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By John J. Mortvedt

Application of some by-products of the metals industry which contain plant nutrients to agricultural lands could constitute resource recovery instead of costly disposal. Some industrial by-products contain appreciable concentrations of heavy metal contaminants, such as Cd, Cr, Ni, and Pb. After land application, these metals may be absorbed by plants and enter the human food chain or be leached to groundwaters. Plant uptake of these heavy metals varies with plant species:, soil pH, soil texture, and the particular metal. Certain leafy vegetables can absorb significant amounts of heavy metals, while absorbed metals are usually poorly translocated to cereal grains. Allowable heavy metal concentrations in fertilizers now are not regulated, but EPA is considering such regulations. Heavy metal impurities in animal feed supplements are regulated by the states; so some by-products may not be permitted for this use.

Jan 1, 1992

By S. Suzuki, Y. Maeda, N. Wakamatsu

"A new pyrometallugical technology, named KLS process, has been developed by Dowa Mining at its Kosaka Smelter to smelt various kinds of lead raw materials.The process consists of clearly separated two reaction steps, smelting and reduction. For this purpose, respective stationary furnaces are installed which are connected by a slag launder.Dry raw materials, together with pulverized coal and oxygen-enriched air, are injected through a lance pipe into the molten slag in the first furnace. It is kept under a high oxygen potential to remove sulfur completely. Resultant PbO rich slag overflows to the second furnace where pulverized coal and insufficient air are also injected through a lance pipe to reduce PbO to lead bullion and to compensate for thermal deficit. The entire operation is carried out continuously. The process development started back in 1981. In late 1986, a pilot plant with a capacity of 3.5t/H was constructed.Already nearly 20,000 tons of raw materials, mostly lead sulfate mixtures have been smelted successfully.IntroductionFor a long time, main raw materials for lead smelting at Kosaka smelter have been such secondary incombustibles as lead sulfate and lead-barium sulfate. The former is leach residue of the copper smelter flue dust and the latter originates from Iijima zinc refinery. While the most of lead concentrates produced locally has been smelted by an ISF of Hachinohe smelter in which Dowa Mining has a share.The surplus lead concentrates were processed at Kosaka by a hydrometallurgical method to convert PbS to PbSO 4 as pretreatment, and followed by simultaneous smelting together with the above secondary materials (1). Approximate output has been 1,5000 /M of lead bullion and slightly more than 2,000t/M of refined lead by adding lead bullion returned back from Hachinohe smelter (2)."

Jan 1, 1988

By H. M. Lima, L. A. Gomiero, C. A. de Morais

ABSTRACT The Caetité-Brazil uranium facility produces approximately 400 tonnes U3O8 per year from an ore averaging 0.29% U3O8. The process steps are ore crushing, heap leaching with sulphuric acid, uranium separation and purification by solvent extraction (SX) with a tertiary amine, followed by stripping with a sodium chloride solution, precipitation as ammonium diuranate (ADU), and product drying. A change in the milling process is being evaluated to increase production and uranium recovery. Heap leaching will be replaced by conventional agitated tank leaching of the –590 µm ground ore slurry in a sulphuric acid medium. Replacement of the stripping reagent is also being considered.

Jan 1, 2012

By K. Biswas

For the pillars, which have been standing long after mining, the stability depends much on the weathering action in the presence of mine moisture. From the field observations, it has been found that this weathering action becomes critical in terms of pillar stability if the coal seam contains partings or binders in it. The weathering action degrades both the partings and coal in terms of their load bearing capacity as the mine moisture penetrates into them. This paper investigates the effect of weathering action on coal and partings in the laboratory. In the field, the strength profile in the coal and the partings and the effect of time (in terms of the pillar age) on them have been studied by using borehole penetrometer. In this paper, an attempt has also been made to establish formulae for time dependent strength of coal and partings.

Jan 1, 1997

By P. K. Jimack, C. E. Goodyer, A. M. Mullis, P. C. Bollada

"We review the application of advanced numerical techniques such as adaptive mesh refmement, implicit time-stepping, multigrid solvers and massively parallel implementations as a route to obtaining solutions to the 3-dimensional phase-field problem with a domain size and interface resolution previously possible only in 2-dimensions. Using such techniques it is shown that such models are tractable even as the interface width approaches the solute capillary length.IntroductionMulti-scale modelling impinges upon many areas of science, engineering and technology where the interplay between processes occurring on disparate length and/or timescales can affect the properties of systems in a complex, and sometimes unforeseen, manner. One such is the processing of materials where interactions at the atomic scale, through the nano- and microstructural scale can have a profound affect on the macro-scale response of engineering components. Here we focus on one such problem, the crystallisation of alloy melts, to illustrate how a range of advanced numerical techniques make the modelling of such systems tractable.The modelling of solidification structures, in particular the growth of dendritic crystals, is a subject of intense and enduring interest within the scientific community, both because dendrites are a prime example of spontaneous pattern formation and they have a pervasive influence on the engineering properties of metals. For alloy systems, which form the vast majority of engineering materials, solidification involves the rejection of both solute and latent heat from the growing solid, forming a coupled diffusion problem in which both the chemical and thermal diffusion equations should be solved. The multi-scale nature of this problem arises from the disparity between the thermal and solutal diffusivities for most liquid metals, which are typically 10-5 m2 s-1 and 10-9 m2 s-1 respectively. The ratio of these two, referred to as the Lewis number (Le =Dia), is therefore typically of the order 10,000 and gives a measure of the multi-scale nature of the problem. In fact, in many cases the thermal diffusivity is so much larger than its solutal counterpart that thermal diffusion is considered instantaneous, wherein the system can be approximated as isothermal such that the multi-scale calculation does not need to be performed. This is certainly a reasonable approach in most conventional castings. However, there is a class of solidification problem in which this approach is far from satisfactory, namely Rapid Solidification (RS). The application of isothermal phase-field models in such situations are highly likely to produce spurious results or to fail totally, particularly for temperatures below To (the temperature at which the free energies of the solid and liquid phases are equal at the concentration of the bulk alloy), wherein partitionless solidification may occur."

Jan 1, 2013

By Robert E. Baker

Cortez Gold Mines, the United States' third largest primary producer of gold, commenced continuous operations on January 10, 1969. The decision to proceed to production was made in March of 1968 and construction of the mill and stripping operations for the pit began in April and July, respectively. Anomalous conditions on the slope of Mt. Tenabo along the Roberts Mountain thrust fault zone were discovered by the U.S.G.S. while conducting geochemical surveys in the old Cortez silver district. Following the discovery of gold an intensive program of drilling was organized. Drilling outlined an orebody with 3.5 million tons of ore averaging 0.28 ounces of gold per ton. It was on the basis of this reserve that a 1700 t. p.d. cyanide plant was designed. Needless to say, with such a limited ore reserve, economies in design and construction would have to be observed. Cortez Gold Mines is a joint venture with American Exploration & Mining Co., The Bunker Hill Company, Vernon F. Taylor, Jr., and Webb Resources, Inc. , as partners. American Exploration & Mining Co. is the operating partner.

Jan 1, 1969

By Rod Heath

The Saskatchewan industry has the advantages of an ore body of a size and consistency unmatched anywhere else in the world, and large, efficient mines with production costs that compare favourably with those in other countries. On the minus side, Saskatchewan is remote from most major markets, and producers face a distribution challenge to reach the offshore markets which is the main focus of this presentation. One of the characteristics of the world potash business is that all of the major sources of production are located in the developed areas of the world, while there is no significant production in any of the highly populated developing countries. The major potash producers are located in Canada and the United States, in West Germany, France, Spain and the U.K., in Russia and East Germany, and in Israel and Jordan. There is currently no significant production in any of the countries in Asia (with the exception of Jordan where a plant is currently in the start-up phase), Africa, Latin America or Oceania, and all of these areas must, therefore, import a11 of their potash requirements from the producing countries.

Jan 1, 1985

By H. A. Johansen

Recent advances in the metallurgy of chromium have enabled this metal to begin to take its place among the refractory metals. Considerable work is being done on the development of high-temperature alloys containing high percentages of chromium.1/2/ In spite of the relatively large amount of work done on these alloys, little is known of the properties of the pure metal. Information in the literature concerning the tensile properties of pure chromium metal is quite scant. This deficiency maybe explained by the great difficulty of preparing test specimens from such a brittle material, resulting in many losses in each phase of the specimen preparation and testing procedure.

Jan 1, 1954

By Y. Huang, P. B. Prangnell

"An Al-0.1Mg alloy was firstly deformed at room temperature by ECAE to a true strain of 10, where a steady state deformation was established and further processing had little effect on grain refinement. The ECAE samples, with an average grain size of ~0.55µm, were then compressed in a channel die at 77K- 473K to various reductions. Microstructures were characterized by electron backscatter imaging and EBSD in a FEGSEM. Grain refinement to the ECAE submicron structure occurred during deformation at cryogenic temperatures of 77 – 213K, whereas coarsening took place during deformation at elevated temperatures. A steady state deformation was observed at all temperatures where a constant grain structure was developed and maintained upon further straining due to dynamic recovery. The mechanisms of dynamic recovery during steady state deformation at cryogenic temperatures are discussed.IntroductionSevere deformation processing (SDP) has been successfully used to produce submicron grain structures, and in some cases nano-scale crystallite sizes, in a wide range of alloys. However, the rate of grain refinement becomes increasingly inefficient at high strains as a steady state grain structure is approached [1-3]. Steady-state grain sizes have also been reported in other ultra-high strain deformation processes, like cryogenic ball-milling [4]. There is thus a minimum grain size achievable in a material by a given SPD process under constant deformation conditions.It is well documented that a steady state subgrain size is observed in warm deformation of metals due to dynamic recovery (e.g. [5]). In severely deformed alloys a constant grain size at ultra-high strains has similarly been attributed to dynamic recovery [1-3]. Mechanisms have been proposed, for rapid deformation induced grain growth including stress driven boundary migration and breakaway from solute pinning [2]. However, as pointed out by Humphreys et al. [2] the restoration processes are currently poorly understood, particularly at low temperatures, where the boundary migration rates required to maintain a constant grain size are orders of magnitude higher than can be satisfactory explained from diffusion controlled migration. Similar to the subgrain size, the steady state grain size obtained during SDP is generally related to the temperature compensated strain rate [2, 6]. Thermally activated restoration processes are thus expected to be suppressed by lowering the deformation temperature and a smaller steady state grain size can be achieved."

Jan 1, 2012

By David Butts

Solar ponding to crystdlize sodium chloride has been used for thousands of years.1 The systems used were inefficient and usually small compared to the large 25,000 acre pond areas seen today. It has only been in the last 25 years that any real effort has been applied to develop solar ponding technology. Many large solar pond systems have been constructed without much thought to efficient and optimum production rates. The recent high costs of labor, of equipment and of energy have forced producers to take a closer look at their solar pond systems in an attempt to squeeze out the highest possible yields. Other companies such as the Arab Potash Company, the Dead Sea Works, Texas Gulf (Moab, Utah) and San Francisco Salt Companies have no more land area in which to expand and therefore efficient ponds are essential. This paper is written to show how the subdivision of solar ponds can result in production increases of up to 20% and beyond.

Jan 1, 1984

By David E. Hardt

"One of the critical variables to be controlled during arc welding is the size or geometry of the weld pool. The measurement of pool geometry has become an increasingly important problem with the advance of welding automation and control, and this paper addresses that problem. The basic concept of pool size estimation via measurement of pool dynamics is presented. The theory underlying this concept is discussed and is followed by a review of the current work in this area. It is concluded that pool dynamics can be characterized by natural frequencies of oscillation, for stationary welds, and that these can be measured by appropriate signal processing performed on the arc voltage. However, it appears that only full penetration welds show a strong correlation between weld size and natural frequency. Also, the extension of these results to the realistic case of moving welds has yet to be considered in detail. Nonetheless, this method of in-process measurement for real-time weld process control is still quite attractive where applicable since it can be accomplished simply by modifying the arc current schedule and by signal processing of the arc voltage.INTRODUCTUIONThe study of welding process control has been dominated by research into methods of in processing sensing of the weld pool geometry. While it has been shown feasible to measure the topside pool geometry using video methods [1,2], the penetration or backside bead width have remained elusive quantities. This is particularly true if a topside sensor location is required.The concept of using weld pool motion as a pool geometry sensing method was proposed by Hardt et al. [3] and later demonstrated by Hardt and Zacksenhouse [5] and Richardson and Renwick [6]. The concept is based on the fluid dynamics of a pool constrained by a solid container and by significant surface tension forces (i.e. a small shallow pool, not a ""pond"" or ""lake""). Such a pool, if subjected to external forces, will exhibit a surface motion is a function of that force, the properties of the fluid, the surface tension, and the shape of the container. Thus, if this motion can be excited and measured, and the relationship to the pool geometry determined, a means of sensing pool shape will exist."

Jan 1, 1986

By G. B. Gait

This report is the third in a series concerning the Bureau of Mines program for microfilming maps of abandoned mines in the Pennsylvania anthracite region; a catalog of the microfilmed maps of mines in the Lackawanna Basin of tile Northern anthracite field is presented. Previous reports IC 8274, published in 1965, and IC 8379, published in 1968, were catalogs of microfilmed maps of mines in the Eastern Middle anthracite field and Wyoming Basin, Northern anthracite field, respectively , Additional catalogs will be published as the microfilming of significant mining areas is completed.

Jan 1, 1970

By Redhead Robert J.

"In 1991, the Canadian Council of Ministers for the Environment (CCME) charged its Waste Management Task Group with developing a nationally coordinated strategy to measure, monitor, and achieve the objective of decreasing the generation of waste (solid and hazardous) by50% from 1988 levels by the year 2000.With the encouragement of the CCME, which viewed hazardous waste as largely an industry problem, a committee, the “Industry Action Group”, representing eleven industry trade associations with a strong interest and involvement in hazardous waste was recruited.The Municipality of Markham, Ontario was also recruited (Appendix 1)."

Jan 1, 1996

By I T. Cameron

The commercial production of copper metal involves a sequence of purification stages. One step of this process eliminates bulk quantities of iron and sulphur from matte Cu2S(FeS to produce blister containing 95.5 per cent copper. This task is traditionally performed in the Pierce-Smith converter, a cylindrical vessel in widespread use throughout the copper industry. Typically, multiple Pierce-Smith converters are arranged along an aisle, simplifying material transfer from vessel to vessel. Materials are moved through the aisle in pots and boats, using overhead cranes. In terms of the overall process, the converter aisle represents a critical processing unitùit contributes significantly to the value added nature of the metal. The aisle is subject to significant process disturbances. Thus, improvements in the operationÆs modes and conditions have a direct impact on process profitability. As with any commercial operation, improvements are always sought to increase process performance. The general approach involves process modelling, followed by an application of control and optimisation theory to this model. The results of such a study are then applied to the real process, leading to improved performance.

Jan 1, 1998

By S. Steinlechner, G. Schneeberger, J. Antrekowitsch

Due to always getting stricter environmental legislations as well as increasing land filling fees the efforts for treating residues from metallurgy are continuously increasing. In case of filter dusts from metallurgical industry, the high zinc bearing electric arc furnace (EAF) dusts or also dusts from secondary copper industry are important sources for the recovery of secondary zinc oxide. Because of low capacities for secondary zinc concentrates (like Waelz oxide) in primary zinc metallurgy, the upgrade of such concentrates to a quality that meets the requirements of high quality (technical) zinc oxide becomes more and more important. This would open the opportunity to break into new markets and use it for example directly in electrolytic galvanizing. Therefore this paper will summarize possibilities for an elimination of halogens from secondary zinc oxides. Furthermore selective volatilization trials, with a synthetic mixture according to the analysis of Waelz oxide, were carried out to remove impurities to achieve an upgraded product quality.

Jan 1, 2011

By S. Peng, Vaughan R. Voller

"Free boundary problems are a common occurrence in materials processing operations. An important example is the filling of material into molds. This paper looks at filling problems associated with polymer processing, in particular Resin Transfer Molding (RTM) and Compression Molding. A general, single governing equation is developed which on numerical solution provides predictions for the position of the polymer front in the mold during filling. Both fixed and deforming finite element solutions are developed. Application to polymer filling test problems reveal that the fixed and deforming grid scheme are accurate and compare closely with each other.IntroductionProblems arising from the analysis of material processing operations often involve the tracking of a moving boundary, on which a balance conditions needs to be met, or the locating of a free surface that defines the solution domain. Material processing examples of so called ""free and moving boundary problems"" include; the tracking of solidification/melting fronts[l], the tracking of the metal/gas interface during the filling of a mold[2] and location and shape of a skull (freeze line) in a melting furnace[3].Computational solution of free and moving boundary problems usually fit into one of two classes, viz.1. Fixed grid scheme: In which the spatial domain is covered by a fixed grid (mesh) of node points and the solution uses an auxiliary variable (e.g. a local liquid fraction) to track the moving boundary or locate the free surface.2. Deforming grid scheme: In which the grid in the spatial domain is continuously deformed (or adapted in a steady state problem) such that a specified set of grid points lie on the moving boundary or the free surface.Details on the basic underlying features in these two classes of solution can be found in the excellent monograph by Crank [4]."

Jan 1, 1994

By C. H. Bucknam

Net carbonate value (NCV) characterization methods for acid generation potential measurement originated from studies on the Carlin Trend during the 1990's and have been subsequently standardized through cooperation of the Acid Drainage Technology Initiative Metal Mining Sector and the American Society of Testing and Materials International. The paper describes the evolution and standardization of the NCV methods, the importance of mineralogy in interpreting the results and application of the methods to implementation of the Global Acid Rock Drainage (GARD) Guide.

Jan 1, 2011

By C. Burton Clark

The important role of the petrographic microscope in the petrology of refractories is discussed, based on 45 years of industrial experience by the author. Highlights of his career are used to illustrate improvements in equipment and techniques during the period. Two specific investigations are described which emphasize the interrelated use of the petrographic microscope with other instruments such as the x-ray diffractometer and scanning electron microscope. Emphasis is placed on the use of phase equilibrium diagrams for guidance in predicting and interpreting reactions that occur under non-equilibrium conditions in the manufacture and use of refractories.

Jan 1, 1982

By C. Stollberg

The recovery of valuable materials from electronic waste is of growing importance for the re-source management not only in the industrialized nations. Being a significant step in an innovative automated process for recycling of metals and plastics from used electric and electronic equipment, the results of the work introduced below, prove the applicability of microbial leaching of metals from printed circuit boards (PCBs) at industrial scale. Within the first project step, which started in March 2005, experiments in shaking flasks with a mixed culture of chemolitotrophic bacteria (mainly Acidithiobacillus ferrooxidans and Leptospirillum ferrooxidans) were carried out to study the solubilization of non-ferrous metals present in the electronic waste. It was found that the best results were achieved by means of a two-stage process in which leaching of these metals was carried out by acidified ferric sulphate solutions generated as a result of the prior bacterial oxidation of ferrous ions to the ferric state. Special reactor systems for bacterial generation of such solutions and for the subsequent leaching of non-ferrous metals from the waste were developed, constructed and tested under laboratory and pilot scale conditions. The optimum technological parameters such as concentration of iron ions, pH-value, temperature and presence of nutrients were established for both reactor systems. Parameters such as particle size, pulp density and flow rate of the suspensions being leached were established for the leaching process carried out under continuous-flow conditions. The complex flow sheet reflects a highly efficient technology on the basis of metal recovery, environmental effect and economical acceptance. The process was successfully implemented into an industrial demonstration unit.

Jan 1, 2014

By T. M. Klemetti, T. J. Batchler, T. J. Matthews

How representative are partial-panel screen tests of the in situ response of screen to roof and rib deterioration and displacements? Can a more representative procedure that tests up to two full screen panels improve the utilization and effectiveness of screen as a roof and rib support? This paper details a new full-panel screen test procedure and the initial results. The full-panel test frame was designed to test a 2.4 by 3.6-meter screened area with bolt spacing as small as 0.3-meter increments. The initial design included up to 6 screen pull points, but additional locations can be added to produce a more uniform loading. The test frame was developed to capitalize on the capabilities of the Mine Roof Simulator (MRS) at the Pittsburgh Mining Research Division (PMRD) of the National Institute for Occupational Safety and Health (NIOSH). The initial tests included a baseline test of a partial panel (1.22 by 1.22-m screen section) using the original 1.52 by 1.52-meter test frame, a 1.22 by 1.22-meter screen section test in the new full-panel test frame, and two tests of 2.4 by 3.6-meter screened area in the full-panel test frame. The 1.22 by 1.22-meter screen section tests in the full-panel test frame produced a peak load 6% higher and a yield load 30% lower than the partial-panel (original) test frame. The multiple pull points of the full-panel frame produced variable yield, peak, and intermediate loads, but on average were lower than the single pull-point tests. INTRODUCTION Roof and rib surface support has become a major component of the stability and safety of underground coal openings in the past 15 years. The use of screen, either metal or synthetic, has proven to decrease the injuries of underground coal miners. By 2005, there were 466 injuries in the United States caused by roof skin failures, with numerous mines not employing roof screen. In contrast, in 2015 there were 175 injuries caused by roof skin failures, with at least some of the reduction due to the increased use of roof screen. A continued effort to increase the utilization of screen in areas of underground coal mines where workers are traveling and working can reduce these injuries even further. To aid in this effort, the testing of various screen types under various loading and attachment conditions is required. Past testing efforts have primarily consisted of partial-panel testing in a laboratory setting. Laboratory testing of roof screen, both metal and composite, has been conducted in several ways by researchers, manufacturers, and other entities. The primary focus on the testing has been evaluating weld integrity of 1.22 by 1.22-meter screen section tests of various screen types utilized in mining (Dolinar, 2006; Dolinar, 2009; Tannant, 2001). There have also been several efforts at numerical simulation of the screen and screen/rock interactions (Murali et al., 2006; Shan et al., 2014). A few full-panel tests were performed with one pull or loading point in the center of the screen panel (Shan et al., 2014). As most previous efforts have mentioned, the only true way to evaluate the capabilities of screen is to conduct full-panel testing. Single wire strand, weld, and partial-panel (1.22 x 1.22-m) tests as well as numerical modeling only provide insight into the actual response of full-panel screen. A new test frame and procedure have been developed at PMRD to conduct various loading, anchoring, and material testing.

Jan 1, 2019