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By Jayesh B. Patel, Zhongyun Fan, Hu-Tian Li

"Melt conditioned direct-chill (MC-DC) casting is a novel technology which combines vertical direct-chill (DC) casting with a high shear device directly immersed in the sump for in situ microstructural control. In this paper, the solidification mechanism of DC casting under varying conditions is discussed. The temperature profiles in the sump were measured under the steady state casting conditions by using sacrificing thermocouples. Detailed comparisons of the derived thermal condition are made. The individual role of grain refiner additions, natural thermosolutal convection and forced convection in the sump and the interplay of these factors in determining the solidification structures of DC cast billets are discussed. The MC-DC casting technology can be used to control microstructural constituents and casting defects in DC cast billets/ingots by in situ manipulating of the thermal and fluid flow conditions.INTRODUCTION Direct-chill (DC) casting of aluminium, has been the essential commercial process for producing feedstock suitable for subsequent processing, such as extrusion, rolling or forging. Fine and equiaxed grain structures in the as-cast billets/ingots are required to enable a fine and uniform distribution of second phase particles and microporosity. This leads to higher productivity, more cost-effective homogenisation and more efficient downstream thermomechanical processing. The addition of chemical inoculants has been the standard industrial operation prior to casting for grain refinement of Al alloys. However, it has been established that less than 1% of the grain refiner particles added actually act as heterogeneous nuclei to refine the grain structures, showing a very low grain refining efficiency (Greer, Bunn, Tronche, Evans, & Bristow, 2000). Moreover, the remaining particles from the grain refiner addition in the final casting may cause surface defects during downstream processing. A major issue of the metallurgical quality of large sized ingots/billets is the non-uniformity of microstructures even with chemical grain refiner additions. This is due to the fact that the grain structure formed in the different zones of the billet depends on the local chemical composition and local cooling rate. The local cooling rate can vary from 0.4~1 K/s at the centre of the billet to around 10–20 K/s at its surface zone (Nadella, Eskin, Du, & Katgerman, 2008). The large thermal gradient along radial direction between billet surface and interior of the melt during conventional DC casting induces thermal stress and cold cracking even with grain refiner addition. Therefore the control of casting defects, such as macrosegregation, porosity, cold/hot cracking and distortion of the billets/slabs, etc., is still challenging in industry, causing high scrap rate of DC cast ingots/billets even with grain refiner addition."

Jan 1, 2018

By K. Gardner

"Many deposits have a geological model developed early in the project stages, which is not always reviewed or modified as the project matures and production commences. Conversely, ongoing pressures, due to a combination of declining head grades, a push for increased revenue and a multitude of other reasons, leads to processing plant modifications, with the primary aim being to increase production. Often, the ore deposit knowledge is not sustained or developed during the operational stages to the level carried out during the prefeasibility and feasibility study phases. This results in the variability within the deposit being poorly understood and a lack of data and knowledge being available to support (and ideally optimise) operations particularly in an environment where the flow sheet has changed and ore feed requirements are complex.INTRODUCTION This paper presents a case study of ore deposit knowledge development and corresponding process plant operating strategy at the Ladolam Gold Deposit, commonly referred to as the Lihir gold deposit in Papua New Guinea. The gold deposit is located in a tropical equatorial climate on the east side of Lihir Island in the New Ireland Province of Papua New Guinea. Gold mineralisation was discovered in 1982, and was followed by a major exploration campaign by a joint venture between Kennecott (Rio Tinto) and Nuigini Mining Limited. The first drillhole was drilled in 1983, and after an extensive period of drilling consisting of 343 holes for 83,500 m, the final Feasibility Study was completed in 1992. The feasibility study was based on a Reserve base of 37.9 Moz in refractory sulphide ore, with gold extraction proposed to occur via whole ore pressure oxidation due to the refractory nature of the mineralisation. The Lihir Special Mining Lease (SML) was granted in 1995 to a new PNG company – Lihir Gold Limited, and Rio Tinto established Lihir Management Company to develop and operate the mine on behalf of LGL. Mining and processing of the deposit commenced in 1997. Newcrest Mining Limited purchased Lihir Gold Limited in August 2010, and subsequently completed a major plant upgrade including the installation of additional grinding, autoclave and carbon-in-leach capacity. Post commissioning of the upgrade, Newcrest has continued to increase throughput and production. A reinvigorated ore body knowledge development program has significantly assisted this process in identifying operating strategies for the process plant and delivering recovery improvement projects to address declining head grade and recovery due to increased stockpile feed and flotation circuit use."

Jan 1, 2017

By J. Y. Hwang

Coal cleaning with traditional magnetic separation usually yields unsatisfactory results because minerals associated with coal, such as quartz, clay, pyrite and calcite, are weak-or non-magnetic. Magnetic reagent technology is a new mineral processing technology with the capability to enhance the magnetic property of minerals selectively. This reagent can be adsorbed selectively on minerals through the control of surface chemistry and, thus, result in selective magnetic enhancement. The application of this technology on coal cleaning has been experimentally demonstrated. Good separation results can be obtained at low to medium magnetic field strength. Comparison with other processing technologies is included.

Jan 1, 1992

By K. Thuro, H. Käsling, F. Menschik

"With increasing data volume, due to enhancing requirements for ground investigation programs for large construction projects, the demand for more efficient filing systems is more and more growing. Depending on the project we also have to use flexible systems to cope with varying data out of different lab and field tests.The chair for Engineering Geology at TUM is developing a web-based database solution to handle all project relevant data in a more appropriate way. We aim to optimize our data management to achieve a fast and easy way of collecting, documenting and analyzing our gained data. The second objective is to provide an easy access to our data for project partners across broadly distributed locations.This Database system consists of a PHP web interface and a MySQL database core. The current setup allows an online access via Internet (www). We are able to grant and constrain access to all data or only arrays of data with our user management system to guarantee the safety of project data and respect all rights and proprietorship. The database system is of modular design and consists of the following three base modules: module of general project data, module of laboratory data and user management module. At the current stage we are able to save and work with all usually generated specific values from unconfined compressive strength tests, brazilian tensile strength tests, point load tests, CERCHAR and LCPC abrasivity tests and ultrasonic tests. The user is able to perform a simple statistical analysis within our database (e.g. average calculation of one sample) and export data as csv or xls files for further analysis.For specific questions within projects we are able to deploy and integrate further modules in our database system. At this moment, we are developing an add on to use this database for different drill test analyses. One of the tools correlates drilling performance and drill head wear measured in the field with rock mechanical properties, and extrapolates the data to estimate the performance and wear in new projects. Today we are managing 90 projects with 550 samples and almost 1350 lab tests with the base module.In our contribution we aim to demonstrate an efficient way of data structuring using a relational database for laboratory and field testing data."

Jan 1, 2015

By Downing Terry L.

Dry mineral beneficiation methods have been developed for separation of borate minerals from montmorillonite claystone gangue. The methods include the use of newly developed dry high intensity magnetic separators. The application of these methods has the potential for economic benefit at U.S. Borax Inc. in three areas: ? Processing surface impoundments (ponds) material. ? Pre concentrating ore to be fed to primary refinery. ? Concentrating borate minerals to produce potential products.

Jan 1, 1995

"Since World War II, urban communities have expanded at an unprecedented rate. The industrial mineral industry supplies the sand, grave], limestone, crushed rock, cement, gyp-sum, etc. for urbanization. Most de-posits in use are close to or within communities. Pollution of water and air has become a matter of public concern. Waste disposal and the effects of noise and vibration are subjects of public debate. Need for the reclamation of land after operations such as strip mining is discussed in magazine articles and on TV pro-grams; i.e., the general public is educated in the unattractive features of mining.Legislation is on the books and being drafted to regulate mining operations and their side effects. To avoid over-regulation and restrictive legislation, it is necessary that the public be educated and legislators informed of problems peculiar to the mining industry. Our side of the story needs publicity."

Jan 1, 1968

Federal Regulations require that coal producers conduct a written, in-house investigation with every lost time injury accident. Besides their obvious value in accident prevention, competently conducted investigations can provide a number of additional benefits to include positive supervisor involvement, the control of rising worker's compensation costs and a measure of protection from civil/criminal proceedings. The paper describes such topics as MSHA minimum requirements, investigator selection and training, accident site procedures, witness interview techniques and the management review process. The reader is also presented with a number of information resources available through MSHA, the National Safety Council and other sources.

Jan 1, 1995

By A Sadri, S Smith

In the metal and mineral industry, different empirical techniques are used to estimate the remaining thickness of the lining within an operating furnace. The disadvantage and costly factor when using these methods is that production needs to be halted. Hatch has developed an accurate and reliable technique based on stress wave propagation principles to determine the condition of the remaining lining whilst the furnace remains online and operational.The technique involves test data collected and compiled to generate 3D imagery used to assist operators and maintenance planning personnel with valuable information showing areas of metal penetration in the lining, remaining lining thickness, exact location of voids, cracks, poor contacts and deterioration due to chemical attack. In this paper, the principals of the AU-E technique will be explained both theoretically and practically. In addition, the use of ultrasound technology for determining the condition of copper cooling elements will be briefly addressed.

Jan 1, 2006

By S. Mohanan, C. R. Kumar, S. K. Bhoja, T. Venugopalan

"A pressing issue that has often been the topic of discussion in iron-making operations in India is the high content of alumina in the country’s iron ore deposits. The presence of alumina has hampered production by affecting slag fluidity, and thereby the hot metal quality. Iron ores from Indian mines are generally rich in hematite, with traces or small amounts of goethite/limonite, kaolinite, gibbsite and quartz reported from time to time. In day-to-day production, emphasis is placed on checking the chemical analysis of product samples, but the true solution to the alumina problem lies in estimating the mineralogy of the ore samples. We developed a mathematical model, based on singular value decomposition, to predict mineralogy from classical chemical analysis. We then used X-ray diffraction patterns, scanning electron microscope analysis, and grain counting with an optical microscope to determine actual mineral compositions and to test the values predicted by the model. The results indicate that with regular calibration, the model can be used as a simple, fast and effective tool to predict on a regular basis the mineralogy of multiple samples.IntroductionIndian blast furnaces use high-grade iron ores (as lumps or as sinter) and coke (obtained from the destructive distillation of coal) as raw materials for the production of high-quality hot metal to be converted into different steel products through the Linz- Donawitz process. The iron ores are mainly sourced from the Singhbhum region of Odisha and Jharkhand states, the Bailadialla region of Chattisgarh state and the Bellary region of Karnataka and Goa states, and are mainly classified based on size as (1) lump ore (fed directly into blast furnaces), (2) fines (converted into sinter/pellets and fed to blast furnaces) and (3) slimes (< 0.15 mm; currently dumped in huge slime ponds). Any variation in the quality of the ores supplied results in variations in the production trends of hot metal."

Jan 1, 2015

By Dr. R. W. Mead

There are two basic problems when one attempts to separate a solution of metal ions utilizing a chelation-solvent extraction cascade (commonly called liquid ion exchange). First, it is impossible to produce any great degree of separation unless the separation factor (also called selectivity, which is the ratio of the distribution coefficients) is very large. Second, the richest possible extracted product, using an infinite number of equilibrium stages, is at best only in equilibrium with the feed solution. These factors combined with equipment design considerations have led to a situation where only the most selective chelating agents are applicable to economic industrial operations. The authors know that distillation techniques are used routinely to separate compounds with nearly identical relative volatilities and that there should be a way of operating solvent extraction cascades in an analogous manner to obtain separations of metal ions. The advantage of this approach would be that solutions of metal ions of any desired purity could be obtained even if the separation factor was close to unity. This paper presents this idea and suggests some possible applications.

Jan 1, 1977

By Charles I. Richman

Aquispirillum magnetotacticum (AM) is gram-negative hetrotrophic bacteria that belongs to a class ,of magnetotactic bacteria that have an ecological niche in marine marches and fresh water swamp sediments. Thiobacillus Ferrooxidans (TF) is a Gram-negative, acidophillic chemoliths that may have similar chemical conditions within the cytoplasmic membrane as Aquaspirillum M. to support growth of Magnetosomes. Magnetosomes are cellular bodies that accumulate under slightly aerobic conditions. Magnetotactic motion occurs in an external magnetic field and depends on the medium viscosity. The Atomic Force Microscope equipped with a magnetic tip shows the presence of Magnetosomes in these bacteria strains. The size, shape of magnetosomes in AM and TF strains are characterized.

Jan 1, 1998

By B Tessier

Checking the quality of a blast may be considered as subjective. Checking this quality will require measuring objective parameters. One of them is the resulting fragmentation of the blasted product. Numerous fragmentation æmeasuringÆ systems have been developed and marketed, based on image-processing. This presentation of FragScan will illustrate advantages and difficulties when using such a system. FragScan is essentially defending a policy of large and representative sampling. The purpose is to show how fragmentation is discriminating both productivity and profit of quarry operations on a blast-by blast basis. The next step will then be to ædriveÆ the blasting process to reach a æbetterÆ fragmentation. Other applications require the fragmentation as an essential result: this is the case for large boulders used in structure-reinforcement. Several case-studies have shown that FragScan can be used for quality-control, checking size-distribution of the product according to the requirements of the end-user. Only clear thinking about the precise use of such a æmeasurementÆ will further the success of this task.

Jan 1, 2001

By Don Eby

The application of electric arc furnace smelting of lead, antimony, and tin bearing slag from a reverberatory furnace will be discussed. The selection procedure for the 4.0 MVA electric arc furnace in Indianapolis, Indiana is presented. The design criteria for the transformer, electrodes, refractories and associated equipment is presented. The operation of the furnace including chaJ:9ing, bullion tapping, slag tapping, ventilation, slag composition, metal recoveries, and toxic leach results of thra.1 away slag are discussed. Flow charts and the equipment specifications are given.

Jan 1, 1990

By F. E. Senftle

Introduction The usual laboratory methods of uranium analysis are either tedious, time-consuming chemical procedures or elaborate physical methods requiring sensitive equipment. There is thus an urgent need for a method of estimating the uranium content of ore samples by approximate analysis in the field. When a new property is being developed, it is desirable to know, with the least possible delay, the uranium content of channel samples in order to guide the diamond drilling and digging operations. Prospectors, too, require approximate analyses of their hand specimens to evaluate their discoveries. To satisfy the demand for these types of analyses, several field procedures have been tried. Two general plans can be followed. One is fast but will yield only a rough estimate. The other is slightly longer but, if done carefully, will give an assay probably within 10 per cent of the true value. For field operation it is necessary to strip the more accurate laboratory methods of analysis of all refinements because of the limited equipment and skilled techniques at hand. Most of the corrections normally applied, with the exception of that for equilibrium, will not alter the gross analysis to any appreciable extent. When uranium atoms in pitchblende disintegrate, they break down into other radioactive elements, and eventually the number of elements being formed is equal to the number breaking down. The ore is then said to be in equilibrium. Certain geological processes, however, such as leaching, may selectively remove some of these elements and hence reduce the radioactivity of the ore sample. The ore is then said to be out of equilibrium. The field analysis may then be in error by as much as 50 per cent since the apparatus is calibrated with standards that are in equilibrium. However, such a large error due to loss of equilibrium is the exception, and in most cases uncorrected field types of analyr.is are justified.

Jan 1, 1949

"Hematite pellets were electro-deoxidized to iron in molten sodium hydroxide to produce iron containing about 10-wt % oxygen. The anodic reaction was the evolution of oxygen on an inert nickel anode. Before the electrochemical reaction, there is a reaction between sodium hydroxide and ferric oxide to form sodium ferrite and, in order to compensate for the reduction in sodium oxide content, 1 wt % sodium oxide is added to the melt. In a laboratory cell, the cell voltage was 1.7 V with a current density of 5000 A m-2, a current efficiency of 90% and an energy consumption of 2.8 kWh kg-1.Introduction The iron and steel industry contributes about 2.3 bn tonnes/annum of the carbon dioxide to the atmosphere, which is about 10% of the total, and some believe that, in order to prevent a catastrophic rise in the earth’s temperature, carbon dioxide emissions must be reduced by 50% come 2050. However, by 2050, it is likely that the iron and steel industry would have grown significantly so that the production may have risen to 2 or 3 bn tonnes/year so in order to meet the 50 % reduction on today’s figure, the carbon dioxide may have to be reduced to 25% or less, which is a very demanding requirement. There are probably three ways of reducing the carbon dioxide output:1. By capture and sequestration, but this may be technically very demanding.2. Reduction using hydrogen in place of carbon."

Jan 1, 2009

By John J. J. Chen, Barry J. Welch

"The production of primary aluminium can potentially lead to metal that, with minimum treatment, meets a high purity standard. Smelters that can achieve a significant proportion of their production in this manner have a competitive edge which is of growing importance as the use grows for such items as compact discs and the like. Superimposed on the desire to produce high quality metal are stringent environmental requirements that the industry must adhere to. The environmental legislation focuses on fluoride emissions and the approach adopted is towards a zero waste management philosophy. The fluoride recycling process does, however, result in volatile impurities being captured and recycled to the cell. Aluminium has an extremely high reduction potential and this results in a significant proportion of the recycled impurities being reduced at the electrolyte metal interface and thus contaminating the metal. This paper reviews sources of impurities and the impact of the operating procedures adopted on metal treatment.IntroductionSeveral factors have contributed to the immense growth in the aluminium smelting industry. Initially the ready availability of hydro electricity provided a primary reduction energy source for the production of the light-weight metal. Because of its unique properties and innovation in the industry there has been a continued exploitation of its unique properties, especially at the high purity end of the metal. The industry has shown considerably versatility and innovation in adapting to the ever increasing demands of quality and purity. It is however a competitive industry and the ability to produce high purity grade metal (>99.9% pure) gives a competitive edge. Emerging markets such as for CD ROM disc production etc, will keep the quality demand stringent.While the industry has met the continuing demands for metal quality, it has also had to respond to stringent environmental requirements for emissions from the production plant. Like all extractive metallurgical processes carbon dioxide is an inevitable reaction byproduct. However, the volatilization and hydrolysis of the solvent electrolyte leads to fluoride emissions that are potentially harmful. Accordingly, the industry has adopted essentially a zero non-process waste management approach. All cell emissions, including reducible impurities, are recycled back to the cell. This has had a significant influence on the metal treatment processes."

Jan 1, 1996

By J. Schmidl

In non-ferrous metallurgy the service life of refractory materials typically ranges from several weeks up to three years or more and is strongly dependent on operating conditions. To support our customers with the most viable refractory solution for their needs RHI Magnesita follows a structured approach of thermo-chemical calculations, experimental evaluation from lab scale up to industrial field tests and post-mortem analysis of used refractory materials. This paper will give an overview of the RHI Magnesita refractory selection process and the most recent developments of the experimental setup for the so called HF-IF test. This is a dynamic corrosion test that allows to determine fundamental properties of different refractory material types under process conditions subjected with respective customers process materials. The HF-IF experimental procedure is an excellent tool to simulate refractory wear in industrial processes, diminishing risks associated with plant trials and support decision making to choose the optimal refractory solution for the customer.

By P Hofmeyr, D Pretorius

Iron ore, which is transported by rail from the iron ore mines at Sishen in the Northern Cape, to the Saldanha Iron Ore Terminal in the Western Cape, needs to be analysed while loading to be exported. Every shipment will be sampled and an average analysis of the ore will be produced which is required by the purchaser at the receiving port. On arrival at the iron ore terminal at Saldanha, the ore is tipped from the rail trucks onto conveyor belts to be either stockpiled or direct-loaded. The conveyor belts run under the sampling plant and the ore is sampled periodically by means of an automated cross-belt sampler. This is the first iron ore port sampling facility in which the automated sampler is situated above the conveyor belts and not adjacent to them. A portion of the primary sample taken off the belt is moved to the dedicated sampling laboratory situated behind the cross-belt sampler and over the conveyor belt lines. The sample is split in the laboratory, one split being used for moisture and particle size determination and the other part is dried and then analysed by means of X-ray fluorescence spectrometry (XRFS) on fusion beads for major and minor elements. Particular care is taken to obtain high quality data for penalty elements.This sampling plant is completely automated and from the primary cross-belt sampler to final analysis by XRFS no manual steps are involved. This has meant that some processes are used which are suitable for automation and are ISO compliant but not necessarily ISO-certificated. The ISO manuals were developed with manual laboratory processes in mind. Precautions are also taken to maintain the integrity and representativity of the samples. This paper is a case study?describing?the automated sampling systems used at the Saldanha Iron Ore Terminal sampling facility and laboratory from conveyor belt to analysis.CITATION:Hofmeyr, P and Pretorius, D, 2012. Automated sampling of iron ore for analysis at the Saldanha Iron Ore Terminal in South Africa, in Proceedings Sampling 2012 , pp 25-32 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 21, 2012

By Jinliang Zhang, Jian Pan, Deqing Zhu

"Limestone and burnt magnesite were added to vary MgO content and basicity (CaO/SiO2 ratio) of pellets for investigating their influences on the properties of specularite pellets. At fixed MgO content, the addition of limestone does not affect on the properties of green balls significantly. The addition of burnt magnesite has obvious influence on the quality of green balls, especially on the thermal shock temperature. Without burnt magnesite, the thermal shock temperatures are about 400°C, and, the thermal shock temperature increases to 600~630°C by adding burnt magnesite. For preheated pellets, when the burnt magnesite is added, the compressive strength will be decreased. For roasted pellets without burnt magnesite, the calcium additives can form binding phase of calcium-ferrite, and suitable liquid phase will improve recrystallization of hematite, but excessive liquid will destroy the structure of pellets, so the compressive strength of pellet increases firstly and then decreases. When adding burnt magnesite, the compressive strength will increase as the basicity increases. When the basicity is more than 0.2, the compressive strength of the pellets various MgO content and basicity is above 2500N/pellet and then MgO-bearing fluxes can be added to prepare pellets with good high temperature properties.IntroductionWith the rapid development of the steel industry in China, oxidized pellets, possessing good mechanical and metallurgical properties, are becoming indispensable burdens for blast furnace ironmaking [1-3]. However, this has resulted in the shortage of domestic iron concentrates, so many Chinese steel plants begin to use imported hematite concentrate to prepare pellets. Compared with magnetite pellets, the hematite pellets require high roasting temperature and narrow roasting temperature range (1300–1350°C) and possess low compressive strength [4,5].1"

Jan 1, 2012

By K P. Tully

In August 1996 a Microseismic Monitoring System developed by ISS International Limited was installed at the Pasminco Broken Hill Mine -Southern Cross area. The project aims were to:Assist in daily safety management in a mine environment which exhibits one of the highest occurrences of microseismic activity recorded in the Australian mining industry. Be used as a proactive tool in design of future development and stoping. The project to-date has been an unqualified success in achieving both goals. Consequently the system is being expanded from 6 to 14 monitoring sites.

Jan 1, 1998