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By K. Kawagishi, J. Ang, A. Sato, H. Harada

"We have recently proposed a new ""EQ Coating"" bond coat system to solve the problem of secondary reaction zone (SRZ) formation caused by bond coats applied on the hot section components of modem jet engines. A viable EQ coating alloy was previously found for a representative znd generation superalloy, TMS-82+. It would be ideal if the same could be done for a representative 5th generation superalloy, TMS-173. In this paper, we will show that the coating with the best oxidation resistance in the EQ system of TMS-173, although possessing considerably better resistance than TMS-173, did not have sufficient oxidation resistance. In order to improve the oxidation resistance of the EQ coating for TMS-173, we have ventured into ""Pseudo-EQ coatings"". A diffusion couple between the Pseudo-EQ coating and TMS-173, after 300hrs at 1100°C, had a 0-15µm IDZ, but no SRZ. A diffusion couple between a conventional coating and TMS-173 formed a 80-150 µm SRZ. After a 1 hr oxidation test at 1100°C, the PseudoEQ coating formed a thinner oxide layer than the EQ coating, but still contained NiO and spinel. Aerospace"

Jan 1, 2006

By David Rees

Tomago Aluminium, a 400,OO tonnes per annum primary aluminium smelter in Australia, has installed Ozone for biological control of its process water. The system was designed in Australia by Ionics Watertec Engineering, whilst ANCO Australia monitors the water quality and provides technical support for the project. The motivation was initially to reduce operating costs, however investigations indicated that there were substantial environmental benefits to be achieved by the elimination of a part, or all of, the chemicals being used to control the system. Also the existing chemicals appeared to be losing their ability to control biological growth in the system, in particular, the legionella bacteria. Ozone water treatment commenced in January 1998 and after a short transition period has operated without chemical addition since. There appears to be no doubt that the biological control is effective, the clarity and purity of the water has improved and initial testing indicates that the corrosion control rate is acceptable, although some chemical corrosion control may be introduced after further testing around the total circuit to guarantee protection

Jan 1, 1999

By Zhi-gang Que, Sheng-li Wu, Guo-liang Zhang, Bo Su, Chao-gang Hou

NOx released during fuel combustion is one of the major air pollutants, such as acid rain and photochemical smog. At present, still not have an economical and effective method of inhibiting NOx emission for sintering flue gas. Therefore, controlling conditions of fuel combustions to enhance the reduction of NOx is important for decreased the emission. In this study, microsintering furnace has been performed to investigate the effects of NOx emission from char-N during coke breeze combustion. The results show that the emission concentration of NOx decreased with increasing temperature when it is sinter bed temperature higher than 1000℃. The lower emission concentration of NOx was obtained when the concentration of oxygen was decreased. And the maximum concentration of NOx will be reduced with the enhanced of heating rate. If heating preservation time was prolonged, it would promote to NOx reduction with reduction substances resulted in lower NOx emissions in the combustion of coke breezes.

Jan 1, 2015

By M. Cross

INTRODUCTION The development of refining processes involving gas injection into liquid metals has seen the evolution of a variety of designs [I]. During the last few years or so the top, bottom and side blown processes have, essentially, been combined to produce a series of mixed gas blowing schemes (eg. the LBE [2,3] and LD-OB processes [4,5]). Although, a variety of mixed gas blowing processes have been carefully engineered and recorded operational experience now attests to their effectiveness, optimising their design and operational performance is another matter. Detailed process analysis of such operations is impeded by the complex nature of the physical and chemical processes involved: . fluid flow behaviour of the liquid metal and injected gases, . chemical reactions in the vessel, . mass and heat transfer within the fluid phases in the vessel, . influence of the geometry (eg. location of the tuyeres, etc.), . monitoring the operational performance. By and large, design and operating parameters evolve from a combination of laboratory scale experiments, pilot plant work and, of course, practical engineering experience. Conventionally, the gas-liquid system used to model the industrial process is air-water, for a number of valid reasons including – . visual demonstration plus geometric and (to some extent) dynamic similarity, . the fact that the system demonstrates, at least, qualitatively many of the complex features of gas injection - interaction between the gas and the liquid - the nature of the gas flow behaviour - qualitative indications of mass transfer rates Important experimental contributions to the understanding of gas liquid systems include the work of Brimacombe [6], Wraith [7], T.Robertson [8], D.Robertson [9], Guthrie [10] and Szekely [11] (these references provide starting points to identify the major published work in this area). Although air-water systems have been instrumental in providing a great deal of qualitative insight into the fluid flow behaviour of the processes, reliable quantitative predictions are more problematic. A number of workers (notably Brimacombe and colleagues [6, 12])have demonstrated that different gas-liquid systems can lead to wide variations in behaviour. Other limitations of physical modelling include the assumptions of isothermal flow, scale- up of turbulent flow behaviour and the inability to directly include the effects of chemical reactions. The above limitations in physical modelling, therefore, yield a natural role for mathematical modelling provided that it can be made comprehensive enough whilst remaining cost-effective. The major physical processes involved in gas injection systems may be summarised as . behaviour of the gas envelope structure in moving through the liquid metal . the global movement of the liquid metal . momentum interaction between the liquid metal and the injected gas . heat transfer and mass exchange via the chemical react ions. The behaviour of gas envelopes forming at a tuyere and then moving through the liquid has been investigated thoroughly by a large number of workers. Such models are generally based upon simple physic- al concepts derived from visual observation. An early model by Davidson and Schuler (DS), based upon a force balance between the liquid inertia and a combination of the bouyancy and momentum forces on the envelope, has proved to be a useful tool in predicting bubble volumes at detachment [13]. The DS model has been successfully modified in a number of ways [14-17] to cope with heat transfer and reactive transfer rates, etc. Furthermore, the basic ideas summarised above have also been confirmed on industrial converters by both Guthrie [I8] and Brimacombe [19]. Models have also been developed to predict the behaviour of the "chemical" component of some gas-liquid systems. However, one thing is clear; all gas-liquid reactive systems are governed by the degree to which effective mixing occurs. As such, the processes are dominated by the behaviour of the heat and mass exchange of the two phase fluid flow system. It is the pattern of movement of the turbulent liquid metal plus its interaction with the injected gas which must be predicted reliably, if sufficiently comprehensive comp-

Jan 1, 1984

By R. H. Lee

WITHOUT doubt, one of the most frequent and serious annoyances connected with the practical running of a blast-furnace, especially in single-furnace plants, is caused by low steam, in spite of the fact that all boilers at blast-furnaces have grates for burning coal, and that coal is more or less continuously burned upon them, from three to a dozen men being pretty constantly engaged around the boilers as firemen or coal- and ash-handlers. At times, when the furnace is ? tight," all available men are put on to assist the regular firemen; yet sufficient steam cannot be got to keep the engines up to their regular number of revolutions, while the stoves, deprived of the gas which has been sent to the boilers, run cold, so that, when the furnace loosens-up and resumes the regular rate of driving, the blast is very considerably below normal temperature, and a.' cold," or at best a " high-sulphur," east is the result. Again, it often happens that a furnace, running at its best, becomes temporarily a little too hot; the pressure rises; the amount of gas made' is diminished; the steam soon commences to go down; and a small scaffold is likely to form before the furnace has been brought back to the proper rate of driving, and thus enabled to take its regular amount of blast. The usual remedy is either to "jerk" the furnace by a sudden, brief intermission in blowing, or to cool the furnace by lowering the heat of the blast; but if the lower blast-temperature be maintained too long, the hearth and descending stock may be cooled below the " critical temperature " mentioned by Mr. .Johnson, and the furnace may go to the other extreme, and become cold. This is especially the case when coal or coke, high in sulphur, is used:

Jul 1, 1906

By R. W. Van Dolah

The Bureau of Mines t.ced its investigations into sympathetic detonation of ammonium nitrate (AN) and ammonium nitrate-fuel oil (AN-FO) to define the scaling law for safe separation from detonating AN-FO. Both missile- and non-missile-producing AN-FO donors, weighing up to 5,400 pounds, were employed with acceptors of the same size. The usual cube-root scaling law was not confirmed; exponents for the relationship S = f(Wx) for AN were 0.51 with non¬missile-producing donors and 0.61 for missile-producing donors. For AN-FO an exponent of 0.80 was indicated in the missile-producing case. AN-F0 in polyethylene bags appeared somewhat more easily initiated than bulk AN-FO. The efficacy of barricades in protecting AN charges was investigated. detonation distances were reduced from one-third to one-seventh when filled barricades were employed. The investigation was extended to dynamite with both types of donors. With 1,600-pound missile-producing donors and an equivalent weight of dynamite, initiation would be expected in 50 percent of the trials at 167 feet. The corresponding value in the non-missile case was 67 feet. The data developed in this program of sympathetic detonation will allow the development of a rational set of safe separation distances for AN, AN-FO, and explosives.

Jan 1, 1966

By Sylvie Lévesque, Cory Hennessey, Daniel Amariei

"In the iron ore industry, fine particles recovery is an important concern in terms of process performance and production costs. Continuous efforts are thus devoted to increase the efficiency in handling these fines.The Reflux Classifier (RC) is a relatively new technology that is mainly used in the coal and industrial minerals industries. The operating principle of this system is based on three mechanisms: hindered settling, autogenous dense medium and lamella settling. A preliminary evaluation of the Reflux Classifier technology for the beneficiation of iron ore fines was formerly done at the pilot scale using a RCTM300 unit. The good results obtained, using iron ore fines from screened spiral stream, made this technology very attractive for the iron industry. However, the high capacity of the RCTM300 unit (1–3 t/h), makes it unsuitable for R&D purposes. Thus, a smaller unit, the RCTM100, was assessed to validate the performances obtained with the RCTM300.This paper summarizes the performances obtained with the RCTM100. The challenges of the scale-down related to the adaptability of this technology to the iron ore industry are also presented. The results are compared to the RCTM300 performances, as well as benchmarked against sink-float tests. The metallurgical results on feed and products issued after the test work with the RCTM100 unit are supported by mineralogical characterization using a Mineral Liberation Analyzer.INTRODUCTIONFine particles recovery by physical separation means is a historical concern (Holland-Batt, 1992; Peukert and Wadenpohl, 2001; Srivastavaa et al., 2001; Majumder et al., 2003). Attempts to improve fine particle recovery at the laboratory, pilot and industrial scales adopting different strategies with traditional equipment or assessing new promising devices such as the MGS (multi-gravity separator), the Kelsey jig, the Yang jig, etc. (Kim, 2002; Goudreau, 2008; Kerr, 2012) have yielded variable success."

Jan 1, 2016

By L. L. Rethi

The U.S. Bureau of Mines summarized injury data for independent contractor employees working at all locations of coal and metal-nonmetal mines from 1983 through 1990. During the eight years, the greatest contrast in degree of injury between independent contractor and operator employees was in fatalities. From 1983 through 1990, there were 132 independent contractor employee fatalities in the mining industry. In 1988 though, independent contractor employees accounted for nearly one-fourth of all mining fatalities. The fatality incidence rates of independent contractors were consistently higher than those of operators during the eight years. For instance, in 1990, the contractors' rate was twice that of operator employees in coalmining and nearly five times that of operators in metal-nonmetal mining. Three other salient facts highlight the independent contractor employees' fatality injury data during these years. First, 82% of the independent contractor employee fatalities occurred at surface locations. Second, two job classifications?truck driver and equipment operator?represented 37% of the fatalities throughout the 8-year period. And finally, four accident classifications?powered haulage, slips and falls, machinery, and electrical?accounted for 71% of all independent contractor employee fatalities.

Jan 1, 1993

By T. R. Ellis

The valuation of mineral properties in the U.S. is only partially regulated. The regulations which have jurisdiction or impact appear to have such mainly as a consequence of unintended fallout, since the regulations were designed for other purposes. Court case history can also be important. The combined results are a mixture of bad and good, with important lessons to be learned. Since 1981, the Securities and Exchange Commission has prohibited U.S. listed companies from reporting quantitative estimates of mineralization and the value of mineralization, other than proven and probable reserves. This results in the minerals appraiser (valuator) working with a shortage of data in his everyday work, both on the subject property and in sales analysis. Between 1989 and 1995, all 50 states and essentially all federal agencies adopted the Uniform Standards of Professional Appraisal Practice (USPAP) for real property appraisals (valuations). The major national appraisal societies also require their members to abide by USPAP. A significant portion of minerals appraisals must now follow these standards. This paper will discuss the content of USPAP. It provides a very good framework for the valuation of a minerals property or a mine, both as real property and as a business. However, the credentialing standards for real property appraisers are now prohibitive for minerals appraisers.

Mar 1, 2002

By T. R. Ellis

"The valuation of mineral properties in the U.S. is only partially regulated. The regulations which have jurisdiction or impact appear to have such mainly as a consequence of unintended fallout, since the regulations were designed for other purposes. Court case history can also be important. The combined results are a mixture of bad and good, with important lessons to be learned.Since 1981, the Securities and ExchangeCommission has prohibited U.S. listed companies from reporting quantitative estimates of mineralization and the value of mineralization, other than proven and probable reserves. This results in the minerals appraiser (valuator) working with a shortage of data in his everyday work, both on the subject property and in sales analysis.Between 1989 and 1995, all 50 states and essentially all federal agencies adopted the Uniform Standards of Professional Appraisal Practice (USPAP) for real property appraisals (valuations). The major national appraisal societies also require their members to abide by USPAP. A significant portion of minerals appraisals must now follow these standards. This paper will discuss the content of USPAP. It provides a very good framework for the valuation of a minerals property or a mine, both as real property and as a business. However, the credentialing standards for real property appraisers are now prohibitive for minerals appraisers."

Jan 1, 2002

By Nourreddine Menad

Plastic materials have been associated with electric and electronic applications since the early days of the electrical industry. Plastics can amount to 30 percents of the scrap mass. Generally, they are treated with flame retardants such as halogenated ones and they can result in different toxic chemical compounds. These plastics can be used as combustibles in the recovery of copper and precious metals. However, during their combustion, halogenated flame retardants can produce dibenzo-p-dioxins and dibenzo-furans. The estimated thermodynamic data of several organic compounds resulting from combustion of electric and electronic scrap, have been used in conjunction with the program HSC to calculate the conditions for dioxin and furan formation. The results show that the formation of the dioxins is dependent on the quantities of carbon, hydrogen, chlorine and oxygen reacting in a given system, as well as on parameters such as temperature and pressure.

Jan 1, 1998

By M. J. Ankeny

Coal-mine haulage ranks second as a cause of coal-mine fatalities, and the prevention of such accidents will materially improve progress in safety in the coal-mining industry. Beginning March 1950, Federal coal-mine inspectors were made responsible for completely investigating all fatal accidents in and around coal mines. During these 10 months, Federal coal-mine inspectors investigated 447 fatal accidents. This is a study of 121 of the fatal haulage accidents investigated, which constituted 27 percent of fatalities from all causes. Haulage employees represent only 12 to 15 percent of mine personnel, but, on the basis of accident frequency, their work is the most hazardous in coal mines. Fatal haulage accidents occurred in 53 bituminous coal-producing counties representing 14 States and Alaska. The physical conditions represent a cross section of' producing coal beds. Mining and transportation methods vary, from those of small hand-loading mines to those of modern mechanized mines.

Jan 1, 1951

By H. M. Lavender

This paper describing the inclined cut-and-fill, and the semishrinkage methods of mining at the Campbell mine of the Calumet and Arizona Mining Co. at Warren, Ariz., is one of a series being prepared by the United States Bureau of fines on mining methods, practices and costs in the various mining districts in the United States. The major portion of the production from the Bisbee mines of the company is mined by these methods. The total average yearly production for the last two years has been 493,612 tons of 5 per cent copper ore. The average employment in the mining department eras 940 men. With the exception of a small tonnage mined for the high iron and sulphur content, the ore is direct-smelting and is mined for its copper con¬tent and associated gold and silver values.

Jan 1, 1930

By Robert Hopler

HUDSON MAXIM A Noted Inventor of High Explosives ALTHOUGH the subject of the present sketch has been a tireless worker in many fields of activity, his name is best known in connection with his work in the development of high explosives and their application to modern ordnance

Jan 1, 2012

By Gabriel Andrade Medeiros, Christian Brugger, Paul Pennerstorfer, Daniel Fuchshuber, Reinhold Leitnerl

State-of-the-art automation technology enables digitalization of the continuous casting process that goes far beyond conventional automation of industrial production. Primetals Technologies provides a digital twin that combines an intelligent digital representation of a casting machine as well as the casting process and the slabs, blooms or billets that are produced. It allows metallurgists and process engineers to predict the behavior of the involved complex production process and optimize parameters before using them in real production. New steel grades or production processes can be evaluated off-line without any risks to process stability and product quality. Primetals Technologies installs the digital twin with every new installation of a continuous caster optimization system. This paper describes how the setup and simulation possibilities of the digital twin provide numerous benefits by modelling and simulating the casting process. It allows for example the calculation of material properties according to the actual composition, strand surface temperature profiles and dynamic soft reduction before the final point of solidification. An outstanding feature of the digital twin is the replay functionality provided for various models to analyze and further optimize real production situations. The paper also gives an example how usage of the digital twin optimized production at a customer.

Oct 1, 2019

By Rodney D. Rosenkranz

Energy consumption in domes tic copper production has increased nearly 60 percent in the last 10 years, reaching approximately 175 trillion Btu in 1973. Energy required to produce 1 pound of copper rose from nearly 41,000 Btu in 1963 to nearly 50,000 Btu in 1973. Production from lower grade ores and strict pollution control regulations have contributed to this increase. Each stage of copper production has been analyzed to determine total energy consumed, energy mix required, cost of the energy, and recent or proposed changes in operations which may affect the consumption of energy by the copper industry. Data have been gathered from a recent Bureau of Mines canvass of the industry, from visits to copper operations, and from conversations with copper industry officials.

Jan 1, 1976

By H. C. Fuller

Submerged combustion and inverse solubility methods were investigated as promising alternative means for crystallizing manganese sulfate from solutions produced by leaching manganese ores with either sulfuric acid or sulfur dioxide. Evaporation of water from typical manganese sulfate solutions by sub-merged combustion techniques enabled production of a slurry containing 32 to 39 pct MnSO4.H2O crystals suspended in a saturated solution of manganese sulfate. Such a slurry required further processing by thickening or filtration and drying to produce crystals of MnSO4.H2O. In a second approach, semicontinuous processing of manganese sulfate solu¬tions by thermal crystallization under pressure effected a recovery of 94.5 pct of the MnSO4.H2O as dry free-flowing crystals. Treatment of a solution containing about 100 grams manganese per liter at 189° C, produced a "barren" solution containing only 1.9 grams manganese per liter. Calculations made on comparable manganese sulfate solutions show that the heat requirement of the thermal crystallization method was about one-third to one-fourth that of the submerged combustion method.

Jan 1, 1966

By Marjorie Benegra

This study aims to compare the wear resistance assessed in rubber wheel abrasion test of nickel aluminide coatings deposited by for Plasma Transferred Arc (PTA) and High Velocity Oxigen Fuel (HVOF) manufacturing, using the same raw material. A nickel aluminide powder was atomized and deposited on 316L steel plate substrate. After deposition, some specimens were submitted to a heat treating (1200 °C for 24 h followed by 760°C for 24 h). The coatings deposited using PTA developed different microstructures due to the incorporation of substrate elements, its performance was better than the HVOF coatings, although their Vickers hardness was similar. After heat treating, a significant variation in hardness and wear resistance was observed. For PTA specimens, there were decrease in hardness of 35%, while for HVOF ones this drop was approximately 20%. Nonetheless, the effect of thermal exposure in wear resistance was quite different: an increase of 21% was observed for HVOF coatings, while a reduction of 20% occurred in PTA ones. Microstructures modifications in PTA coatings were significant for their wear resistance. On the other hand, the reduction of porosity and sintering were responsible for a better performance of heat-treated HVOF coatings.

Jul 31, 2018

By Lindsay D. Norman

Four chloride and seven fixed-nitrogen processes for recovering manganese from domestic resources are described. The chloride processes are divided into two classes (leaching and chloridization) depending upon the major operation responsible for converting the manganese minerals to the chloride from which manganese oxide products are obtained. The fixed nitrogen processes, all of which yield high-grade manganese oxide products, are essentially either leaching or roasting processes. The 11 processes include HC1 leach, HC1 chloridization, HC1 chloride volatilization, CaC12 chloride volatilization, NO2 leach, HNO3 leach, HNO3 ?NO2 leach, H3 ?CO2-H2O system leach, (NH4)2SO4 leach, (NH4)2SO4 roast , and ammonium salt roast .

Jan 1, 1963

By T. Bohmer, L. Auret, N. Pillay, Z. Horn, P. Rambalee, A. Haasbroek

As part of a broader digital technology-enabled transformation programme, a major mining company is systematically implementing Advanced Process Control (APC) solutions and associated instrumentation throughout their operations. This paper highlights the approach and benefits of this holistic approach for a specific instrumentation installation, and APC installation at a South African coal processing plant. For the coal processing plant under consideration, a systematic approach was followed. Process sections/units are considered from upstream to downstream processing. APC solutions are designed for each process section and each process section is interrogated in terms of availability of sufficient process measurements to ensure stable, capable, and ultimately, optimised performance. Where insufficient process measurements are available, instrumentation upgrades are implemented. Finally, APC solutions are implemented, and evaluated in terms of productivity, safety, health, and environmental benefits. For the flotation section, an opportunity was identified to install froth sensors. The installed froth sensors provide measurements on froth velocity, bubble size, height, colour, and stability. The improved visibility that the froth sensors provided on the flotation process resulted in quick gains in terms of productivity: for example, instability in the feed to the flotation section could be quantified. This resulted in targeted process troubleshooting in an upstream thickener, and subsequent improvement of process stability, and reduced feed variance. The measurements from the froth sensors were further integrated in an APC solution. Proportional mass pull contributions per cell and per line can be inferred from the froth sensors, serving as controlled variables, while pulp level set points serve as the manipulated variables. On-off tests indicated that the advanced process control solution provided increases in yield and product quality.

Sep 1, 2021