern part of Powell township, about forty-five miles southeast of Timmins, Ontario. The local town, two miles distant, in Matachewan, which is twenty-five miles northwest of Elk Lake, the terminus of a branch line of the Temiskaming and Northern Ontario railway. Mining is confined to one of a group of five claims. The ore occurs in a body of syen.ite porphyry which is intruded along a contact of Timiskaming conglomerates with Keewatin altered ruffs and greenstones. This intrusion extends in a north-easterly direction from Davidson creek for 3,300 feet, of which length 700 feet lies within the Matachewan Consolidated property. The maximum width of the mass is 700 feet; it tapers off as it extends east-ward. The Orebody.-The syenite porphyry is of three types, probably all differentiates of the same magma, but only one of them is gold bearing. This is a cherry-red, coarsely crystalline type which forms the central part of the mass. It is more brittle and more fractured than the others, and consequently has allowed easier access to the gold-bearing solutions. The gold has been brought in by a branching system of quartz veins and along minute fractures. It is mainly in the form of very fine 'free' gold, but also occurs in pyrite, which is the chief metallic mineral.

Jan 1, 1942

By C. E. Rodgers

WHEN I was asked to prepare, for presentation at the 1938 Annual Meeting of the Institute, some data concerning low-discharge grinding at the Sylvanite mill, it seemed entirely reasonable to expect to have at my disposal the results of at least four full months' operation after the last unit, as then proposed, was installed. Delays in delivery of equipment, nevertheless, shortened the interval, as will be shown herein. In submitting the data contained in this discussion, I wish distinctly to state that the intention is not to claim that final conclusions can be reached at this time concerning our operation. Test periods, in certain instances at least, have been too short for this purpose, although some, where so stated, have been extended through March and April. It is hoped, however, that an advantageous trend in practice can be shown and that the experience related may be of interest to others who are now operating, or who are considering the operation of, low-discharge grinding mills. In the plant under review, four mills are in use: one primary and three secondary. Present mill capacity (grinding, as shown by screen test, about 99 per cent through-200-mesh and approximately 88 to 89 per cent minus-325-mesh with infrasizer giving about 90 per cent of the latter) averages about 525 tons per day. A brief description of each unit will be given and comments will also be made relating to operation. This will be followed by certain test data from which, in conclusion, operating results are summarized.

Jan 1, 1938

By B Clements, R Dunne, J Dioses, S Hart

In April 2003 plant upgrades in the æLow GradeÆ Cadia Hill circuit were undertaken in order to improve concentrate quality and metal recoveries from the flotation circuit. The major changes involved: circuit reconfiguration to allow all concentrates to be reground to less than 38 ¦m prior to final cleaning; increasing ball charge in the regrind mill to fully utilise all of the installed power; desliming of the cleaner scavenger concentrate to improve the circuit water balance; and the inclusion of a gravity concentrator in the regrind circuit to recover more free gold to bullion.Once the flotation circuit had stabilised under the new operating conditions concentrate launder modifications and increased froth crowding on the scavenger flotation cells permitted the introduction of stronger collectors without compromising concentrate quality or circuit stability.Twelve months on, the copper concentrate grade has increased by two per cent and metal recoveries increased by three per cent and seven per cent for copper and gold respectively. The project capital outlay of approximately $2.0 million has been repaid in less than three months. This paper will review the project from the design, construction and commissioning perspective as well as the subsequent debottlenecking exercise that was required to eventually yield the full benefits of this upgrade.

Jan 1, 2005

By L. E. Fischer

The background for the 630-million-dollar-plus iron ore project at Kudremukh is outlined. The system and plants for mining, crushing, concentrating, transporting via a slurry pipeline, filtering and shiploading 7.5 million metric tons of iron ore per year are fully described. The mode of operation and the problems encountered in such a transfer of North American technology to developing countries are analyzed. Difficulties encountered during construction are discussed and the progress milestones made over a two-year period are enumerated.

Jan 1, 1979

By R. W. Diamond

Low-grade ores can be designated by two main classifications: (1) simple low-grade ores, and (2) complex low-grade ores. As a rule the first type has a relatively small metal content, although low- grade iron ores contain a rather high percentage of metal. As the simple type is the one that is ordinarily in mind when the term "low-grade ore" is used, the paper will be devoted mainly to ores in this general category. Cheap treatment is the prime requirement in utilizing low-grade ores of the simple type, although in some cases the value of nonmetallic by-products, such as limestone for fer- tilizer and silica for flux, allows a little more lati- tude than in the usual situation. When the costs are divided under the three headings-mining, milling, and smelting-it is apparent that the last group will not constitute an important factor as a rule because the high concentrating ratio makes the smelting cost per ton of ore fairly low.

Jan 1, 1949