Search Documents

By L. Bos

The availability and reliability of large grinding mills and their Gearless Mill Drives (GMDs) are of paramount importance for the grinding process. Although GMDs have been in service for decades, and are known for their operational efficiency (reliability and robustness with reduced operating cost per ton), compared to conventional drives, in the last decade due to certain reasons some failures led to serious unscheduled shutdowns and significant insurance events. The majority of these notable "insured" failures have happened on GMDs installed on relatively large mills, as the financial impact of a failure is proportional to the through-put of the mill. Despite the occurrences of these events, as mining operations are driven by lower ore grades and the ability to continue reducing operating costs per ton, the trend for having larger mills is still very present and there is no reason why this trend should not continue. It is obvious that if not handled correctly, the possibility of large value GMD loss events, coupled with the continuing increase in mill size or required availability and reliability targets, could potentially lead to major conflicts as it becomes difficult for the insurance companies to judge the risk and hence may result in hesitation to insure these grinding circuits. This paper will not only describe the conflicting situation from both an insurer's perspective and from an equipment supplier's perspective, but also how these conflicting challenges can be successfully mastered. It has to be noted that not only the mining companies themselves, but also their insurance companies and the involved equipment suppliers have a common interest: to reach the highest availability and reliability in order to avoid or at least minimize unscheduled shut down times, and most importantly prevent unplanned events that result in extended production stoppages or reductions in through-put of GMD driven mills. From the very beginning onwards, the complete service concept together with emergency plans must be integrated on every level in the design of the grinding circuit. This approach must be implemented continuously and without compromises by all involved parties during all following stages, such as basic design, detail design, manufacturing, quality inspection and testing, packing, transportation, storage, installation, commissioning, operation and maintenance. The concept of formal risk analysis related to mill operations, maintenance and spare parts strategies must be an integral part of mining companies? decisions related to the selection for installation and continued use of large mills powered by GMDs. The service concept in place for operating mills shall also have a clear focus on very early detection of any abnormalities, so that the risk can be mitigated and unscheduled shutdown times avoided. However, if a major failure occurs, then procedures and tools shall already be available in order to ensure that production impact is minimized.

Jan 1, 2012

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 J. D. Clucas, N. Verbaan, T. Grammatikopoulos, D. B. Dreisinger, C. Forstner, M. Aghamirian

"Search Minerals is currently exploring the Port Hope Simpson (PHS) Rare Earth Element District in southeastern Labrador, Canada. The Foxtrot Rare Earth Element (REE) Project in the PHS District has a 43-101 resource estimate consisting of 3,410,000 tonnes of Indicated Mineral Resources and 5,850,000 tonnes of Inferred Mineral Resources. The indicated and inferred resources contain 1.07% and 0.98% total rare earth element oxide (including yttrium), respectively. The dysprosium and neodymium grades are particularly attractive at 218 ppm Dy2O3 and 1687 ppm Nd2O3 for the indicated resources and 208 ppm Dy2O3 and 1494 ppm Nd2O3 for the inferred resources. The mineralization remains open along strike and at depth and is only one of a number of attractive exploration targets in the Port Hope Simpson area. The REE minerals fergusonite and allanite are present. The ore can be beneficiated by gravity, magnetic separation and flotation to a recovery of +80% for the individual REE. Acid bake and water leaching may be used to extract REE into solution for subsequent purification and recovery. The extraction range for single stage leach tests were 91-96% for Nd, 84-87% for Tm and 92-94 % for Dy with modest acid consumptions. INTRODUCTIONSearch Minerals Inc. (Search) is exploring the 100% owned Port Hope - Simpson District in Labrador, Canada for rare earth elements (REE). This District is approximately 135 km by 12 km in size, and is highly prospective for heavy and light rare earth elements. A total of 11 REE prospects have been discovered in the District to date, including the Foxtrot. In addition, Search is exploring in the 100% owned Henley Harbour region and has joint ventures with Quest Rare Minerals in the Strange Lake region, and with Great Western Minerals Group in the Red Wine complex, all in Labrador. These exploration locations are illustrated in the Figure 1. The focus of this paper is the investigation of the mineralogy and processing of Foxtrot REE materials. The Foxtrot resource falls within the claims held by Search in the Port Hope Simpson REE District. The infrastructure available at Foxtrot is excellent with a deep water port, air strip and road and power infrastructure at Port Hope Simpson. Over $7 Million has been spent to date on exploration and development of the District. The Foxtrot has been explored using prospecting geochemical methods, geophysics (airborne and ground), channel sampling of surface outcrops, mapping and three phases of drilling (18,934 m total)."

Jan 1, 2012

By C. Cornejo, C. Schuffeneger, J. Rosas

"At the end of 2010 the AMSA Esperanza Concentrator started commissioning. Located in the Atacama Desert this project is the first of several large size concentrators developed recently to operate in Northern Chile. In addition to the new operations to be implemented in the short term, many existing installations are planning expansions. The use of large size equipment is one of the common characteristics of the new concentrators, but also new technologies are being considered and innovation is present in most cases. Sea water or desalinated water will be required to process large tonnages of sulphide copper ores as well as gold bearing ores, since process water supply from the Andes will no longer be available. The high cost of sea water or desalinated water supply and the high cost of energy are not a limitation as the current metal market scenario allows obtaining an attractive NPV even from installations designed to process relatively low grade ores. A review of the current concentrators being developed in Chile is presented, including a description of the main design issues related to technology and innovation. An analysis of the Chilean mining industry is also presented, detailing mine and plant capacities as well as expected final products.INTRODUCTION The mining sector in Chile has become a reference when analysing the large concentrator plants projected or currently in operation all over the world. At present and as a consequence of the high price of metal commodities, most South American countries have an active mining sector. Chile is known as a major producer of metals. First records of copper production exported to Spain are dated to the early XVII century. Since then Chile has produced over 13% of the total copper ever produced in the world. After 1990 Chilean mining and the associated cluster of activities has substantially grown to levels never reached before, especially in the production of copper, gold and other non-metallic minerals. This dramatic increase is the result of an economic policy based on delivering comparative advantages and incentives for the admission of foreign capital to offset the weak domestic investment in previous decades. Massive mining of its huge mineral resources has allowed Chile to be a world leader in the production of copper and other base metals and mineral products."

Jan 1, 2012

By Frédéric Pineau, Guillaume D'Amours

Semisolid metal processing of metallic alloys takes advantage of the thixotropic behavior of material with non-dendritic microstructure to produce near-net-shape components with improved mechanical properties. The much higher apparent viscosity of the semisolid billet limits the risk of oxide formed on the free surfaces to become incorporated into the easting during the process. But, the external-skin on the periphery of the billet, which is often partially solidified and contaminated with lubricants, should not be included into the casting as this can be a cause of reject for most structural parts. In this paper, a preliminary model is set-up using the LS-DYNA SPH formulation to follow the paths of the skin. Calculations carried out show that this approach appears to be very promising to predict the paths of contaminated skins into semisolid castings. It can then be utilized to design suitable molds and gating systems.

Jan 1, 2012

By A. Anderko, V. G. Papangelakis, G. Moldoveanu, G. Azimi, M. Carlos

"OLI Analyzer is a software package that uses the powerful Mixed Solvent Electrolyte (MSE) model to simulate the behavior of multicomponent electrolyte solutions from infinite dilution to the limit of fused salt, and from temperatures below the freezing point up to near critical temperature of the mixture. The software also allows the creation of thermodynamic parameters for new chemical systems unavailable yet in public-domain or commercial software databanks. This communication reviews the basics of the model and provides some examples of modeling hydrometallurgical applications with emphasis on high temperature applications, including calcium sulfate scale formation in autoclaves, high temperature pH inference and iron control. INTRODUCTIONModeling of electrolyte systems has been of particular interest to various industrial processes, such as separation processes (e.g., solution crystallization, extractive distillation, seawater desalination or bio-separations), environmental applications (e.g., gas treatment, wastewater treatment or chemical waste disposal) and hydrometallurgy (e.g., pH control and neutralization, iron control, scaling and fouling of equipment). Using a chemical model, time-effective predictions of various properties of electrolytes can be obtained, which is beneficial not only during process monitoring, but also during process optimization and process scale up. As a result, pilot scale studies can sometimes be eliminated where budgetary constraints exist. Development of such a powerful model requires the use of a speciation-based model, in which solution chemistry is explicitly addressed (as compared with some models that treat electrolytes either as undissociated or fully dissociated systems), despite being computationally challenging. In addition, as a feature of electrolyte systems, speciation equilibria inherently influence the phase equilibria due to complex formation, ion pairing, and acid-base reactions. Therefore, how the electrolyte solutions behave at various conditions may differ significantly due to the non-ideality, which must be carefully addressed to obtain a model that is applicable to a wide range of conditions such as concentration, temperature, pressure and solvent system."

Jan 1, 2012

By Alex Luyima, Honglan Shi, Lifeng Zhang, Yongqing Jiang

"Leaching process has been suggested to recover most metals from waste PWBs. In this study, the leaching behavior of most metals present in waste PWBs is evaluated before and thermal treatment. Different leaching acids: hydrochloric acid (HCl), nitric acid (HNO3) and aqua regia are compared. The effects of acid concentration, particle size of sample, leaching time and temperature are examined. Results revealed that most metals are present in small particle size and sequential leaching of PWBs with a combination of HCl acid and aqua regia is capable of dissolving most of the metals content of PWBs. Leaching of thermally treated PWBs produced the highest leaching percentages for similar leaching conditions.IntroductionApproximately 20–50 million tonnes of electronic waste (e-waste) is produced globally per year. Waste Electrical and Electronic Equipment (WEEE) or E-waste is one of the fastest growing waste streams in the world. In developed countries, it equals 1% of total solid waste on an average [1]. The growing stockpile of used and obsolete consumer electronics has been called the “largest toxic waste problem of the 21st century [2]. Printed wiring boards (PWBs) is an essential part of almost all WEEE, and accounts approximately 3% of all WEEE by weight [3]. PWBs are a platform upon which microelectronic components are mounted. PWBs contain metals (~40 wt. %), ceramics (~30 wt. %) and plastics (~30 wt. %) [4]. The metallic part includes; Cu, Pb, Zn, Fe, Cd, Be, Cr, Au, Pt, Pd, Ag, etc. The plastic part of the PWBs is mostly epoxy resins. These plastic resins also contain very toxic halogenated flame retardants (HFRs) [5]."

Jan 1, 2012

"Previous studies on the effect of polytetrafluoroethylene addition during chalcopyrite leaching under conditions similar to those of the CESL process have reportedly resulted in complete leaching of the copper without the need for grinding of the flotation concentrate. However, these studies employed a pulp density of only 1% and finely sized PTFE particle that required the use of high impeller rotation rates that are not sustainable at an industrial scale. This paper explores the performance of 1/8” diameter balls of PTFE, that readily sink in the leach solution, on leaching performance at impeller rotation rates and ore pulp densities more typical of industrial practice. Possible routes for separation of the PTFE from the leach residues and their regeneration for recycling back to the leaching stage are also discussed.INTRODUCTIONChalcopyrite, CuFeS2, is the most important primary sulfide source of copper. While pyrometallurgical smelting of chalcopyrite remains the only widely accepted route for treating chalcopyrite concentrates, several medium temperature pressure oxidation processes are claimed to be economically feasible (Muir & McDonald, 2007). Among these, the CESL process has been extensively piloted and demonstrated at the prototype scale. The overall process chemistry of the CESL process may be summarized as follows (Marsden & Wilmot, 2007):4CuFeS2 + 5O2 + 4H2SO4 ? 4Cu2+ + 4SO4 2- + 2Fe2O3 + 8S0 + 4H2O (1)4CuFeS2 + 17O2 + 2H2SO4 ? 4Cu2+ + 10SO4 2- + 4Fe3+ + 2H2O (2)Though copper extractions of over 95 % are achieved, the CESL process requires extra grinding of the concentrate (Muir & McDonald, 2007). This is because leaching is conducted at temperatures around 150 °C, where the elemental sulfur produced is molten and grows thicker on the mineral’s surfaces as oxidation progresses, creating an increasingly large barrier for mass transport. In addition, the sulfur is sticky and tends to cause the mineral particles to agglomerate, effectively halting further oxidation of the particles that end up embedded within the agglomerates. Consumable surfactants, such as ligin sulfonate, have been shown to be effective at avoiding agglomeration, but they are not effective at removing sulfur from the minerals. Hence, their use does not obviate the need for fine grinding."

Jan 1, 2012

By Eric Roller, Elliott Giles

All flyrock incidents have the potential to result in injuries or fatalities that can result in loss of company reputation, license to operate with clients, and bear the exposure to high cost liability. From 2007 to 2009,one NA Quarry and Construction Business experienced a series of flyrock incidents. In the spring of 2009, this business declared that the frequency and severity of Flyrock Incidents had reached an unacceptable level. A Flyrock Elimination Program was launched.

Jan 1, 2012

By Stephen A. Gasiorowski, Frank J. Hrach, James D. Bittner

Separation Technologies, LLC (ST) has developed a processing system based on triboelectric charging and electrostatic separation that provides the mineral processing industry a means to beneficiate fine materials with an entirely dry technology. The environmentally friendly process can eliminate wet processing and required drying of the final material. The process requires little if any pre-treatment of the material other than grinding and operates at high capacity - up to 40 tonnes per hour by a compact machine. Energy consumption is low, approximately 1 kWh/tonne of material processed. Since the only potential emission of the process is dust, permitting is typically relatively easy. In contrast to the other available electrostatic separation processes that are typically limited to particles greater than 75 µm in size, the ST belt separator is ideally suited for separation of very fine (<1 µm) to moderately coarse (500 µm) materials with very high throughputs. The triboelectric particle charging is effective for a wide range of materials and only requires particle-particle contact. The small gap, high electric field, counter-current flow, vigorous particle-particle agitation and self-cleaning action of the belt on the electrodes are the critical features of the ST separator. The high efficiency multi-stage separation through charging / recharging and internal recycle results in far superior separations and is effective on fine materials that cannot be separated at all by the conventional electrostatic techniques. Since 1995, this triboelectric process has been extensively used for the beneficiation of coal fly ash with eighteen separators in place and over 100 machine-years of operation at locations in North America and Europe. The technology has been also successfully applied to the beneficiation of a variety of minerals including calcium carbonates, talc, and potash.

Jan 1, 2012

By Jan C. Still

The Glacier Bay subarea is that part of the Juneau Mining District (JMD) within Glacier Bay National Park and Preserve (GBNP). It is the western portion of the JMD and consists of the land between the Fairweather Range crest and the Takhinsha and Chilkat Ranges crests (excluding that land east of Excursion Inlet.) Figure B-1 shows the area. It is bounded on the north by the Alaska-British Columbia International boundary, to the south by Cross Sound and Icy Strait, and contains Glacier Bay. During 1975 -1977 the Bureau conducted a detailed study of the occurrences, prospects, and deposits in GBNP (B_4).2 This work was in cooperation with the U.S. Geological Survey (USGS) under the provisions of the Wilderness Act (Public Law 88-577). As a follow up to this earlier Bureau work, limited studies were conducted, during 1985 and 1986, as part of the JMD study. This report covers the most important aspects of the earlier studies and the 1985 and 1986 studies. ACCESS The Glacier Bay area may be reached through Gustavus airport, a paved strip which is serviced by scheduled jet airliners in the summer and air taxi services year-round. The airport is connected to Bartlett Cove (GBNP headquarters) by an all-weather road. No other roads exist in the area except a skid road to the LeRoy Mine and mill in the Reid Inlet area. Much of the Glacier Bay area is accessible through the salt water inlets and fjords which are part of Glacier Bay. Cruise ships, charter boats, and fishing boats visit these inlets and fjords during the summer months. Elevations within the area range from sea level to over 15,000 feet in the rugged Fairweather Mountain Range. More remote areas are accessible by small boat, foot, or helicopter. Glacier ice is a year-round hazard to navigation in Glacier Bay, and during the winter months some of the more northerly inlets are frozen.

Jan 1, 2012

By Robert Hopler

Of the common causes of the larger mine accidents, such as falls of roof and coal, gas and dust explosions, mine fires, and the misuse of explosives, all of which are often closely related, each must be studied and fought in a manner peculiar to itself. The last mentioned, the misuse of black powder and other explosives, is sometimes considered the least important of these causes of mine accidents; but its importance is much greater than the statistics indicate, for the reason that the misuse of explosives is the true cause of many of the fatal mine fires, gas or dust explosions, and falls of roof that are credited to other causes.

Jan 1, 2012

Editor?s note: Each year, the June issue of Mining Engineering features an industrial minerals review. Several people put in a fair amount of time in developing the material for this issue, all the while doing their own jobs. Thank you to the industrial minerals annual review editor, to the Industrial Minerals and Aggregates Division technical committee chair and vice-chairs, and to the authors of the individual commodity profiles. Jim Norman, member SME, of Tetra Tech, is the industrial minerals annual review editor. Candace Trimble, member SME, of Oil-Dri Corporation of America, is chair of the Industrial Minerals and Aggregates Division?s Technical Committee.

Jan 1, 2012

By M. Al-Khawaja, F. Hassani, F. Mucciardi, N. Razavinia

"In today’s economy many industries are becoming aware of the need to recover some of the waste heat they create. Industrial processes release, on a global scale, over 100 tera-Joules (i.e. 1014 J) of waste heat annually. The recovery of waste heat can lead to a reduction of greenhouse gas emissions and it can also provide a financial benefit which can be obtained by converting some of this excess heat to electricity. At McGill, a research program has been initiated so that low grade waste heat (temperature between 100ºC and 300oC) from process off-gases found in pyro-metallurgical industries is captured and concentrated by using heat pipes and then converted to electricity by a mechanical engine. This paper illustrates the 3 C’s process (capture, concentrate and convert waste heat to electricity). It also provides some preliminary experimental data. INTRODUCTIONThe problematic climate change caused by the use of fossil fuels, the rapid depletion of global reserves and the catastrophic consequences of nuclear power generation call for renewable and safe, resources of energy, for both man and the environment. Extensive researches in the production of energy from renewable sources and improvements in efficiency of current technologies can help us to reverse this trend.The greatest advantages of using renewable energies are that they don’t deplete and they also contribute to a green environment. On the other hand the disadvantage of using these resources is that the energy available from renewable sources is much less concentrated than that provided by fossil fuels and nuclear energy. This makes renewable energy less attractive for large scale industrial uses in most cases. A key target for society for the 21st century is the production of energy from renewable sources at a cost that is competitive with fossil fuels. Fossil fuels represent a concentrated form of energy; usually it is referred to as high grade energy. Nonetheless, there is a vast supply of alternative energy. The sun, wind, water and biomass were the first to be explored. While these are all valid options that warrant concerted efforts and large investments, there is another source of energy that typically is produced by manufacturing industries. This energy is often referred to as low grade waste heat. Most of this energy is simply vented to the environment through the stream of off-gases. In the future it will be necessary to capture and convert some of the low grade heat to a valuable form such as electricity if we are to improve on the efficiency of energy usage."

Jan 1, 2012

By R. Lodha, C. Oprea, G. Oprea, H. Zargar, T. Troczynski

"The basic refractories used in non-ferrous industry contain chrome ore for improving the thermal shock resistance, thus reducing the penetration of molten metal and fayalite-type slags into the lining. The current study aims to replace chrome ore with Me4+ ions along with Fe3+ ions in order to form MgO-Al2O3- FeOx-Me4+O2 based complex spinel systems that could perform similar to the complex chromia-bearing spinel in the magnesia-chrome refractories. This system allows for lower temperatures of synthesis and sintering. In our study, compositions with 60% MgO were fired below 1500°C and resulted in complete formation of complex spinel, and open porosity less than 5%. The in-situ formation of the complex spinel from the fine mix of oxides in the MgO-Al2O3-FeOx-Me4+O2 system offers a suitable alternative of binding system to produce basic refractories at lower temperatures and of similar physical and mechanical properties with magnesia-chrome bricks fired above 1750ºC. INTRODUCTIONThe synthesis of magnesium aluminate spinel (MgAl2O4) (Maschio, Fabbri, & Fiori, 1988) or magnesium chromate spinel (MgCr2O4) from their respective oxides is diffusion controlled resulting in a sluggish reaction even at high temperatures. For instance, the diffusion of Mg2+ and Al3+ ions in the intermediate spinel layer during reaction is slower than the diffusion of Mg2+ in corundum and Al3+ in periclase. The interfacial layer of spinel formed during the reaction increases the diffusion path for the spinel forming cations. This accompanied by ~8% volume expansion retards further reaction resulting in incomplete spinel forming reaction during sintering and hence densification during the reaction cannot be achieved. In order to assess sintering studies with fine particulate oxides that would result in a lower diffusion path, a mechanical mixture of the hydroxides of aluminium and magnesium calcined at 1400ºC to 1600ºC for 1 hour does not result in complete spinel formation (Sarkar, Das, & Banerjee, 2003), which indicates that reaction sintering of stoichiometric magnesium aluminate spinel is retarded by initial reaction forming the interfacial spinel layer. The basic bricks used as linings in non-ferrous pyro-metallurgical convertors are manufactured using magnesia and chrome ore, the sintering of which produce spinel solid solution. This solid solution is a mix of both normal and inverse spinel structures that sinters at temperatures in excess of 1800ºC in air."

Jan 1, 2012

By H. J. McQueen

Mineral and energy resource consumption were continuously reduced by process improvements as chemical understanding was developed and applied. During the past two centuries, technological improvements increased human productivity that was accompanied by social advances and labour saving products; however, these sometimes proliferated to endanger sustainability, e.g., automobiles. In the steel industry, precisely controlled rolling of HSLA steels required little extra mineral consumption but reduced weight and heat-treating energy. Continuous casting of slabs reduced scrap compared to ingots and energy for the homogenizing soaking pit. Al alloy extrusions were improved by retaining the strengthening in the near-surface substructure, of high strength textures and of press quenching that is suitable for direct age hardening. Continuous bar casting of Al-0.65Fe, coupled with rod rolling and followed by wire drawing with only a final recovery anneal, yielded electrical wiring for households to replace less plentiful Cu and later for light-weighting use in autos and aircraft Looking backwards, the 1970 decade saw the first oil crisis and inspired Ottawa to undertake a campaign to develop an energy strategy that would decrease dependence on imported fuels. One significant undertaking under Energy Mines and Resources was the organization of industrial energy conservation, managed by each industry association,that collected detailed current statistics and set the goals for a 2-year campaign. The metal producing industries, as compared by E.C.N. Perryman to about 7.2 exajoules (EJ) for the nation, consumed about 0.8 EJ, being about one third of all heavy industries. While manufacturing consumed 30.2% of total energy, it created 87.3% of total national dollar value. Within the industrial envelope, smelting and refining utilized 28% (0.67 EJ, mining beneficiation 6.7%, 0.16 EJ); there was a significant contribution to exports: 80% of iron ore and 70% of aluminium in 1973. A general concern was that decreases in ore grade would lead to a rise in energy expenditures countering benefits from processing efficiency.

Jan 1, 2012

By G. J. Simandl

"Since the 1980s, China has become the predominant producer of REEs. Recently, it introduced REE export quotas and this started a world-scale REE exploration rush. REE resources are concentrated in carbonatite-related deposits, peralkaline igneous rocks, pegmatites, REE ± P veins, ion adsorption clays, placers, and some deep ocean sediments. REEs could also be derived as a by-product of phosphate fertilizer, U processing, Ti-Zr-bearing placers, and exploitation of Olympic Dam-type sub-type of IOCG deposits. The ideal REE development target would be located in a politically stable jurisdiction such as Canada. REE grade and tonnage, mineralogy, and permissive metallurgy are some of the key technical factors that could be used to screen projects. INTRODUCTIONAccording to the International Union of Pure and Applied Chemistry (IUPAC), the term “rare earth elements” (REEs) encompasses yttrium (Y), scandium (Sc), and the lanthanide series: lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), and lutetium (Lu). This definition is used throughout this paper.REEs are subdivided into light (LREE) and heavy (HREE) categories. LREEs include, Sc, La, Ce, Pr, Nd, Sm, Eu, and Gd and HREE include Tb, Dy, Ho, Er, Tm, Yb, Lu, and Y. Promethium (Pm) does not occur in nature. Concentrations of individual LREEs in the upper crust of the Earth are comparable to those of base metals. Even the least abundant REE (Lu) is about 200 times more abundant than gold.The production of REEs, reported in the form of oxides (REOs), for 2011 is estimated at 140 000 t (Figure 1a). Although high technology industries can substitute several REEs with other materials, these substitutes are typically more expensive or less effective than the REEs they replace. A number of countries, including the United States, consider several REEs essential for national security, their economy, and a general reduction in green house gas emissions. The forecasted demand for individual LREOs is much higher than that of HREOs (Figure 2). Dy, Eu, Tb, Nd, and Y are essential for the US economy and subject to predicted supply disruptions (U.S. Department of Energy, 2010)."

Jan 1, 2012

By Kuiting Wang, Jinshan Liu, Ninglei Sun, Aiguo Dong, Yeda Lu

"Eliminating the environmental threat caused by waste effluent containing magnesium sulfate derived from the process of nickel laterite sulfuric acid leaching and subsequent nickel precipitation is always a focus in the metallurgy field. A new flowsheet whose procedures include vaporization, crystallization, two stages precipitation of magnesium, causticizing treatment of filtrate and ammonia recycle was investigated. Both the details of the flowsheet and its application are described in this article. It is confirmed to be an effective and economical method to prevent the pollution by the waste effluent, simultaneity, a series of magnesium products recovered during the process own good economic returns.IntroductionSulfuric acid leaching is the conventional procedure of extraction valuable metals from ores in hydrometallurgy field. During the process of nickel laterite sulfuric acid leaching, several metals, including Ni, Co, Al Mn, Fe, Mg etc., migrate into the leachate in the form of soluble metal sulfate. After subsequent procedure of purification, precipitation of Ni and Co and neutralization, an enormous stream of waste effluent which contains a concentration of approx. 15-40g/L Mg is exhausted. Such solution containing magnesium sulfate is toxic, which causes diarrhea for both human and animals. On the other hand, large amount of sulfate acid was consumed during the process of leaching by the compound of Mg, which increases cost of a hydro nickel plant.In arid areas, the waste effluent mentioned above is treated via evaporate pond owning large acreage, which needs not only the appropriate meteorologic condition, but occupies much land. In coastal areas, it is directly discharged to the sea, which probably deteriorates ecological system of offshore strip. The most widespread method to treat with the waste effluent is neutralization by lime cream, the residues of which containing magnesium hydroxide and gypsum are transported to residues pool. Neutralization is a simple process, but it never recycles the Mg and sulfate anion into new application, meanwhile, the residues are potential threat to the environment."

Jan 1, 2012

By I. Perus, M. Fazarinc, G. Kugler, M. Tercelj

"Ledeburitic tool steels are highly alloyed steels used for specific highly loaded applications but are characterized by low and variable hot workability. In this contribution the importance of selecting the right choice of some essential process parameters, i.e. casting temperature, solidification rate and soaking temperature, needed for improving the intrinsic hot deformability of ledeburitic tool steels, is studied. An inappropriate selection of casting temperature and cooling rate results in precipitation of unusual eutectic carbides that decreases the hot workability, whereas with the selection of appropriate soaking temperature the temperature range of safe hot working can be broadened. For each initial as-cast microstructure individually determined soaking temperature should be selected.IntroductionThe surface cracking during hot deformation of ledeburitic tool steels reduces mechanical properties and their industrial yield. These tool steels have high hardness, wear resistance and high tempering resistance on one hand, and high flow stresses and low hot deformability on the other. Decreased hot deformability of the tool steels is attributed to the type, size, shape, distribution, fraction of eutectic carbides and/or other phases, grain growth, etc. at upper limit while precipitation of secondary carbides and decreased recrystallization rate at lower limit of the safe hot deformation temperature range, [1-6].The occurrence of cracks on most exposed areas of workpiece are related to the areas where similar conditions related to upper and/or lower limit of temperature working range prevail, i.e. areas with accelerated cooling, areas with higher value of accumulated strains where also decreased recrystallization rate with simultaneously presence of higher tensile stresses takes place, furthermore areas of workpiece which are due to combustion conditions in furnace heated to higher temperatures, etc. Thus the areas, where combination of previously mentioned conditions prevails, are more exposed to cracking. This additionally requires that hot deformability of ledeburitic tool steel should be considered as a complex problem. Publications in the literature with regards to hot deformability of tool steels are predominately of a partial nature thus all reasons for unexpected occurrence of cracks are not sufficiently explained in available literature so far. Furthermore modern practice proves that previous processing parameters significantly influence the hot deformability and thus this cannot be considered as a constant value. During heating, soaking and hot deformation various processes take place: decay (decomposition) of carbides, formation of new carbides, dissolution of carbides and of alloying elements, etc. Thus depending on variation of process parameters and chemical composition, that consequently influences the processes related to carbides, shifting of decreased deformability at both limits of temperature working range to higher and/or to lower temperatures can occur, [1-14]."

Jan 1, 2012

By David R. Shields, Michael T. Bracher

"The $330 million (U.S.) Dana-Farber Cancer Institute’s Yawkey Center for Cancer Care (Yawkey Center) sits in the heart of Boston’s Longwood Medical Area. The Yawkey Center is a cutting-edge cancer care facility that houses Dana-Farber’s adult clinical care and clinical research programs. Standing 14 stories above grade, it includes 7 stories of underground parking extending 75 ft (23 m) below ground. The structure is on a 198 by 186 ft (60 by 57 m) site sandwiched between Dana-Farber’s 13-story Richard A. and Susan F. Smith Research Laboratories Building, the Medical Area Total Energy Plant (MATEP), Jimmy Fund Way, and Brookline Avenue, a busy four lane artery through the heart of the Longwood Medical Area. Together with Simon Design Engineering, the project structural engineer, GEI Consultants designed an innovative foundation and excavation support system to isolate the building from ground vibrations generated by the adjacent MATEP power plant. In effect, the Yawkey Center is a 21-story free-standing structure that starts 7 stories below grade.The MATEP facility provides power for 9 million sq ft (840,000 sq m) of occupied space in the medical area. There are six 32-cylinder diesel engine generators in the facility that produce low-frequency ground vibrations in the 10 Hz range, similar to the natural frequency of typical building elements. The resonant response of the Yawkey Center building structure to these ground vibrations would affect the performance of sensitive medical research equipment and cause an unacceptable environment for clinical care.The soil profile at the site consists of stiff clay, fine sand, glacial till, and bedrock consisting of hard metamorphosed conglomerate. In-situ measurements of ground vibrations performed in boreholes showed that there was little attenuation of the vibrations with depth in the soil layers overlying the bedrock, but the vibration amplitude in the bedrock was markedly lower than in the overlying soil. Based on this data, an innovative foundation system was designed to support the building on bedrock located up to 110 ft (34 m) below ground surface, while isolating it from the surrounding soil. This was done by physically separating the below-grade parking garage floors from the perimeter foundation walls to create a free-standing structure supported on the bedrock"

Jan 1, 2012