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By T. Nishi, D. Teguri, K. Saitoh

In recent years the requirement for high carbon ferro-manganese (HCFeMn), which is the key product of our company, has increased due to bullish demand for steel products. In our Tokushima works, we have 2 closed types of electric furnaces (1F and 2F), with which we are manufacturing HCFeMn. In order to meet the increase in demand, we made various modifications to these furnaces and we tried to increase the furnace operating loads. Especially for 1F, we deepened the furnace. In this paper, we report the results of this modification. The operational situations of the above-mentioned two furnaces are different because they have different individual profiles. As for 1F prior to modification, the depth of the furnace was one meter shallower than2F, because 1F was designed for the manufacturing of SiMn. On the other hand, our Tokushima works specialized in HCFeMn 14 years ago. However, the profile of 1F was not optimized for HCFeMn. In comparison to 2F, 1F was more difficult to stabilize due to the smaller tolerance for the adjustment of the electrode length, the metal / slag level, and the coke-mixing ratio. We deepened 1F by 770mm by disposing of the furnace rolling mechanism. We consequently achieved a 10% increase in production capacity. This meant the operating load was enhanced from 24.5MW to 27MW, the furnace became more stable and the tapping speed of both metal and slag increased, all which made the tapping easier than before.

Jan 1, 2007

By Zhuofei Yang, Jidong Kang, David S. Wilkinson

The fatigue behavior of AM60 high pressure die casting magnesium alloys was studied in a straincontrolled manner. The fatigue test was interrupted every 2,000 cycles for X-ray tomography scanning. The specimen was removed to be scanned on a desktop micro-CT system. The value of using X-ray tomography in a fatigue properties study was assessed with respect to porosity, cracks and fracture surfaces. The 3D analysis and model results showed porosity could be well measured and modelled in 3D. Defects bands are made of pores under 50 µm in volume-equivalent sphere diameter. Larger pores are randomly distributed in the region between two defect bands. Observation of cracks by X-ray tomography occurs in three ways such that the 3D model gives the best illustration of crack-porosity interaction while the other two methods have better detectability on crack initiation and crack tip observation. X-ray tomography is also of value in failure analysis on fracture surfaces. By summarizing X-ray tomography data during fatigue testing and observing fracture surfaces on a 3D model, a better understanding on the crack initiation, crack-porosity interaction and the morphology of fracture surface is achieved.

Jan 1, 2014

By James W. Reil

A test series of small, precisely-controlled and thoroughly-monitored production blasts was conducted at two quarries. In each series, all variables except delay were kept constant, as much as practically possible. The first aim of the study was to determine the effect of local geology on ground vibration. The second aim was to test several hypotheses relating the effect of millisecond delay intervals to fragmentation and ground vibration. A resonant frequency of ground vibration was shown to be related to the thickness of the overburden, in accord with a model proposed by Gupta (1961). Since the overburden geology creating this resonant vibration cannot usually be changed, two methods were tested to choose delays such that blast vibrations would destructively interfere. These were shown to be effective in modifying both the peak particle velocity and response spectra of ground vibration. The delay interval chosen also affects fragmentation, primarily in massive rock, with an optimum relief between holes of 2 ms/ft. Strain gage records indicate a possible mechanism consistent with this information.

Jan 1, 1985

By W. J. Kroll

Despite the fact that barium minerals are plentiful and widely distributed in nature, this element is one that we do not yet know how to prepare cheaply in metallic form. This is due to its chemical activity, as evidenced by its great affinity for fluorine, chlorine, oxygen, nitrogen, hydrogen, and sulfur. Furthermore, it forms a very stable subchloride and subfluoride, which prevents isolation of the metal by fusion electrolysis from a halide bath. A good survey of the metallurgy of barium calcium, arid strontium has been made recently in Light Metals (54,55).3/ Metallic magnesium (46), calcium (83), barium, and strontium (27) reduce each other's oxides. Proof of this can be found in the activation of BaO after reduction with Mg, which leads to the formation of so-called "Maquenne" mixtures (58) used for absorbing gases. However, it is impossible to extract the reduced metal- from the residue, a fact that Guntz (25) attributed to the formation of barium suboxide. There is no necessity for presuming the formation of such a compound, as it has boon established that in the reduction there is always formed an alloy of the alkaline-earth metal with the magnesium, which is capable of producing hydrogen when brought into contact with water. The reduction of alkaline earth-metal oxides with aluminum was observed by Mallet (57) in 1877, but recent investigations have shown that the end product of the reaction is an alloy of aluminum with the alkaline earth metal (1,2). Silicon also has been suggested as a reducing agent, and the results obtained are the same (84,85).

Jan 1, 1945

In the interest of safety in underground coal mining, the Bureau of Mines recommends: 1. That doors used to control ventilation (a) Shall be installed in pairs to form air locks, (b) Shall be self-closing, (c) Shall not have latches or other devices for holding them open, (d) Shall be constructed and maintained to prevent excessive air leakage through or around them, (e) Shall be fire resistant. 2. That wherever practicable the use of doors shall be limited to development openings. The Mine Safety Board is of the opinion that the best practice in coal-mine ventilation makes use of a split system employing overcasts or undercasts with doors limited as far as feasible to development openings. The distance between air-lock doors on haulageways should be sufficient to accommodate a trip or train of maximum length. Where auxiliary doors are installed to control ventilation during emergencies, they should be so placed that they can be utilized readily in case of damage to the air-lock doors.

Jan 1, 1938

By G. K. Derby

Five different types of drilling systems were developed under the flexible drill program that was initiated by the Federal Bureau of Mines to protect roof bolter operators. The systems were designed for underground coal mines with seams as low as 30 inches, and with roof bolts longer than the height of the seam opening. Four of the developed systems were true flexible drills; the fifth was a remote-controlled, automatic rod changer concept. Only two of the five firms successfully completed testing requirements under the original contracts: BendixCorp.,4 with a true-flex drill; and Ingersoll-Rand Research, Inc., with the rod changer concept. The Bendix drill was rated best, and the Ingersoll-Rand drill was rated second. Because of the closeness of the ratings and the vast differences in the two development concepts, both systems had sufficient potential to justify further development funding for design updating and testing. Also, both systems warranted consideration for inclusion into other ongoing development projects under both safety and energy directed programs.

Jan 1, 1978

By F. W. Wood

The Bureau of Mines has sought clarification of the Ti-TiN system by studying the phases formed by diffusion reactions between titanium and titanium nitride. Reaction couples were prepared by embedding pockets of TiN powder in arc-melted buttons of titanium. Specimens were vacuum annealed at nominal temperatures of 800°, 950°, 1,200°, and 1,500° C. Metallographically mounted cross sections from reacted specimens and from some that were not annealed were examined optically, with an electron microprobe, with an election microscope, and by X-ray diffraction. Each annealed specimen contained a segregated core primarily of d-phase material, an ?-phase diffusion layer, an a-phase diffusion layer, and host metal. On the basis of corresponding microprobe analyses, and considering results of certain other research, a new phase diagram is proposed. It contains no qualitative innovations, only quantitative adjustments. Results were also analyzed from the viewpoint of diffusion behavior. Diffusion coefficients calculated for the ? phase were sufficiently scattered that the parameters are very tentative. Nevertheless, the diffusion behavior reported is in reasonable agreement with one of two prior studies if it is assumed that the earlier investigators were mistaken in their identification of the nitride phase in which the diffusion occurred.

Jan 1, 1974

By Manis Kumar Jha

Leaching studies were carried out for the recovery/ recycling of metals from PCBs containing 17.05% Cu, 0.74% Ni, 1.74% Fe, 4.35% Pb and 8.32% Sn using various acids such as H2SO4, HCl and HNO3. While sulfuric acid was not a suitable leachant for the dissolution of metals from PCBs, hydrochloric acid selectively dissolved tin. The nitric acid was found to be effective lixiviant with the recovery of 99.99% Cu, Fe, Ni and 36.7% Pb in 6M HNO3 at S/L ratio of 100 g/L and 90oC. The kinetic studies carried out with 2M and 4M HNO3 at 90oC showed ?Ash diffusion control dense constant size-spherical particles? model.

Jan 1, 2010

The Ministry of Commerce has been carrying out an evaluation of the resources of the Northwest Nelson region. In part this was to revisit the issues covered in the earlier proposal to close part of Northwest Nelson to mining under section 24 of the Mining Act (1971) initiated in 1990. In addition, the option of using GIS to integrate a variety of spatial data sets to aid policy formulation could be tested. The Northwest Nelson assessment would be a useful trial. The subsequent national park proposal provided a major impetus to the project and resulted in the scope of the study being broadened to include all energy and minerals resources.

Jan 1, 1993

By J. D. Ramsdell

To obtain information on the effects of cobalt on microstructure and tensile properties of titanium-vanadium-cobalt alloys, the composition ranges of 4 to 16 percent vanadium with 1 to 4 percent cobalt have been studied. The beta phase was not completely retained with vanadium additions up to 16 weight-percent or in the same alloys containing up to 4 percent cobalt.

Jan 1, 1960

By H Thanasekaran, J Kohmuench, B Seaman

To achieve an efficient separation in the flotation process, valuable particles need to be selectively segregated from the gangue while utilising a minimum number of flotation stages. TodayÆs existing flotation technologies are effective for fine particle size classes; however, limitations due to particle buoyancy and bubble-particle detachment restrict the effectiveness of traditional flotation approaches on coarser particles. As a result, flotation circuits are generally configured to process only fine particle size classes in order to maximise recovery in the primary stages. Eriez has invented a novel flotation technology, the HydroFloat, which overcomes these limitations by carrying-out flotation in a dense, fluidised-bed medium allowing for the recovery of coarse particles (>0.250 mm). Over the last 15 years, this technology has been successfully applied to industrial minerals with several full-scale units installed to recover particles up to and exceeding 3 mm diameter in primary flotation circuits. This paper includes discussions on the history of this technology, process theory, existing applications, and a review of recent sulphide-based laboratory test work conducted for Newcrest mining and others. Benefits of this approach, such as improved recovery, low energy consumption and reduced reagent addition will also be reviewed.CITATION:Kohmuench, J, Thanasekaran, H and Seaman, B, 2013. Advances in coarse particle flotation - Copper and gold, in Proceedings MetPlant 2013 , pp 378-386 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By Art Cooper

Granulation systems are common in the metals industry. The process of granulating slags, mattes and metals is more than a century old, and a number of different systems have been developed to accomplish this task. These systems have followed an evolutionary path, and may be characterized by common elements in terms of molten material handling, granulation methods and post-granulation processing. This paper will summarize the more common systems used in the metals industry, with particular reference to non-ferrous applications.

Jan 1, 2006

By William H. Langer

Large amounts of limestone fines co-produced during the processing of crushed lime-stone may be useful in the sequestration of carbon dioxide (CO2). Accelerated weathering of limestone (AWL) is proposed as a low-tech method to capture and sequester CO2 from fossil fuel-fired power plants and other point sources such as cement manufacturing. AWL reactants are readily available, inexpensive and environmentally benign. Waste CO2 is hydrated with water to produce carbonic acid. This reacts with and is neutralized by limestone fines, thus converting CO2 gas to dissolved calcium bicarbonate. AWL waste products can be disposed of in the ocean. Feasibility requires access to an inexpensive source of limestone and to seawater, thus limiting AWL facilities to within about 10 km (6 miles) of the coastline. The majority of U.S. coastal power-generating facilities are within economical transport distance of limestone resources. AWL presents opportunities for collaborative efforts among the crushed stone industry, electrical utilities, cement manufacturers and research scientists. There is a concern that CO2 generated from human activities is contributing to climatic and environmental changes. Approximately one-third of anthropogenic CO2 emissions come from burning fossil fuels to generate electricity. Each power plant is capable of emitting several million tons of CO2 annually. A variety of other industrial processes, such as cement manufacture, oil refining, and iron and steel production, also emit large amounts of CO2. The level of atmospheric CO2 can be reduced by capturing CO2 from point-source emissions and storing or sequestering it in isolation from the atmosphere (U.S. Department of Energy, 2003). In 1999, G.H. Rau and K. Caldeira proposed a geochemistry-based method that is referred to as accelerated weathering of limestone (AWL) in a paper titled ?Accelerating carbonate dissolution to sequester carbon dioxide in the ocean ? geochemical implications.?

Jan 1, 2009

By B. M. Harra, O&apos

Zinc smelting is frequently termed a backward art. The term is hardly true, for great progress has been made in recent years in the design and in the thermal efficiency of the retort furnace, in the quality of retorts, in the recovery of zinc, and in the ability to treat more impure and complex ores. The fact remains, however, that the peculiar physical and chemical properties of zinc have delayed such immense advances-large smelting units, high recovery, low-unit costs, and ability to treat low-grade ores-as have been made in the metallurgy of lead and copper. In current retort-smelting practice, the ores, if carbonates, are calcined to remove carbon dioxide; or, if sulphides, are roasted to remove sulphur. The sulphur must be eliminated as completely as possible, usually to less than 1 per cent. This means that the roast must be continued for a long time at a high temperature, with resulting high cost and small capacity per furnace. The roasted ore is mixed with about 50 per cent of its weight of reducer, which may be fine coke, anthracite, or nonbituminous coal. This mixture is charged into horizontal fire-clay retorts. The retorts used in this country are about 8 inches in internal diameter by 4 feet in length and hold 50 or 60 pounds of ore. The diameter of the retort is limited by the time required for the heat to penetrate to the center of the charge; the length by the strength of the retort, which at the high temperature employed can not support the weight of the charge if the span is more than about 50 inches. The retorts are heated externally by coal, natural gas, or producer gas to a temperature of 1,200° C. or more. The zinc oxide is reduced to zinc, which is volatile at this temperature, and passes into a conical fire-clay condenser attached to one end of the retort, where it condenses to liquid zinc and is removed. Twenty-four hours are required for distillation, and because of the low heat conductivity of the retort walls and of the ore charge itself, the heat efficiency even of the most modern regenerative furnaces is only about 12 per cent. The retorts have a short life, 30 to 60 days, at the high temperature required; zinc

Jan 1, 1923

By Terry McMahon

This Bureau of Mines report describes the rock burst problem and measures being taken for its alleviation in the deep underground mines of the Coeur d?Alene Mining District in northern Idaho. The geologic features that contribute to rock bursting in that area are discussed and briefly compared with similar features in other burst-prone mining districts throughout the world. Early investigations to understand and control rock bursting are reviewed, and the mechanics of bursting are discussed in terms of the seismic events that produce them. Sources of strain energy, rock failure mechanisms, and the conditions necessary for the release of seismic energy are covered in detail. Rock burst research in the Coeur d'Alene District is described. Included are discussions of the microseismic method as both a research tool and as a rock burst monitoring system, rock destress blasting and preconditioning methods for rock burst control, and stoping methods currently being developed to reduce rock burst hazards.

Jan 1, 1988

By Joseph A. Vanous

The inductive communication system was developed under this contract for use in the hoist of deep mines. This program was a four phase program with experimental dual frequency equipment resulting from Phase I, emergency single frequency equipment developed under Phase II, and equipment documentation required under Phase III. An additional emergency system was provided under Phase IV.

Jan 1, 1976

By W. Vorster

Bateman Engineering Project's acid-plant track record goes back to 1977. Bateman Engineering can design sulphuric plants based on gas from sulphur burners, metallurgical off gas as well as pyrite roasting systems. Bateman Engineering has a technology marketing agreement with NORAM Engineering Ltd of Canada to provide state-of-the-art, well-proven acid plant technology, and also has access to roaster technology from several sources, including Chinese technology. Utilising the Noram technology agreement, Bateman was awarded the Engineering and Procurement (EP) contract for the Ambatovy Nickel Project, Sulphuric Acid Facilities in 2007. This is the first Greenfield sulphuric acid plant Bateman has designed for many years, producing a combined 5,500tpd, and is one of the largest sulphur burning acid plants in the world. This paper gives an overview of the sulphuric acid plant for the Ambatovy Nickel Project, advantages of Noram?s unique technology on offer, an overview of work conducted on a recent study of an pyrite roasting acid plants as well as a new technology currently being developed by Bateman for the direct combustion of solid sulphur to form sulphur dioxide.

Jan 1, 2009

ALTHOUGH the development of the various flotation processes during the last 8 years has been so revolutionary, this development has been, until recently, entirely confined to the separation of the gangue from the mixed metalliferous sulphides.The desirability of finding some method of separating the independent sulphides from such a miXture, by means of flotation, has long been recognized. ThIS need was emphasized when the slimes resulting from the grinding of Broken Hill sulphide ores were for the first time successfully dealt with by the Mineral Separation Company's process on the Central mine. This process proved the practicability of separating the sulphides of lead and zinc as a mixed concentrate from the gangue present in slime. Although this was a very notable achievement, the process has not been generally used, owing to the mixed lead and zinc concentrates resulting from the treatment being acceptable neither to the zinc nor the lead smelters.Although the introduction of eucalyptus oil in minute quantities as an emulsifying agent has simplified the work of the subsequent tabling of mixed sulphide concentrates, rendering unnecessary the burning off or removal of the oil, there will always be a considerable quantity of slimy product too fine to settle on the moving surface of the concentrating machines, and therefore requiring other means for its division into lead and zinc concentrates.

Jan 1, 1912

Scope / Agenda ? What is Situation Awareness (SA)? ? Background on SA theory ? SA is critical in a wide variety of domains ? SA and human performance ? Consequences of poor SA ? Significant challenges for SA in mining operations ? Technology centric design ? SA-oriented design methodology ? Goal-Directed Task Analysis ? Design ? SA Measurement and Evaluation ? Applications of SA-oriented design

Aug 1, 2013

By A. Mahmoudkhani

Primary cementing is the process of placing cement in the annulus between the casing and the formations exposed to the wellbore. Portland cement was first used in 1903 in the Lopoc Field in California for well cementing. Since then, the major objective of primary cementing has always been to provide zonal isolation in oil, gas and water wells, i.e. to exclude fluid(s) in one zone from another zone in the well. To achieve this objective a hydraulic seal must be created between the casing and cement and between the cement and the formations, while at the same time preventing fluid channels in the cement sheath. This requirement makes primary cementing the most important operation performed on a well. Without complete isolation in the wellbore, the well may never reach its full producing potential. The industry knowledge on cements relies heavily on empirical data, but the chemistry, physics and structure of cement are not fully understood yet. The strength of concrete can be increased essentially by reducing its porosity through optimizing the size distribution of its components and filling the residual porosity of the hydrated cement phase with inorganic fillers. This approach has successfully utilized in different ways and several technologies for placing high performance oil and gas well cements have been developed over the last few decades. There are reasons to believe that the next source of improvement will lie in the fine-tuning of the hydrates themselves and of the different parameters that drive short (ionic?covalent bonding) and long (ionic correlation) interactions.

Jan 1, 2012