Search Documents

By Laihua Wang, Peter Hayes, Hae-Geon Lee

"This paper introduces a new process for the efficient removal of dissolved gases and inclusions from liquid metals. This process involves the creation and dispersion of fine bubbles in molten metals by introducing inert or reactive gas into a region of turbulent flow. The highly turbulent metal flow splits the gas into fine bubbles and results in good mixing between the gas and molten metal phases. These conditions are ideal for contacting inclusions in the metal with the bubbles and subsequent flotation of the inclusions to the metal-slag interface where the inclusions are then absorbed by the covering slag layer. Dissolved gases, such as [H], [0], [N] in the metals are also transferred to the gas bubbles and removed from solution.The process concept has been previously demonstrated using a full-scale air/water model to simulate the ladle-to-tundish system of continuous casting of steel. The present cold modelling work has further demonstrated the ability of the process to remove gas solutes. The results indicate that the efficiency of new process is several hundred times greater than that of conventional high speed rotating injectors which are currently applied in the treatment of liquid light metals.IntroductionDuring metal smelting, refining and alloying processes, unwanted gas and second phase liquid or solid impurities are incorporated into liquid metals. In the case of steelmaking, the gas-forming impurities include [0], [H] and [N], and the solid impurities as a result of deoxidation include Ah03, Si02 inclusions. Common impurities in liquid aluminium are dissolved hydrogen and solid Ah03. To avoid subsequent problems during processing and to improve the physical properties of the metal products it is necessary to significantly reduce the level of impurities."

Jan 1, 1996

By David A. Orava, Richard C. Swider

"The technical knowledge and practical experience accumulated by industry and others in abating acid mine drainage (AMD) is being proactively applied at every phase of the mine life cycle. This paper traces the mine life cycle from exploration to post closure monitoring and maintenance, and reviews AMD abatement measures that have become an integral component of exploration and mining activities.Attention is increasingly being given to evaluating AMD potential as part of exploration work, and studies related to project feasibility and design. Mining, mineral processing, and waste management options are selected taking into consideration their suitability to inhibit AMD. These inhibition measures are typically committed to in closure plans submit-ted at the permitting stage. Mines are operated and decommissioned, often progressively, as planned and in accordance with environ-mental protection policies."

Jan 1, 1996

By III Cocanour

The line scan video photometer is a personal computer (PC) based, software-driven instrument which is used for the real time, on-line analysis of industrial process streams. The novelty of the instrument lies in the integration of its various components: (l) a true Red/Green/Blue (R/G/B) color video camera; (2) a unique, line-scan color sample and hold technique which provides a 4 to 20 mA analog signal to a commercial 12 bit analog to digital (A/D) converter; (3) software which converts data through a color absorbance algorithm to correlate elemental color to concentration; and (4) software-based control which utilizes color data, along with temperature and conductivity data to control process equipment. The photometer can be used for noninvasive analysis wherever color hues are representative of process variables such as chemical concentrations or mineralogy color reflectance. The line scan video photometer has been successfully demonstrated in solvent extraction/electrowinning (SX/EW) and ball mill circuits of copper producers.

Jan 1, 1996

By João M. S. Rodrigues

The use of sandblasting as a treatment method for conditioning anodes for zinc electro-winning was investigated and compared with conventional fluoride preconditioning. The anodes were made from two different lead-based alloys (Pb-Ag-Ca and Pb-Ag). Laboratory results showed that sandblasting and preconditioning both minimize lead contamination in the zinc and sludge generation. Sandblasting was found to have no aggravating effect on the anode corrosion. The sandblasting treatment was tested on Pb- Ag-Ca anodes on an industrial scale in the celJhouse of a local zinc producer. An unexpected finding of the large-scale tests was that the sandblasting appeared to strengthen the anodes, resulting in reduced warping during handling and operation.

Jan 1, 1996

By Garg. D.

Premixed bronze powders are widely used to produce a wide variety of P/M components including bearings and bushings by the powder metal industry. The physical and mechanical properties of sintered bronze components such as dimensions, strength, microstructural characteristics, and sintered density are well known to change with sinlering furnace design, particle size distribution in powders, green density, preheating and sinlering time" and temperature, and protective atmosphere flow rate. " However, not much is known about the effect of protective atmosphere composition on physical and mechanical properties of sintered bronze components; This paper describes effects of protective atmosphere composition and sintering temperature on physical and mechanical properties of sintered bronze components

Jan 1, 1996

By Louis J. Cabri

The ion microprobe (dynamic SIMS technique) is a very sensitive instrument for the quantitative determination of trace concentrations of precious metals (often at the ppb level) occurring in common sulfide minerals, either chemically-bound or as discrete particles too small for resolution by SEM. The technique involves sputtering a 250 x 250 Jim area of the grains to a depth of about one ILm and analysing the secondary ions emitted from a circular central region in the sputter crater with a 62.5 I'm diameter. The combination of quantitative mineral-specific sub-ppm analyses together with depth-profiling and the ability to produce secondary ion maps of trace precious metals makes this a very powerful technique in quantifying the precious metal distribution in refractory and other sulfide ores and process products. The technique is particularly well-established for analysis of gold-and platinum-bearing ores and process products.

Jan 1, 1996

By G. White

Traditional atmospheres used for Aluminum annealing have been air, exothermic gas, and cryogenic purity Nitrogen. Air and exothermic gas have several problems associated with them such as surface discoloration, toxic emissions, and explosion hazards. High Oxygen levels can cause Magnesium streaking and oil staining, and therefore pure Nitrogen has been the atmosphere of choice for high quality Aluminum coils. A comparative study was made on key Aluminum alloys annealed in Nitrogen with different Oxygen concentrations to determine the effect on surface quality. The atmosphere composition inside the furnace was analyzed during the purge and heat cycle to determine its effects on purge times and exhaust emissions. The Aluminum coils after annealing were visually inspected for surface staining before and after rolling. The lab study revealed that Nitrogen with up to 1.0% Oxygen is acceptable, and did not adversely effects the surface quality or any of the other processing variables. However it isbelieved that higher Oxygen concentrations are acceptable depending on the rolling oils and alloy systems.

Jan 1, 1996

By R. J. McLaughlin

Acid mine drainage (AMD) can occur as a natural phenomenon through oxidation of sulfide minerals. Oxidation by air and water can be exacerbated by mining. Because AMD can exhibit low pH, it is capable of extracting heavy metals from mineral deposits. The result is highly acidic drainage with elevated heavy metal concentrations -the combination of which can cause extensive environmental damage. Because of the importance of these factors, this paper is focused on sulfate based AMD. Due to widespread mining, the occurrence of AMD is ubiquitous. As a result, several approaches to treatment have been developed. Chemical treatment using alkali is most commonly employed to treat AMD. There are alternative methods of treatment, as well as alternative ways of handling treatment sludges or concentrates. Dewatering of sludge or concentrates is beyond the scope of this paper.

Jan 1, 1996

By G. Belardi

The purpose of the study was to check on the level of environmental contamination and to design a project for cleaning up the Abetina Mine area at Piancastagnaio (Grosseto, Italy). Contamination of this area had occurred during the mining and treatment of cinnabar (HgS) over a prolonged period. The aim of the project is to remove the sources of contamination or render them harmless. Mining of the Piancastagnaio deposit started in 1840, mercury metal being extracted from the ore by thermal treatment. Together with Spain, Italy was the first country to produce this metal and was the world leader in this field between 1936 and 1943. Though mercury production in the Monte Amiata region of Tuscany ceased in 1974 the ensuing environmental impact is very evident, taking the form of rusty old mining and processing works, plus waste tips which still contain considerable amount of mercury even after the ore had been subject to thermal extraction treatment. The research which has been conducted included mapping the area to identify the main sources of mercury and arsenic pollution, as well as the level of environmental contamination. Mercury and arsenic values in excess of 16,000 and 150 ppm respectively are encountered in the most highly-contaminated places. The cleanup project has been drawn up on the basis of the field and laboratory investigations. This provides for a combination of remediation measures on the land concerned, as well as in situ inertization of contaminating elements by means of mixtures of chemical compounds such as cyclosiloxanes. Due account has been taken of Italian and EU environmental regulations when establishing the measures for rendering the various polluting element innocuous. 'The efficacy of the inertization techniques has been checked by yield tests in acetic acid and carbon dioxide, reducing the Hg and As contents of the material in the untreated and treated states from maximum values of 7 mgll to minima close to zero.

Jan 1, 1996

By Fathi Habashi

During the recovery of copper, nickel, zinc, and lead from their sulfide ores, large amounts of sulfur dioxide are generated. A fraction of this gas is captured and transformed into sulfuric acid and liquid SOl and the remainder is emitted to the atmosphere. Numerous proposals were made to solve this problem. Hydrometallurgy offers the only valid solution by which elemental sulfur instead of sulfur dioxide can be produced. Sulfur can be easily stored, transported long distances, or transformed into S02 and H2S04 when desired.

Jan 1, 1996

"Injection technology has been an important subject from the early days of ladle metallurgy until the present. During the last decade, there have not been many publications in the area of injection technology. It is the author's opinion that with the challenge to find new solutions especially to environmental and energy related problems as well as better understanding of phenomenas from computer modelling, a new era of inventive injection technology developments is at hand. This is illustrated in the article with examples from six different areas where MEFOS is or have recently carried out R&D work related to issues from the injection technology field. IntroductionThe boom in injection technologies came with the introduction of ladle metallurgy treatment during the '70s and '80s. Since then, the theories and principles have been thoroughly laid down by a number of scientists and also published at several early SCANINJECT conferences.Not many new technologies/applications have been presented during the last ten years. This might lead one to believe that everything is known and done. Those, like MEFOS, who are challenged to find technological solutions to a number of environmental problems and energy saving issues in the pyrometallurgical field are, however, continuously faced with the task of developing new injection technologies.Especially, the call for sustainable technologies to solve environmental problems is a challenge for metallurgists all over the world and it will surely induce a revival of injection technologies. So, in order to encourage all injection experts, let us share some new experiences and let us encourage each other's creativity to solve some of the demands of the future society.The following show some examples of technologies under development, or recently tested."

Jan 1, 1996

The National Mining Hall of Fame and Museum will hold its Ninth Annual Induction Banquet Sept. 8, 1996, at the Las Vegas Hilton Hotel. Six mining greats, two of them living, will be enshrined at the event. They will join 126 other mining legends previously honored by the hall of fame. The keynote speaker will be William Perry Pendley, president and chief legal officer of Mountain States Legal Foundation in Denver, CO. Jeffrey Zelms, president and chief executive officer of The Doe Run Co., will be master of ceremonies. Richard Swayne, regional director USA for Boart Longyear Co. of Salt Lake City, UT, will introduce the speakers. Thomas Falkie, president of Berwind Natural Resources Corp. and chairman of the Mining Hall of Fame’s board of governors, will enshrine the inductees.

Jan 1, 1996

By Robert B. Hopler

The hazards which naturally prevail in underground coal mines, always severe and unpredictable due to the loosely-consolidated strata in which coal is frequently found, are increased by the commonly-occurring combination of coal dust, methane, and explosives. It was recognized by the mid-nineteenth century that coal dust was the basic factor contributing to disastrous explosions killing hundreds of miners, and that the ignition of methane gas was often the source of the coal dust explosions. It was apparent that preventing the ignition of methane was a critical part of avoiding these disasters, and it was also apparent that one cause of such ignitions was the firing of explosives. In addition, it was found that dust explosions were often initiated by blown-out shots of explosives in the absence of methane.

Jan 1, 1996

By Fumihiko Sumiya, Kunihisa Katsuyama, Yuji Ogata, Yuji Wada, Yukio Katoh, Yoshikazu Hirosaki

In our previous work, the results of photographic observation using a high speed framing camera showed that the difference between precursor air shock wave velocity and detonation velocity was primary factor for the channel effect. It is assumed that the decreasing precursor air shock wave velocity can prevent the channel effect in charge hole.

Jan 1, 1996

By J Lyall Workman, Peter N. Calder

"Large hole rotary drilling is one of the most common methods of producing blastholes in open pitmining. Large hole drilling generally refers to diameters from 9 to 17 inch (229 to 432 mm), however aconsiderable amount of rotary drilling is done in diameters from. 6% to 9 inch (165 to 229 mm). Thesesmaller diameters are especially prevalent in gold mining and quarrying."

Jan 1, 1996

Slide presentation at conference

Jan 1, 1996

By N. B. Gray, A. E. Guerra, D. E. Morton

"The formation of splash in pyrometallurgical operations that involve the injection of gases into a liquid has been the subject of a number of studies over the last few decades. Given the complexity of the phenomena, there have been some advances in understanding the microscale formation of splash but the ability to accurately predict the amount and character of the splash formed is still in its infancy. First, the macroscale mechanisms for splash formation is very varied. Second, the timescales for splash formation are very small, usually less than 100 milliseconds, making experiments elucidating the formation of splash difficult and costly. Work at the GKW CRC has shown that the microscale mechanism of splash formation is primarily is due to the Kelvin-Helmholtz instability. Substantial progress has been made in understanding the behaviour of large bubbles in effecting splash formation and a simple model has been developed to estimate the behaviour of splash formed from a top submerged lance. Direct numerical computation of splash formation using the GKMAC codes developed at the Centre has been successful in simulating the impact of liquid drops onto a liquid bath.IntroductionInjection of gases into melts is used in the metallurgical industry to promote mixing to ensure acceptable heat and mass transfer rates, conveying solids for alloying, provide efficient contact for gas-melt reactions, and as a reactant. High gas injection rates bring about the formation of splash and slop. Extensive splash formation leads to loss of valuable product, creation of safety hazards, formation of accretion on refractory lining and exhaust ducts, and increased load on dust removal equipment. Many operators and researchers have claimed that splash formation is the limiting factor in many gas injected processes. The problems listed above lead to loss of production and increased maintenance, adding to the cost of processing base metals. Over the last five years, the GKW CRC has been studying the formation of splash from a number of sources. They include the impingment of drops on liquids[ l·2.31, slopping of bath liquidI4.51, breakup of gas bubbles at the liquid-gas interfacel61, shearing of liquids by gases[7·81, and impact of packets of fluids on solidsl81. Theoretically, the extreme deformation of fluid shape and the influence of surface tension makes the simulation of flow resulting from only a drop impacting on a liquid surface a very challenging computational fluid dynamics problem. Recently, we have been successful in simulating the formation of the Rayleigh jet resulting from a drop impact showing the effect of drop Froude number on the shape of the Rayleigh jet."

Jan 1, 1996

By G. P. Neobutov

The near surface inclined gold ore deposit is mined out at freezing temperature. The replacement of ore pillars by artificial freezing rocks during the rock pressures control in this conditions presented no difficulties. At the present, the mining operations are maintained at a depth of more than 300 meters. The exploration of mining conditions showed partial warming of rock mass and unstable ground conditions. Analytical calculations using a mathematical model of heat exchange predicted undesirable duration of freezing of artificial pillars. Practical techniques and recommendations for mining with ice pillars as an artificial support system using a new freezing method are discussed.

Jan 1, 1996

Physical and chemical methods were investigated to tower thorium levels in Eneabba Ilmenite from the natural levels of 180-500 ppm to give Becher Process synthetic rutile with less than 100 ppm thorium. Chemlcal treatments, but not physical separations were successful. A pilot plant trial of a sodium hydroxide leach (25M NaOH at 75°C and 40 wt% solids for Ih) followed by a sulphuric acid leach (3M H2S04 at 90°C and 60 wt% solids for 211) confirmed that thorium could be removed to below 100 ppm. However, the activity of the ilmenite was not lowered to the same extent

Jan 1, 1996

By G. Laird, N. B. Gray, N. Lawson

"Photographic, video, laser, hot film and conductivity methods are used in the experimental study of gas-liquid flows. A discussion of their capabilities and limitations are given in this paper illustrating the wide range of phenomena that can be studied. Most of these methods are limited to physical models at room temperature with transparent fluids, although they can be extended for use with opaque and hot fluids. A number of these techniques have been used by the GKW CRC in studies on industrial plants and their usage is increasing although a number of technical difficulties still need to be overcome. An in-depth discussion of the laser doppler anemometry (LDA) and particle image velocimetry (PIV) methods is given with experimental results on the flow field of an air plume in water based on advanced development of the techniques and studies carried out at the GKW CRC. The LDA method provides high resolution data on the velocity profiles, while the PIV method provides an overall view of the complex flow structure occurring at the gas-liquid regions. These two methods complement each other in providing experimental data for validating numerical models and exploring the complexities of multi phase flows.IntroductionThe injection of gases into melts is an important operation in the metallurgical industry. It is used in converters, anode furnaces, blast furnaces, ladles, bath smelters, zinc fumers and many other smelting processes. In many of these processes, the gas is injected into a molten bath resulting in the formation of bubbles that promote reaction, mixing, alloying and heat transfer. The study of gas-liquid systems presents enormous challenges to the researcher due to the complexity of the mathematical and physical modelling which require innovative numerical and experimental skills."

Jan 1, 1996