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By D. P. Bishop, G. J. Kipouros, R. L. Hexemer Jr., I. W. Donaldson, W. F. Caley

Aluminum powder metallurgy (APM) is an advanced metal forming technology frequently employed to fabricate complex structural components in a near-net-shape fashion. Exhibiting nearly 100% material utilization, APM continues to rise in popularity. Recent research initiatives in this field have emphasized the development and processing of advanced 2xxx and 7xxx series alloys. In particular, APM equivalents to wrought 7075 and 2024 have been sought. An overview of work completed in this area is presented. Included are data on the various production stages (powder compaction, sintering, forging, and heat treatment) as well as the microstructure and mechanical properties of the finished products.

Jan 1, 2010

By Alan Weakly

The Powder River Basin (PRB) of northeastern Wyoming and south-central Montana is the largest strippable reserve of compliant coal (0.6 or less lb of sulfur per million Btu) in the United States. In mining parlance, it is the Mother Lode! Wyoming’s portion of the Basin provides one fifth of the coal produced in the United States annually, and the state has been the nation’s top coal producer for the past six years. Based on 1993 production statistics and estimated strippable compliance coal reserves, Wyoming may remain the nation’s top producer for the next 76 plus years. Past articles on the PRB have focused mainly on production. After living and working in the Basin for the past five years, I have developed an appreciation for the area and its major industry that transcends size and production data. In the fall of 1993, MINING ENGINEERING’s publisher and I decided to present a series of articles that would cover many other aspects of the Basin. Ten topics were outlined, and specific individuals, selected for their knowledge and experience, were asked to contribute articles about their specialties. Although Montana has four large mines producing coal from the PRB, this series of articles will concentrate on the Wyoming portion of the Basin.

Jan 1, 1994

By L. Alan Weakly

The Powder River Basin of northeastern Wyoming and southcentral Montana contains the largest strip minable reserve of compliance coal (0.27 kg or 0.6 or less Ibs of sulfur per million Btu) in the United States. In mining parlance, it is the mother lode. Wyoming's portion of the Basin is called the Southern Powder River Basin (SPRB). It has been the nation's top coal producer for the past nine years. And based on 1997 production statistics and estimated strippable compliance coal reserves, Wyoming should remain the nation's top producer for the next 51 plus years. In August 1994, ME featured 10 articles that covered all aspects of coal production in the SPRB. In this issue, five authors update the 1994 articles and provide a pre- diction of what the Basin will look like at the turn of the century. In addition to this article, the titles and authors of the other five articles include: ? "Geology of Wyoming's Powder River Basin coal field," by Gary B. Glass and Robert M. Lyman. ? "Coal quality challenges in the Powder River Basin," by Sharon Roness, Richard A. Turpin and Robert A. Young. ? "Markets for Southern Powder River Basin coal," by , Patti J. Best and Patrick W. Wright. ? "Evolution of mining equipment in the Powder River Basin," by Kenneth R. Miller and James L. Long. ? "Hauling coal into the 21st century," by Dave Willis and Will Cunningham.

Jan 1, 1998

By Colin C. Harris, Jie Zheng, P. Sornasundaran

Powder surface and polymer structural changes during stirred milling have been studied as a function of grinding time, solid concentration and polymer molecular weight. It was found that specific surface area of limestone particles can be increased over 100% by using polymer additives. Particle surface and polymer structure were also found to change during grinding. Powder surface and polymer properties have been determined using Surface Tension, Fluorescence, TOC and HPLC/GPC analysis, and surface and polymer properties are correlated with operating variables and the mechanisms involved are explored. Particularly, the fragmentation of the polymer molecules was found to occur during long term grinding and this was beneficial for ultrafine grinding.

Jan 1, 1998

By E. H. Hamilton

WHEN starting a series of experiments on the use of powdered coal in lead blast furnaces to replace coke, I realized that in copper smelting the problem is simpler because the sulfur recovers the copper in the form of matte. In lead smelting there are greater difficulties because a reducing atmosphere must be maintained in the active, zone corresponding to each tuyere in order to get the best recovery of lead. Therefore, the feed of powdered coal must be quite regular, uniform and under control. The molten products issuing from the taphole are the resultant of the work of all the tuyeres and it can readily be con-ceived that one part of the furnace may be forming slag with a higher lead content than the slag formed in other parts of the furnace. At first, we used only one tuyere situated on the back of the furnace. This was for the purpose of getting all of our regulations under the regular operating conditions. We tried every known system of feed and found they were not dependable and our present system was finally worked out, and so far as we know, is the only working system that will give uniformly good saving in lead blast furnaces. We placed a Bristol self-recording thermometer on the feed floor. This gives a 24-hr. continuous record of the temperature of the gases leaving the furnace. We put a self-recording gage on the "15-lb." air used in the injector. A second recording Bristol gage was put on the low-pressure air (40 oz.). I realized that it was necessary that we should know the exact weight of coal going into each tuyere and that it should 'be under observation at all times. L. W. Kirk was assigned to the problem and developed the open sight feed and the distributor, so that we now have the coal being fed into each tuyere in sight of the men in charge. We have an apothecary's balance beside the furnace, and the operator takes the pan and inserts it under the stream of falling powdered coal for one minute, and places the pan on the scale, the other scale pan having weights indicating the desired amount to be fed to each tuyere per minute.

Jan 10, 1922

By A. W. Hahn

USE of gold leaf goes back to biblical and even to prehistoric times. Both gold and silver, as well as other metals, were employed in illustrating or illuminating manuscripts. The medieval monks also used bronze powders. Metals were subdivided as finely as possible by mechanical methods, or by granulation and then were pounded into finely divided flakes. Substances such as honey have also been employed, since early times to keep the flakes of metal apart during grinding. Stearic acid is a more modern agent used in flaking aluminum and other metals. Finely divided "blue powder" is a by-product in retorting zinc ores, and contains from 78 to 90 per cent of zinc metal. This has been used as a precipitant for precious metals in the cyanide process and for chemical reduction processes. The making of zinc dust by atomizing is a step well known in electrolytic zinc plants. The Thermit process of Goldschmidt also requires the use of finely divided aluminum.

Jan 1, 1937

By R. C. McMurchy

"The Powell mine is in western Quebec about 2 miles northwest of the adjoining towns of Noranda and Rouyn. It is the original discovery of the area, its gold-bearing quartz vein having been discovered in 1922. Considerable work was done on this vein by several companies and discontinued because the grade, when gold was $20 an ounce, was too low for profitable extraction. Between 1922 and 1924 an inclined shaft was sunk to 225 feet and drifts were driven 240 feet on the 100-foot level.In 1929, due to the discovery and development of the Horne mine at Noranda, interest was revived in the property. Sulphide deposits of the disseminated and vein types were explored on the Powell claims. On the B copper 'showing', a vertical shaft, now known as the 'old copper shaft', was sunk to ·a depth of 167 feet and 300 feet of lateral work was carried out on the 150-foot level. As no orebody was discovered this work was discontinued.In 1933 the present company, Powell Rouyn Gold Mines, Limited, was formed and the gold-bearing quartz veins were again tested by drilling and trenching. In 1936, the price of gold having risen to $35 an ounce, operations were resumed. Since then the inclined shaft (No. 1) has been deepened to 500 feet, a second shaft (No. 2, vertical) on the main quartz vein has been sunk to 2,630 feet, and ll; shallow vertical shaft (No. 3) on the same vein but in the south claim has been sunk to 500 feet.Lateral work now approximates 9 miles, and to November 15th, 1946, 1,685,674 tons of ore, which averaged 0.129 oz. gold per ton and 73.6 per cent. Si02, had been extracted."

Jan 1, 1954

23.1-SOURCE, POWER-SYSTEM ELEMENTS A. J. T HUM Basic considerations in providing power for mine production and collateral operations are: 1. Mining operations of any size normally use electric motors for driving all equipment except mobile service units. 2. The electricity for power may be purchased or self-generated, depending on the location, size and specific operating circumstances of the individual property. 3. The major elements of the power system will be the source, either an incoming transmission line from a utility in the case of purchased power or the power plant if self-generated. Energy for the power plant may be water, hydrocarbon fuels, waste heat or nuclear, which will govern the type of prime mover selected. 4. The electricity normally is generated in the form of alternating current and must be distributed to the points of usage. This usually requires a primary substation for transformation to suitable voltages and secondary substations at points of usage throughout the operations, The power is delivered from the primary to the secondary substations over transmission lines or cables, depending on distances, voltages and local conditions. 5. At the points of use, there will be starting and protective devices for each motor. In some instances, direct current will be needed and rectifiers of various types can be used to provide it. 6. The entire electrical system requires suitable switching and protective devices to prevent damage to the equipment in case of power failues or faults; also, in most cases, sufficient metering to establish the demand and amount of electrical energy consumed. 23.2-PURCHASED POWER A. J. THULI 1. Where public-utility or government-generated power is available, it usually is advantageous for the mine owner to purchase rather than generate. Purchased power generally will be cheaper and more reliable than operating a small generating plant except in some cases where waste heat is available as the source of energy and can be used to supply all or a portion of the power requirements. 2. If it is decided to purchase power, the owner usually must participate in the cost of constructing the connecting line from the closest existing utility line to his point of usage. If the connected load is less than 1,000 lip, it probably is best to let the utility provide the primary substation. For larger connected loads the owner can obtain a more favorable "primary voltage" rate if he provides the primary substation to receive the incoming power and transform it to the distributing and usage voltages. 3. The cost of purchased power usually is made up of a demand charge, deter¬mined by the maximum amount of power the customer takes during any 15-min period throughout a month, and a graduated energy charge for the kilowatt-hours consumed-that is, so much for the first block of energy based on the demand,

Jan 1, 1973

By A. Gutiérrez

At present, most ore milling is done in tumbling mills, consisting of huge cylinders turning on their horizontal axis. This rotational motion causes the ore charge and the grinding balls to interact by impact, compression and abrasion, to reduce the size of the ore. This method is very inefficient since only around 12% of the energy supplied is used for actual grinding, the rest being used in moving the large mass of balls and ore within the mill. This work aimed at better understanding the milling process by evaluating the movement of the load through the Discrete Elements Method (DEM). First, the number of bodies (balls and ore) moving inside the mill is determined, to correlate to the potential impacts that constitute one of the milling mechanisms. Then, the number of high energy impacts is evaluated to correlate to the bodies in motion. At this stage, a differentiation between grinding media and the ore, as well as between the types of contact taking place in the mill, has to be made. This latter issue is of great relevance since from the five identified contact types (ball-ball, ball-liner, ore-ore, ball-ore and ore-liner) only the last three actually contribute to the milling process, the other two causing structural damage to the mill.

Jan 1, 2007

By L. A. Vaisberg

"Crushing and grinding are the two most common industrial processes. These processes consume nearly 20 per cent of the entire electric power produced worldwide. This enormous amount of electric power consumed results from the fact that modern crushing and grinding machines employ the processes first introduced by the prehistoric man, namely those of compression, impact, attrition, and cutting. The material thus handled decomposes indiscriminately, and almost completely ignoring the microscopic cracks and other defects of its structure. Apart from the irrational use of the power, the crushing and grinding processes currently in use result in irretrievable loss of useful components or else in a substantial deterioration of the final products obtained, all as a result of incomplete grinding or, reversely, of overgrinding, palletizing, or fracture of particles.The principal type of equipment that has almost universally been used all over the world for more than 150 years for crushing both natural and synthetic minerals comprises unbalanced jaw and cone crushers. The driving element of crushing bodies in these machines is an unbalanced weight, which transfers the crushing body, allowing it to squeeze the material within the eccentricity value only. The maximum reduction ratio achieved by such a drive is 5, which is due to the rigid kinematic arrangement of the crusher, its dynamic unbalance, and the impossibility of increasing the number of impacts on the material being crushed. Moreover, conventional machines cannot cope with super hard materials, and their mechanism is vulnerable to damage by uncrushable objects.On the basis of fundamental research into the theories of solid body and vibration, OAO Mekhanobr- Tekhnika have developed a range of vibrating jaw and cone inertia crushers that make a reduction ratio of 30 feasible in an open-circuit operation with the reduction ratio monitored within a wide range. In these crushers, the eccentric drive is replaced with a vibrating one. In this way the rigid kinematic drive became dynamic, thus allowing pieces of material to be crushed in a thick layer due to the effect of their bumping into each other, and with the amplitude changing automatically. This results in a number of advantages as compared with conventional crushers:"

Jan 1, 2003

By Colin C. Harris, Jie Zheng

While applications of stirred media mills for fine particle production have continued to increase, there is a lack of understanding of operating behavior and power requirement. Investigations in laboratory stirred media mills have been carried out with grinding media, limestone and yttria stabilized zirconia. The torque required to rotate impellers immersed in dense particulate media with supernatant versus impeller rotational speed displays four regions marked by sharp transitions: transition from static to dynamic friction; channel- ling; dispersing; and centrifuging. Equations, including dimension- less group correlations of power and modified Reynolds number, for relating power, speed, impeller and tank dimensions and design, media size and density, solid concentration, and other relevant variables have been established. Scale-up guidelines with respect to power consumption are also proposed. The best operating conditions for grinding limestone in the laboratory stirred media mill have been identified. Complexation by the polymer during ultrafine grinding of zirconia has been found to cause extraction of yttrium into solution with possibly significant changes in the surface chemical composition of the product.

Jan 1, 1995

By T. W. Camm

Aristotle made the observation that man is a political animal. Engineers often like to think they are above the fray when it comes to organizational politics, but most organizational theorists believe politics is a fundamental dynamic in any group. This paper examines the various ways that people use power within organizations to negotiate the political interactions in the work place.

Feb 27, 2013

By J. R. Cooper

Since man began beneficiating ores, a limited number of factors influenced the type of treatment. The ore itself has always been a factor. The first form of concentration was probably hand sorting, and the grade of concentrate and recovery had to be considered from the start. The cost of labor as a factor in mill design did not attain importance until the period following World War I. Power was one of the cheapest commodities available, and consequently power consumption was ignored. That no longer holds true. The present work does nothing to simplify the work of the metallurgist, or designer. On the contrary it adds another element to the design considerations. And while this report concentrates on power consumption, the mill designer must take the other factors into account as well. This study is based on a compilation of data supplied by a number of Western United States copper operations, as well as information from equipment manufacturers. Although its conclusiones apply to other minerals and geographic areas, the information is more precise, when applied to similar ores. The discussion has been divided into sections covering crushing, grinding, and flotation as these are the principal power consuming functions.

Jan 1, 1977

By P. Somasundaran, C. C. Harris

The power consumption of stirred-media mills was studied using an approach developed from work on stirred reactors. Evaluated were the relationships of factors such as stirring speed and impeller and tank dimensions on the torque required to rotate disc and pin impellers immersed in dense particulate media. Data collected under carious experimental conditions were analyzed. The results were summarized and presented in the form of characteristic plots, general equations and dimensionless group correlations involving power and modified Reynolds numbers. Special attention was directed towards the rheological properties of the media, which was considered a non-Newtonian liquid, and hence the equation of power-law liquids was employed. A procedure for estimating the parameters of effective viscosity and scale-up guidelines (with respect to power consumption) are proposed.

Jan 1, 1996

Power consumption of stirred media mills has been studied by an approach developed from work on stirred reactors. Relationships between torque required to rotate both disc and pin impellers immersed in dense particulate media as a function of speed, impeller and tank dimensions, and other relevant variables are evaluated. Data collected during numerous different experimental conditions are analyzed. The results can be summarized and presented in the form of characteristic plots, general equations and dimensionless group correlations involving power and modified Reynolds numbers. Special attention is directed towards the rheological properties of the media, which is considered as non-Newtonian liquids and hence, the equation of power law liquids is employed. Procedure for estimating parameters of effective viscosity and scale-up guidelines with respect to power consumption are put forward.

Jan 1, 1994

By Lukas Pichler

The market trend of advanced high strength steel (AHSS) with demand for higher strength products is increasing continuously. The inline cooling technologies have established as the most powerful metallurgical tool to achieve these demands. However, the cooling capabilities of existing hot strip mills, plate and Steckel mills are often not adequate to generate high cooling rates and the cooling accuracy required for the production of AHSS. Hence there have been many developments for an intensive, highly flexible accurate homogeneous cooling technology. Considering the wide variety of strip and plate geometry, Primetals Technologies have developed Power Cooling Technology for strip and introduced MULPIC®4 Technology for the plate production. In this paper we shall discuss these enhanced technologies that provide the inline cooling requirement with examples from the recently commissioned machines.

Aug 17, 2017

By G. T. Lineberry

Power requirements for a piece of mobile mining equipment are largely dependent on the set of conditions in which they must operate. These conditions are isolated and key parameters are identified. The effect of operating conditions on power determination is investigated. A simulation technique is developed to predict ranges of power demands for off-highway haul units as an archetype, permitting the analysis of changeable operating conditions. This program uses given data, conditions, and probabilities and ranges to solve for individual components of power, which can then be summed. By adopting such a technique, a systematic and rational determination of power is made possible. The usefulness of this basic approach in the determination of power requirements for other mobile mining equipment is emphasized.

Jan 1, 1983

The development of Mount Isa Mines Limited power supply is traced through the history of the mine operations. As would be expected, growth of the power supply system follows closely the increase in mine output, although it will be seen that total kWh. produced per ton milled shows a considerable reduction in later years when the mine output showed a more rapid rate of increase. That this reduction is not more marked is possibly due to the increased community and Shire Council power usage per head of population.INTRODUCTIONThe geographical position of Mount lsa, far from any large regional power supply Authority, dictated the policy that the Company be responsible for the production and suppiy of all power required for the plant operation. The Company also, in November 1937, accepted responsibility for the supply of a part of the power requirements of the township of Mount Isa. The history of power supply to the Mine may be divided into several phases.1. The supply Of lighting and power during the first plant construction period 1929-1931.2. The construction of the first section of the Mines Power Station, comprising Nos. 1 and 2 turbo alternators and boilers.3. The addition of No. 3 turbo alternator and boiler.4. The addition of No. 4 turbo alternator and boiler.5. The addition of No. 5 boiler.6. The addition of a. 2 turbo blowers for air supply to the Copper Smelter converters; b. 1 turbo blower for air supply to the L.ead Smelter; c. 2 turbo compressors for compressed air supply to the Mine and surface plant.

Jan 1, 1961

By David De Klerk, Maximilian Richter, Thirunavukkarasu Pathmathas, Indresan Govender

We consider the average power dissipation distribution for dense granular flows of an idealised mono-sized charge (5 mm glass beads) in a 300 mm diameter tumbling mill operated in the cascading-to-cataracting Froude regime. By combining the inherent frictional nature of particles within a dense flow regime and noting that tumbling mills are typically characterised by collisional and turbulent stresses, we derive the power dissipation distribution for athermal boundary conditions. The input data to the model (velocity, solids concentration, pressure and flow depth) are obtained directly from non-invasive measurement using a nuclear imaging technique: Positron Emission Particle tracking (PEPT). The power dissipation due shear stresses is shown to be the dominant mode of dissipation in the tumbling mill with up to two orders of magnitude difference between pressure induced dissipation and shear.

Jan 1, 2014

By C. D. Woodward

THE Anaconda Copper Mining Co. purchases 25,000 kw. of electric power for its mining operations at Butte Mont. This power is delivered, over duplicate feeders, in the form of 60-cycle, 2400-volt, three-phase current, to five compressor plants, where most of the energy is used for driving air compressors. At the compressor plants are located the switching apparatus for controlling the 2400-volt power and distributing it to the various mines. At these points, also, there are a number of motor-generator sets for converting the alternating current to 275-volt. direct current for the haulage systems. Pole lines convey the power from the compressor plants to outdoor transformer substations at most of the mines. When it is not economical to distribute the power at the lower voltages in the mines, transformers and motor-generator sets are placed at strategic points .underground. All power is purchased on a maximum-demand basis, therefore there is installed at one of the compressor plants an eight-element totalizing graphic wattmeter. This instrument records simultaneously the value of all power taken at the numerous points of delivery, which not only eliminates the diversity factor but permits load dispatching between compressor and pumping plants, and thus materially reduces the maximum demand from the power system. As most of the mine hoisting is done, by 90-lb. compressed-air winding engines, the air-compressor equipment for the winding engines and mining operations is quite extensive. The standard air compressor has a rating of 7500 cu. ft. per min. of free air, and most of the compressors are directly connected to synchronous motors. The synchronous motors are designed for 80 per cent. leading power factor, thus facilitating power-factor correction of total mine load. Consequently by cooperation with the power company, the voltage of the power received at the compressor plants is constant.

Jan 2, 1922