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By Fu Ping-Hao, J-P Franzidis, Sergio Mauricio Vianna, Ewen Silvester, Emmy V. Manlapig

"Over the last 5 years, an ambitious project has been undertaken at the Julius Kruttschnitt Mineral Research Centre (JKMRC) aiming to isolate, study and, if possible, model the effect of particle size, liberation and collector adsorption density on the floatability of mineral particles. As part of this project, we have conducted highly controlled flotation test-work, combined with state-of-the-art solution and surface analytical techniques such as High Performance Liquid Chromatography (HPLC), Time of Flight Secondary Ion Mass Spectroscopy (TOF-SIMS) and detailed mineralogical analysis to fully characterize the flotation behavior of a natural ore.The flotation tests were undertaken using a high-grade lead-zinc ore from BHP-Billiton's Cannington mine (Australia) in a specially designed continuously operated laboratory scale flotation rig. Solution and adsorbed collector concentrations were measured independently during the course of the flotation tests using HPLC based ex-situ techniques. Liberation studies were performed using the JKMRC Mineral Liberation Analyser (MLA) on selected size intervals of different streams to estimate the specific surface area of galena. These results were used to calculate the collector adsorption density (collector coverage) on galena particles, with the eventual aim of developing a mathematical model describing the relationship between pulp chemistry, feed mineralogy, and floatability of galena particles."

Jan 1, 2003

By M. Seerane, R. Machaka, P. Ndlangamandla

"Metal injection moulding (MIM) is a near-net-shaping powder metallurgy technique suitable for the cost-effective mass production of small and complex components. In this paper, the effects of the metal powder particle size on the final properties of 17-4 PH stainless steel are reported. Three different particle sizes (d50 33.0, 7.91 and 4.04 µm) were used to prepare the injectable MIM feedstocks using a CSIR-developed wax-based binder system at a fixed solids loading of 60 vol.%. The distribution slope parameter and the rheological flow index behaviour were used to predict the flowability of the feedstocks. The effects of the particle size on MIM products were established. The results are discussed in terms of the subsequent microstructural and mechanical properties of MIM 17-4 PH stainless steel against the established MPIF Standard 35. IntroductionMetal injection moulding (MIM) is a near-netshape manufacturing process established as an alternative to produce complex small-tomedium shaped components that were previously fabricated by conventional methods at higher costs (Attia and Alcock, 2011; Todd and Sidambe, 2013).Although recent advances in micromanufacturing (mainly machining and electrodeposition-based) have enabled the fabrication of complex micro-size geometries directly into miniaturized parts, these processes are generally neither routine nor easily accessible at present (Attia and Alcock, 2011).Typically, the MIM process consists of four steps: mixing, injection moulding, debinding and sintering. Mixing involves blending of the desired metal powder composition with carefully selected multicomponent organic binders at the right proportion. This mixture, which is called feedstock, is then injected into a mould of a required shape to form a ‘green part’. Debinding is the removal of the binders by chemical, thermal, or catalytic means while maintaining the shape of the part. Finally, the debound part is sintered to a full or near-full density part (Sotomayor, Varez and Levenfeld, 2010). The MIM process is essentially a combination of plastic injection moulding with conventional powder metallurgy technologies."

Jan 1, 2016

By Furuyama Takashi, Mori Sukeyuki, Hara Tsuyoshi, Fukushima Yujin

In mineral processing practice, flocculation is largely established as an engineering technique of waste water treatment and the study of parameters increasing the settling velocity of particles is still of great importance to improve the process. Further investigations were made using quartz (Q89) and fluorite samples (F91) which included 58.8% and 65.8% of -2.3 µm particles respectively. In all the experiments the flocculation phenomena were observed varying the pH value of the aqueous suspension. In contrast to quartz particles (Q89) which did not flocculate for all pH values, it was, noticed that fluorite particles (F91) flocculated in the alkaline range of pH over 11. With an aqueous suspension containing equal quantities of Q89 and F91, a hetero-flocculation of particles was observed at a range of pH below 10. In this case, the maximum floc size of the hetero-flocculation was 37.0-26.2 µm This size was about three times larger than when quartz (Q84) and fluorite particles (F85) were used with 32.4% and 40.4% of -2.31 µm particles respectively. Besides, in the experiments using Q89 and F91, the maximum size of hetero-flocculated single particles was found to be 6.54 µm instead of 3.27 µm as obtained with Q84 and F85.

Jan 1, 1995

By Richard L. Ash

In many instances, blasting exerts the dominant control over the economics and safety of excavation, where the materials involved are too hard and tough to be fragmented efficiently by other means. However, associated with the fragmentation process other effects very often result that are not desirable and may even be hazardous, such as fly rock, air blast, excessive overbreak, and damaging ground virbrations. It has always been the desire of those concerned with blasting to better control the forces involved so as to improve the breakage of materials, but at the same time reduce, or eliminate if possible, the unwanted side effects. Until the last decade or two, little was known of the phenomena concerned with blasting. However, since that time many investigators have studied blast mechanisms produced from both chemical and nuclear explosions, with the result that general concepts of the principles have been developed. But, in general, it is assumed that the energy from the explosion would be propagated spherically throughout the material, the latter of which for convenience of analyses is considered homogeneous and isotropic, i.e., the properties are the same in all directions, However, rocks are not isotropic as a rule, and evidence clearly indicates blasting forces rarely function uniformly or in spherical form as theorized.

Jan 1, 1965

By James P. Bennett, Jinichiro Nakano, Anna Nakano, Hani Abu El Hawa

Carbon feedstocks used in power, chemical and metallurgical industries typically contain numerous minerals or impurities that liquefy during high temperature processing to form slag as a byproduct. Slags have many industrial applications, for example, as construction materials and for element recovery. In addition to other variables, the extent of slag utilization is dependent on its com- position and post treatments. In this work, the in fluence of temperature and phos- phorus additions on phase evolution in coal slag was investigated. Synthetic slag mixtures with varying AlPO4 contents (0–14 wt%) were heated from 1380–1470 ° C in air, then water-quenched to preserve the phases formed. SEM/EDS, XRF and XRD analyses were performed before/after testing to gain insight about slag chemistry and phases present. It was found that coal slag exhibited a large solubility of phosphorous, affecting morphology of mullite formed under the conditions studied. Results obtained and their significance are discussed.

Mar 1, 2017

By Wills BA, Barley RW

A brief description of viscosity measuring devices used in Dense Media Separation (DMS) plants is given, including a new On-line viscometer system. The various factors which affect suspension viscosity are identified. The effect of temperature variation on viscosity and viscosity measurement is examined in detail. Practical problems in using a modified Stormer viscometer for laboratory testwork are noted. Likely problems of continuous viscosity measurements are also discussed.

Jan 1, 1987

By N. Singh

Merensky Reef is mined extensively within the Bushveld Complex. In previously mined-out areas on the Merensky Reef horizon there are pillars, potholes and remnants that have not been mined. These unmined blocks of ground on the Merensky Reef horizon can influence the mining of the underlying UG2 Reef. The extent of the influence will depend on the size of unmined ground and the middling between the two reef horizons. This paper quantifies the influence of partially extracted Merensky Reef on mining of the UG2 Reef, and aims to provide recommendations for mining strategies, as well as regional and local support to achieve efficient and safe extraction of the UG2 Reef, for various middlings beneath the Merensky Reef horizon. In some cases it was found that relatively shallow UG2 Reef mining could encounter conditions similar to those experienced in deep and ultra-deep mining environments.

Jan 1, 2005

By D. A. Rice

In pelletizing magnetic iron ore concentrates, about 6 to 18 lb of bentonite binder are added per ton of concentrate during balling to give green and dry strengths to the unfired pellets. The dry bentonite is mixed into the filtercake following the magnetic concentration circuit of the plant. The filtercake contains about 10% moisture, and the water may be of highly variable composition, depending on the particular concentration circuit, its source, and the ore being treated. A knowledge of the parameters that influence the balling operation is essential for optimal efficiency in producing balls strong enough to survive the treatment during transportation from the balling device to the furnace and during the firing operation. Furthermore, very weak unfired pellets probably contribute to high dust losses and poor furnace control. The factors that determine the strength of unfired pellets have received considerable study (1,2,3,4). Tigerschiold and Ilmoni(l) pointed out the significance of the surface area of the particles being pelletized. Merklin and Childs(2) reported on the effect of material size consist, chemical additives such as soda ash, lime, balling time, ball size, and the moisture content of green balls. Iwasaki and Zetterstrom(3) examined the detrimental effects of fatty acids on the pelletizing process. Stone(4) correlated the zeta potential of bentonites with the strength of unfired pellets. He found that, in general, a high negative charge on the bentonite is conducive to good balling. Although studies of pelletizing in the iron ore industry deal with a complex multicomponent system consisting mainly of the iron mineral, bentonite, and water, the last of these has received little attention, particularly with regard to the possible effects of mill water chemistry on the pelletizing process and the strength of unfired pellets. It is widely known that the composition of mill process water is an important variable in unit operations such as flotation, thickening, and filtering and that impure water can lead to poor metallurgical results. The results of the present study indicate that the chemistry of the mill water may be an important variable in the balling operation as well. Knowledge about this variable should contribute to lowering bentonite and oil consumption and to improving furnace performance. Such knowledge can also assist those who use balling in evaluating commercial bentonites for plant use as well as those investigating balling from a more fundamental point of view In this study we have examined 1) the effects of replacing mill process water in the magnetic concentrate filtercake with pure water, and 2) the effects of several chemical impurities that are commonly found in mill process waters upon the strength of unfired pellets. The results are interpreted in terms of the zeta potential of the bentonite and magnetite particles. The data lend support to a suggested mechanism whereby the electrostatic attraction of oppositely charged particle surfaces causes bentonite-bentonite and magnetite-bentonite bonding. This mechanism would also explain why several chemical additives e.g., sodium carbonates and phosphates, have such marked effects on increasing the strength of unfired pellets.

Jan 1, 1971

By B. W. Williams

The crack propagation behaviour of Zr-2.5Nb pressure tube material was studied through comparison of the measured behaviour with the predicted response from finite element analysis. Three-dimensional finite element simulations of compact tension specimens were performed using the crack tip opening angle as a fracture criterion to allow for crack propagation. To obtain reasonable agreement with the measured behaviour, it was important to capture both the anisotropic plastic deformation behaviour of the Zr-2.5Nb material through use of the Hill-48 yield criterion and damage due to void growth, nucleation, and coalescence through the use of a Gurson-based constitutive model in the simulations.

Jan 1, 2010

By W. T. Thompson, S. Durham, K. M. Jaansalu

The role of platinum on the relative stability of gamma - gamma prime equilibrium is only qualitatively known, and may bear upon the stability of a superalloy under a protective coating. The binary phase diagrams Ni-Pt and Al-Pt, and the Ni-rich corner of the Ni-Al-Pt ternary, are reviewed and simple self-consistent thermodynamic models are derived. These thermodynamic models are incorporated into a database used to predict the gamma-gamma prime equilibrium for single crystal superalloys. In small concentrations, platinum is predicted to increase the temperature stability, but not the proportion, of the gamma prime phase over the gamma phase in third generation alloys such as CMSX-10. Another effect of platinum addition is to significantly lower the solidus temperature. These findings are compared to experimental data in the literature.

Jan 1, 2004

By Lei Pan, Venkata Atluri, Xuming Wang, Yuesheng Gao, Jan D. Miller

Polysaccharides have been used as depressants for naturally hydrophobic talc in the flotation of base metal sulfide ores, precious metal sulfide ores and platinum group metal (PGM) sulfide ores. The results of this surface chemistry study confirm guar gum as a preferred polysaccharide for talc depression in the flotation of these ores. In addition to the practical application of the research results, the surface chemistry results are of academic significance, providing further information to understand how polysaccharide depressants function in these complex sulfide flotation systems.

By Lei Pan, Venkata Atluri, Xuming Wang, Yuesheng Gao, Jan D. Miller

The wetting characteristics and water film stability at the talc surface have been studied, particularly the effect of polysaccharides such as guar gum, starch, and dextrin. Talc is a gangue mineral in the flotation of base metal sulfide ores, precious metal sulfide ores, and platinum group metal (PGM) sulfide ores. Talc surfaces were investigated using surface analysis techniques including atomic force microscopy, high-speed video bubble attachment measurements, and wetting film stability measurements using a synchronized tri-wavelength reflection interferometry microscope (STRIM). In the presence of polysaccharides, there is a significant increase in bubble attachment time at the talc surface, but only a slight change in contact angle, which suggests that polysaccharide depression of talc is due primarily to the slow rate of bubble attachment and not due to a change in contact angle. The critical rupture thickness (hc) for a hydrophobic talc surface was found to be 56 nm, while the hydrophilic phlogopite surface of similar structure has an equilibrium film thickness (he) of 25 nm. At low polysaccharide concentrations, the wetting films formed on the talc surfaces were unstable, but at high concentrations the wetting films became stable with similar thickness values as the critical rupture thickness, and bubble attachment did not occur. However, it was found that the critical and equilibrium film thickness values do not change significantly with the polysaccharide type or concentration. The results from this research help us understand further details of film rupture and displacement during bubble attachment.

By R. J. Dippenaar, W. H. Van Niekerk, D. A. Kotze

It is generally accepted that alkalis attack and degrade the carbon fraction of coke in a blast furnace. Because South African cokes contain relatively high amounts of ash, the influence of alkalis on the ash fraction was investigated, the carbon and ash fractions being separated and studied separately. Potassium engenders the formation of liquid, with a resultant expansion of volume and a decrease in the strength of the coke ash. However, the ash did not play a significant part in the degradation of the coke, and it was found that the catalytic effect of potassium on the Boudouard reaction was the overriding factor in the coke-degradation process.

Jan 1, 1986

By Torrance AC

A joint research programme conducted by BHP Central Research Laboratories and Du Pont Wesfarmers Pty Ltd examined the effect of the size of cast primers on the run up and steady state detonation veloci- ties of ammonium nitrate based explosives as a function of blasthole diameter. Both continuous and point to point velocity of detonation meas- urement techniques were used. The field trials examined a number of the Du Pont HDP series of primers in conjunction with ANFO, emulsion and watergel explosives. Results indicate that the run up velocity of 187mm diameter ANFO charges is negligible using cast primers as small as 150g. owever, emulsion and watergel explosives did exhibit run up in both 187 and 311mm diameter blastholes, independent of the size of primer. This could last from 7 to 10 blasthole diameters.

Jan 1, 1988

By Ian A. Niell, Alastair C. Torrance

A joint research programme conducted by BHP Central Research Laboratories and Du Pont Wesfarmers Pty Ltd examined the effect of the size of cast primers on the run up and steady state detonation velocities of ammonium nitrate based explosives as a function of blasthole diameter. Both continuous and point to point velocity of detonation measurement techniques were used. The field trials examined a number of the Du Pont HDP series of primers in conjunction with ANFO, emulsion and watergel explosives. Results indicate that the run up velocity of 187mm diameter ANFO charges is negligible using cast primers as small as 1509. However, emulsion and watergel explosives did exhibit run up in both 187 and 311mm diameter blastholes, independent of the size of primer. This could last from 7 to 10 blasthole diameters.

Jan 1, 1990

By R. A. L. Drew, J. P. Immarigeon, F. Jalilian, M. Jahazi

In the present work TLP bonding of Inconel 617 is investigated. The influence of the main processing parameters i.e. time and thickness of the interlayer were studied with optical and scanning electron microscopy. Boron containing interlayers with two different thicknesses were used and the influence of various holding times from 5 min to 24 hours on the microstructure of the bond region was investigated. The results indicated that, for the testing temperature of 1065°C and holding times above 2 hours with an interlayer of 25.4 microns thick no liquid phase was observed. The same phenomenon occurred only after 6 hours for a 76.2 microns thick interlayer. Precipitate growth started at grain boundaries and continued inside the grains. The composition, size and morphology of the precipitates were studied using electron microprobe analysis. No noticeable changes were observed in the grain size of the base metal with increasing holding times.

Jan 1, 2004

The influence of pulp potential on the flotation behaviour of sulphide minerals in laboratory batch flotation tests is discussed in terms of self-induced flota- tion, collector-induced flotation, and depression.' Assuming that the pulp poten- tial is controlled by the same factors that determine the genuine redox poten- tial, an attempt is made to interpret the experimental results in terms of potential-dependent reactions based on bulk thermodynamic data. Self-induced flotation is displayed by many sulphides in moderately oxidizing solutions but not in reducing solutions. The available evidence suggests that the hydrophobic entity could be sulphur produced by superficial oxidation of the mineral but this has not been established beyond dispute. In general, flotation is observed near the potentials at which sul- phur would be expected to form and the minerals which produce sulphur seem to float the most strongly. Collector-induced flotation is most conveniently studied on minerals which have only slight self-induced floatab- ility. The mineral-collector interaction is potential-dependent hence flotation is generally only observed in limited ranges of potentials. While the general form of the floatability-potential relationship is similar to that predicted from thermody- namic data close correspondence between predicted and experimental results is not always observed.

Jan 1, 1984

Folklore suggests that oxidation is detrimental to sulfide mineral flotation, and in many instances is the reason given for values reporting in the tailing. However, while a considerable body of work examining galena oxidation is available in the literature there are very few studies that investigate the consequences of galena oxidation on its subsequent flotation in base metal sulfide ores. This work clearly demonstrates that pyrite forms a galvanic couple with galena, due to the large difference in their rest potentials, and results in accelerated oxidation of galena, particularly as the pyrite content of the ore is increased. The most obvious effect of the galvanic oxidation of galena by pyrite is the release into the system of galena oxidation products, providing an ample supply of lead ions available to activate gangue minerals, most notably of which in lead/zinc ores is sphalerite. The inadvertent activation of sphalerite by lead ions inevitably leads to the recovery of liberated sphalerite into the lead concentrate, and as a consequence a reduction in the lead concentrate grade. That is, a loss of selectivity for galena against sphalerite. If galena oxidation is excessive not only is there a considerable loss in lead concentrate grade, but also a marked decreased in lead recovery as the flotation rates of the gangue minerals increase, until they rival that of galena.

Jan 1, 2005

By L Teixeira, C J. Greet, P Karageorgos

Pyrite is ubiquitous within copper ores, and presents significant challenges to most operations in terms of its impact on copper sulfide concentrate grade and recovery.Samples of ore containing from 3 to 47 percent pyrite, with nominally the same chalcopyrite feed grade, were collected from a copper mine in eastern Australia for testing. The ores were ground under standard conditions using forged steel grinding media in the Magotteaux Mill® to determine the impact of increasing pyrite feed grade on the pulp chemistry of the system and subsequent rougher flotation response. Attempts were made to correlate the pulp chemical parameters (oxygen demand and EDTA extractable metal ions) with flotation behaviour to determine if one (or more) could be used as a metric to infer metallurgical behaviour.The observations made were then tested under different grinding environments (obtained using more electrochemically inert high chromium) grinding media to determine if they hold true.CITATION:Greet, C J, Karageorgos, P and Teixeira, L, 2015. The influence of pyrite on the pulp chemistry and copper flotation response of a chalcopyrite ore, in Proceedings MetPlant 2015, pp 175–187 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Sep 7, 2015

By N. Sarmady, Mei Li, N. C. Parson, W. J. Poole

"The mechanical behaviour of AA6082 is a function of the extrusion conditions and in particular, the quench rate after extrusion. It is well known that precipitation of Mg-Si phases on grain boundaries during quenching can negatively affect the ductility of the alloy. In this study, AA6082 alloys containing 0.5 wt. % Mn and 0.15 wt. % Cr were direct chill (DC) cast, homogenized and then extruded to produce 3 mm x 42 mm strips. The microstructure in the as-extruded strips was unrecrystallized due to the Zener-Smith drag from the Mn/Cr dispersoids. It was shown that a solution treatment of 5 minutes at 560°C did not significantly affecting the as-extruded microstructure but if the as-extruded strip was cold rolled prior to heating, recrystallization occurred concurrently with the solution treatment. As such, 3 initial microstructures were produced, i.e. unrecrystallized and recrystallized with a grain size of 9 and 40 µm. After the solution treatment, controlled cooling experiments were conducted using the Gleeble 3500 thermomechanical simulator with cooling rates of 10, 25, 80°C/s as well as water quenched. The mechanical properties (e.g. yield stress, fracture stress and fracture strain) were determined from tensile tests for the different combinations of initial microstructure and cooling rate. The relationship between the quench rate and precipitation of Mg-Si phases on grain boundaries was examined by FEG-SEM. It was found that the yield stress decreased as the cooling rate decreased and that there was complex relationship between the fracture properties and the microstructure.INTRODUCTION As the automotive industry strives to reduce fuel consumption and CO2 emissions with the goal of reducing the environmental impact, there is a need for lighter vehicles. As a result, aluminum alloys are gaining popularity to replace steel parts as structural components. An exemplar of this is the Ford F-150 pickup truck which has an aluminum body and is ˜750 pounds lighter than the previous steel version of the vehicle. The structure includes a mix of aluminum sheet, extrusions and cast alloys. The current research is concerned with the performance of aluminum extrusions in applications such as side rails, crash tubes and other structural parts. These components experience a combination of bending, stretching and folding both during the forming of the part and in service, e.g. crash of a vehicle. There is a need to have detailed information on the influence of processing on final material performance, in particular the cooling rate after extrusion."

Jan 1, 2018