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It is now 32 years since Walsh's classic publication (1) heralded the beginning of atomic absorption spectrophotometry (AA) as we know it today. During this time, AA has developed into the most widely used analytical techniques for the determination of the metallic elements. The years have seen progressive changes in instrumentation so that today it is a highly sophisticated technique. One area of development in AA that is experiencing renewed attention is in the area of electrothermal excitation. In this technique a flame is not used by the analyte solution is atomised by an electrically heated graphite furnace. For a large number of elements the graphite furnace atomic absorption spectrophotometer (GFAA) is considerably more sensitive than flame work. It is common to be able to detect concentrations one hundred times smaller than those possible by flame. Today's geochemists are finding that they can gain valuable information out of very low limits of detection. Electrothermal atomic absorption spectrophotometry (or GFAA) allows for low limits of detection and can be seen to be a valuable aid to geochemical prospecting Analysis.

Jan 1, 1987

By John G. Whellock

Over the last decade new constraints have emerged in the metallurgical industry which challenge the very basis of design and construction of smelters and refineries. The hackneyed designs of the past will not now serve the revised objectives of: - minimal cost of ownership - improved productivity - reduced energy consumption - greater flexibility in feed or product - minimized recycle loops and by-products - more stringent environmental control The impact of these constraints has been channeled constructively into process intensification - exemplified at the large scale by the introduction of flash smelting technology and at the smaller scale by the application of rotary process vessels and converters for augmented heat and mass transfer. The design of successful process plants depends on the understanding of the unit operations and their interactions which is the discipline of systems engineering. With the advent of increased process intensification the importance of a systems approach to process design and implementation becomes paramount. This paper describes the systems approach with specific reference to medium scale projects in the primary and secondary metallurgical industry.

Jan 1, 1985

By R. G. Robins, O. J. Kwok

The application of chemical thermodynamic theory to high temperature aqueous systems is discussed as a basis for the explanation of thermal precipitation. The derivation of high temperature potential/ pH diagrams is briefly outlined in order to show a temperature/pH relationship for hydrolytic precipitation, which is an effect that is caused simply by heating an aqueous solution. Various examples of thermal precipitation are given, with particular reference to separation of metal values from leach solutions. Metal sulphate solutions are shown to precipitate basic sulphates, hydrated sulphates , oxides, hydroxides, and oxydroxides of the metal depending largely on the pH, the concentration of metal ion, and the concentration of sulphate or bisulphate. The CuS04-H2S04-H20 system is treated in some detail, and the separation of copper from other metal ions is investigated. Other separations involving Fe, Ni, Zn, Cd, and Cr are considered. Other advantages of thermal precipitation, such as the formation of high purity, large particle size and easily filterable materials, are presented. The kinetics of thermal precipitation are also briefly examined.

Jan 1, 1973

By Charles P. Lazzara, Charles D. Litton, Frank J. Perzak

This U.S. Bureau of Mines report details the results of a series of large-scale experiments where small coal fires were used to ignite the conveyor belt at air velocities ranging from 0.76 to 6.1 m/s. In the tests, electrical strip heaters imbedded within a pile of coal were used to heat the coal to a point of flaming ignition. The flaming coal subsequently ignited the conveyor belt located approximately 5 to 10 cm above the coal pile. During the tests, temperature, CO, and smoke levels were continuously measured in order to determine both alarm time and level as the fire intensity progressed through the stages of smoldering coal, flaming coal, and flaming coal plus flaming belt. Analysis of the data leads to certain conditions of air velocity and sensor alarm levels that are required for early detection of conveyor belt entry fires. Two nomographs are presented, which define sensor alarm levels and sensor spacings as a function of belt entry cross-sectional area and belt entry air velocity.

Jan 1, 1991

In underground coal mining, one of the biggest challenges is spontaneous combustion, which will not only present safety hazards but result in reserve losses as a result of burnt coal. The released heat coupled with other combustible gases commonly encountered underground will significantly increase the risk of explosion. In this paper, three-phase foam as an environment-friendly fire fighting agent composed of nitrogen, water and fly ash is introduced. The nitrogen facilitates inertization of the fire zone; the water helps cool down the fire and the fly ash can closely cover the coal to isolate the oxygen. What's more, the fly ash and the foaming agent are good free radical absorption. The comprehensive merits mentioned above make three-phase foam quite effective in quenching spontaneous combustion. Experiments indicate that three-phase foam can significantly slow down the temperature rise of coal during oxidation. The comparison between slurry and three-phase foam shows that the latter one is capable of flowing upward in the porous media so as to extinguish the high-point fire and concealed fire.

Jan 1, 2011

By T. B. Gyles

Zinc is made by the National Smelting Co. and its associates by both the horizontal retort process and the vertical retort process developed by the New Jersey Zinc Co. This paper deals only with the horizontal retort practice at Avonmouth. That the horizontal retort process does survive in all countries in some form or other is due to at least partial success in overcoming some of the inherent difficulties of the process. The horizontal retort furnaces ran into considerable difficulties when the product of the selective flotation of mixed lead and zinc ores became the normal material for treatment. It is necessary, therefore, to make some reference in connection with the process to the preliminary treatment of the ore prior to distillation.. Therefore we include some small reference to this aspect in our description. Furnace Design and Structure Of the types of furnaces in operation at the company's various works, those at Avonmouth are perhaps more typical of the trend to utilize large units, with a subsequent saving in costs, such as heating and supervision.

Jan 1, 1937

By Yael Miron

Ammonium nitrate-fuel oil (AN-FO) mixtures are used as blasting agents in mining pyrite-bearing ores. The temperature of these ores can increase by the continuous, though at times slow, oxidation weathering of the pyrites. At elevated temperatures, AN-FO reacts exothermally with pyrite, and the reaction becomes self-sustained at 120° C ± 10° C. The Bureau of Mines has conducted an investigation to determine the reactivity of mixtures of AN-FO with pyrite containing ferrous sulfate. The results of tests in a heated vessel simulating a hot borehole demonstrate that small amounts of ferrous sulfate, a major product of pyrite weathering, initiate a self-sustained exothermic reaction with AN-FO at 80° C. Five pct by weight of urea was found sufficient to prevent a reaction among the three ingredients, at least within the limits of the test, which reached 180° C. Smaller amounts of urea and of potassium oxalate slowed down the reaction and delayed its onset to higher temperatures, but did not prevent it.

Jan 1, 1979

By I. A. Jacobson

In a closely controlled laboratory retorting system for oil shale, a relationship was developed by the Bureau of Mines between the temperature in the retort and the weight ratio of ethylene to ethane in the gases produced. Reciprocal temperature was shown to be directly proportional to the log ([ethylene]/[ethane]). From this relationship a number, called retorting index, was developed. The retorting index has the dimension of temperature, but its magnitude depends on both temperature and residence time for the reactants in the heated zone in the oil-shale retort. The slopes of the lines relating reciprocal temperature and the logarithm of the ethylene-ethane ratios are nearly constant for each of the retorting processes for which data have been presented. The retorting index should be a valuable tool to control the operation of oil-shale retorts, either aboveground or in situ. If an optimum operating condition can be established, the maintenance of the optimum or the departure from it should be easily monitored by use of the index.

Jan 1, 1974

By J. J. Craron

MR. J. J. CRARON: If Ross Weber rings that bell of his, I think I have a few secrets on him that I will tell. It is not such a long time ago when the sales and executive departments of the coal industry were constantly urging the operating department to increase their output, and this cry for increased production resulted in vast development work and increased capacity to the point where the operating departments are today in position to produce coal upon sudden demand far in excess of the ability of their sales departments to dispose of it. So today our ability to produce coal is away ahead of our ability to market it. There are many reasons, of course, for this condition. First, the present economic situation, which has prevented even a normal consumption of coal. Secondly, the over-development and production of every commodity and industry as the result of war time and post-war time prosperity. Thirdly, the inroads made by competitive fields, particularly oil and gas, because of the desire of the public for automatic heat.

Jan 1, 1934

By Morrison AL

The volume changes occurring during the reduction by hydrogen of single, high-grade hematite pellets under isothermal and non- isothermal conditions were investigated using a time-lapse photographic technique. The major cause of swelling during iso- thermal reduction at temperatures in the range 600-1000¦C, was the disruptive stresses set up during the transformation of hematite to mag- netite. The severity of the disruption was temperature dependent; the degree of swelling increased with increases in the reduction temp erature. Under non-isothermal reduction conditions, in which the pellet temperatures were increased at constant heating rates over the temperature range 500-1000¦C, minor swelling (6-8%) occurred in the initial stages of reduction followed by pellet contractions of up to 15% in the final reduction stages. The low initial swelling and high final pellet shrinkages were due to a com- bination of the temperature dependence of the swelling mechanism, and the sintering of fine pores in the reduced iron in the latter stages of reduction at higher temperatures.

Jan 1, 1980

By Cornell J. B

Scaling in Bayer Refineries is a natural consequence of the super-saturated liquors used in the process. The caustic liquor is supersaturated not only with alumina but also silica and calcia at various stages of the process. The basic scaling mechanisms are reviewed and examples of the two basic types, growth and settled scales, are given. Examples include gibbsite scales formed in the precipitators and silica scales formed in heat exchangers. The main factors affecting the rate of growth of growth scales are temperature and supersaturation and are highlighted using a silica scale example. For growth scales chemical cleaning rates can readily be predicted from kinetics and an example for a gibbsite scale is given. For settled scales the growth rate cannot be predicted and the hydrodynamics within the system have most effect. There is no simple method to predict the potential for chemical cleaning of settled scales; some of the relevant issues are discussed, in particular methods to identify the cementing phase in the scale. An example of design considerations for a scaling system, transport of slaked lime, is Given.

Jan 1, 1996

By G. A. Brady

Seven samples of Pennsylvania anthracite from the Bottom Ross bed were analyzed and tested to obtain data on cleaning characteristics, proximate and ultimate analyses, specific gravity, grindability, heating value, and ash softening temperature. Ash content of the samples varied irregularly from 9.0 to 34.4 percent, the range being narrowed to an upper limit of 14.8 percent ash by removing impurities dense enough to sink in a medium with a specific gravity of 1.90. Ash content of the sink material with specific gravity greater than 1.90 ranged from 56.4 to 80.4 percent; corresponding specific gravities were 2.095 to 2.534. Volatile matter contents were indicated to be higher for the ash-forming minerals than for the pure coal substance in the various specific gravity fractions of a given sample. Specific gravities of anthracites with compa¬rable ash contents but from different locations in the bed varied as much as 0.06. The grindability index increased significantly with increasing ash con¬tent of specific gravity fractions from all the samples.

Jan 1, 1968

By Yi Luo

Bolting the mine roof is one of the noisiest underground mining operations. The main contribution to the high noise is the drilling of the roof bolt holes, especially in hard rock. A previous research shows that the specific energy consumed in drilling the bolt holes is inversely proportional to the bite depth (i.e., penetration per drill revolution). Less specific energy at a reasonably high bite depth means less energy is wasted in the drilling process to produce heat, bit wear and noise. Therefore, control of drilling operation to achieve a higher bite depth can provide an opportunity to reduce drilling noise from its sources as a proactive noise control approach. In order to explore the feasibility and to develop the proactive technology for reducing drilling noise, drilling tests have been conducted in laboratory settings. The preliminary results show significant reduction in noise dose can be achieved by drilling in medium hard rock at a reasonably high bite depth. This paper presents the findings from the laboratory experimental studies conducted so far.

Jan 1, 2013

By R. H. Lien

The Bureau of Mines developed a flue gas desulfurization process as part of its goal of minimizing the undesirable environmental impacts associated with energy and mineral-processing plants. The modified citrate process involves absorption of sulfur dioxide (S02) in a buffered citric acid solution. The S02-loaded solution is regenerated by countercurrent contact with steam in a packed tower. The wet S02 product is then dried and can be liquefied or further processed to make sulfuric acid. Test data from process investigation unit studies are presented. Material balances, flowsheets, and cost estimates are given for recovering S02 from copper smelter reverberatory gas, lead smelter sintering machine tail gas, and power-plant stack gas. Operating cost estimates show the process will add $0.04 per pound of copper, $0.01 per pound of lead, and $0.015 per kwhr to the cost of the respective operations. These costs could be substantially reduced if a source of waste heat was avail-able to provide the process steam requirements.

Jan 1, 1982

By L. D. Fetterolf

The New Jersey Zinc Zompany operates at Depue, Illinois, an integrated zinc smelting plant using tie vertical retort reduction process. The overall operation comprises green concentrate roasting, sintering, vertical retort smelting and metal refining. In the roasting operation, the fine concentrate is pelletized, the dried pellets fluidized and autogenously roasted with air in a “fluid column” with minimal formation of dust requiring recirculation. The roasted pellets and any associated roaster dust are agglomerated in a rotating drum and laid down, in combination with coal for fuel, on a Dwight-Lloyd sintering machine which converts to a semi-fused mass - a physical state more suitable for vertical retort smelting. The smeltins plant of 27 vertical retorts rated at 8 T zinc each per day on average requires the following major processing steps - mix preparation and briquettine, briquet coking, vertical retort reduction, vapor condensation and slab casting of metal. A portion of zinc production is converted to 99.99+ percent purity by boiling and fractional distillation in columns consisting of externally heated, superimposed trays of high-conductivity refractory.

Jan 1, 1970

By W. C. Phalen

SALT-MAKING PROCESSES THE production of salt in the United States divides itself at the outset into two distinct classes: (1) The mining of rock salt and its purification and separation into marketable sizes, and (2) the production of salt by evaporation from brines, bitterns, and other solutions. The processes employed at the present time in the manufacture of salt by evaporation may be outlined as follows: 1. Solar evaporation. 2. Direct-heat evaporation (a) in open kettles; (b) in open pans. 3. Steam evaporation, (a) in jacketed kettles, (b) in grainers. 4. Vacuum-pan evaporation. In this paper only the solar-evaporation processes practised in different parts of the United States will be described. SOLAR EVAPORATION Localities In the Eastern States the solar-evaporation process is not generally employed for climatic reasons. In the Western States, particularly in California and Utah, the great bulk of the salt produced originates in the solar-evaporation process. Of the Eastern States producing salt, this process, so far as the writer is aware, is employed in New York State only.

Jan 9, 1914

The combustion characteristics of Australian coals which contain high inertinite have been studied in a laboratory drop tube furnace and a Thermogravimetric Analyser. The pyrolysis chars and combustion residues were microscopically characterised using a modified coal petrography technique. Results indicated that the overall burnout of inertinite-rich Australian coals under pulverised fuel combustion conditions could be generally within a range of 97 - 99 per cent burnout. The studies showed that poor coal burnout cannot be generally related to high inertinite content in the Australian coals. The extent of coal burnout varies from coal to coal and vitrinite as well as inertinite may contribute to the unbumt chars in combustion residues. Combustion conditions had greater influence over char formation and coal burnout than the coal properties. However, under similar pf combustion conditions, coal rank and coal maceral composition had a strong influence over the coal combustion behaviours and final coal burnout. Simple correlations using coal properties may be used but with caution to determine coal volatile release and burnout at high temperature and rapid heating conditions.

Jan 1, 1991

By S. Ramachandran, R. A. Walsh, J. C. Fulton

A method has been developed for calculating the oxygen content of commercially melted stainless steels. Application of thermodynamics to the de-oxidation reaction in straight chromium and Cr-Ni stainless steels has resulted in a set of equations DURING the past 30 years, many rewarding developments have resulted from the application of physical chemistry to steelmaking. A need still ex- which permits the calculation of oxygen contents. The model was programmed for computer calc~ilations. The validity of the method was demonstrated on routine oxygen samples from numerous commercially melted heats of stainless steel. ists for further progress in the use of thermodynamics to meet the more stringent requirements for cleaner steel. Current electric furnace practices have been developed around minimizing residual-oxygen content, one of the most important factors controlling the inclusion content of stainless steels. The residual oxygen is controlled by the use of deoxidizers during the finishing period and a number of empirical rules have been evolved. Although this feature of electric furnace practice has long been in use, only in recent years has funda-

Jan 1, 1963

By Norwood B. Melcher

This report describes preliminary experiments by the Federal Bureau of Mines on the practicability of adding raw pellets of taconite concentrate to blast furnace feeds. The usual industrial practice is to harden the pellets by heating before they are charged to the furnace. The Bureau research demonstrated that raw pellets could be successfully smelted in an experimental furnace with no significant change in coke consumption and only a moderate increase in dust losses. The dust loss was 43 pounds per ton of metal for an all-pellet charge, compared with 7 pounds per ton for an all-sinter charge. Raw taconite pellets undergo only slight degradation during charging to the furnace if 1 percent bentonite is used as a binder. INTRODUCTION Fines and concentrates must be consolidated or agglomerated into larger masses before they can be smelted in a commercial blast furnace. Such agglomeration is usually done by sintering, pelletizing, nodulizing, or briquetting. Sintering has been the more common practice, but with the advent of taconite concentrates pelletizing is increasing in importance.

Jan 1, 1960

By Hebi Yin

A two-dimensional multi-scale solidification model was developed to study the heat transfer, fluid flow, and grain growth occurring in the molten pool during the laser engineered net shaping (LENS) process. This model coupled the finite element method to calculate mass, energy and momentum transport in the macroscale with the cellular automaton technique to calculate liquid/solid phase change at the microscale. The validation of the model was performed by comparing the simulation results with experimental data from previously published works, showing good agreement in temperature distribution and the dendrite morphology (size and shape). The simulation results showed that Marangoni convection, caused by the temperature gradient along the pool surface, played a critical role in determining the flow pattern in the molten pool and exerted influence on the pool size and shape. It was also found that columnar dendrites can be formed, with dendrite arm spacings as fine as a few microns due to the high cooling rate during the LENS process. In addition, the influence of fluid flow on the dendrite growth in the pool was discussed.

Jan 1, 2010