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By Niraj Bala

Boiler tubes of coal-fired boilers suffer severe erosion-corrosion (E-C). One method to counteract this problem is by the use of therma, spray protective coatings. Cold spray coating process was used to deposit Ni-20Cr powder on SA 516 (Grade 70) boiler steel. The bare as wel, as the coated steels were subjected to cyclic experimenta, studies, in the superheater zone of a coa, fired boiler. The weight change technique was used to establish kinetics of the erosion-corrosion. XRD, FE-SEM/EDS and X-ray mapping techniques were used to analyse the as-sprayed and corroded specimens.

Jan 1, 2010

By C. E. Meissner

THE need for a practical method of deciding upon new alloy steel analyses to widen its markets was the problem facing the Chrome Steel Works at the beginning of 1927. In addition to determining the physical properties of the alloys under consideration, it was necessary to test their value in service. Small melts of steel in a crucible, from which test specimens could be made, were insufficient to determine more than physical properties, therefore actual castings and ingots had to be made before the products could be placed in service. Furthermore, to save further experimental work, it was desirable that these heats should be made on a "pilot" basis; that is, actually duplicating regular open-hearth furnace practice. Therefore a one-ton (2000-lb.) acid open-hearth furnace was built. FURNACE DESIGN There are no special features in the design of this furnace. Standard acid open-hearth practice is followed, with the reproportioning of the dimensions necessitated by its small size; notably, a considerably increased length in proportion to width in order to get proper flame propagation. After the first heat was made it was found that the checkers were insufficient. The checker chambers were increased in size and the checker openings were made much smaller. The furnace was started late in March, 1927, and made 65 heats. Experimental work was then stopped until the data accumulated could be worked up and summarized. The run was resumed in November and the furnace is still operating, having made at this writing 60 additional heats. For the last series of runs, there was some rebuilding of both the furnace itself and the checkers. Slag pockets were added. Fig. 1 shows details of construction; Fig. 2, the, general appearance. All designing was done by the operating and engineering staff. Construction materials were those available around the plant. The reversing valve is a standard butterfly type taken from an old furnace.

Jan 1, 1928

By C. E. Meissner

The need for a practical method of deciding upon new alloy steel analyses to widen its markets was the problem facing the Chrome Steel Works at the beginning of 1927. In addition to determining the physical properties of the alloys under consideration, it was necessary to test their value in service. Small melts of steel in a crucible, from which test specimens could be made, were insufficient to determine more than physical properties, therefore actual castings and ingots had to be made before the products could be placed in service. Furthermore, to save further experimental work, it was desirable that these heats should be made on a "pilot" basis; that is, actually duplicating regular open-hearth furnace practice. Therefore a one-ton (2000-lb.) acid open-hearth furnace was built. Furnace Design There are no special features in the design of this furnace. Standard acid open-hearth practice is followed, with the reproportioning of the dimensions necessitated by its small size; notably, a considerably increased length in proportion to width in order to get proper flame propagation. After the first heat was made it was found that the check-ers were insufficient. The checker chambers were increased in size and the checker openings were made much smaller. The furnace was started late in March, 1927, and made 65 heats. Experimental work was then stopped unti1, the data accumulated could be worked up and summarized. The run was resumed in November and the furnace is still operating, having made at this writing 60 additional heats. For the last series of runs, there was some rebuilding of both the furnace itself and the checkers. Slag pockets were added. Fig. 1 shows details of construction; Fig. 2, the general appearance. All designing was done by the operating and engineering staff. Construction materials were those available around the plant. The reversing valve is a standard butterfly type taken from an old furnace. The slag pockets and checkers are cleaned by digging down to arched openings which have been bricked up.

By William R. Barton

It is generally conceded as axiomatic that the aggregate producer and the average urban resident have mutually incompatible goals. The producer wants to be near his mass market and the average resident wants him as far away as possible. The traditional economic decision to mine local material to avoid transportation costs is increasingly challenged by zoning and planning bodies and by citizens' groups. This conflict generated much written and spoken word and offered opportunity for great flights of rhetoric. The pressure on the producer also has forced re¬appraisal of the need for the classic confrontation with indications that much of the conflict is more apparent than substantive. In New England several factors combine to increase complexity of the siting problem. It is a region of high land values and population density. Due to the proximity of metropolitan areas, even rural communities have experienced a prolif¬eration of environmental groups with concomitant enthusiastic regional planning and critical watch over land use. In New England where there is little public understanding of the necessity for, and the realities of, mineral production a sophisticated approach to aggregate production site location is required.

Jan 1, 1975

By Felicia F. Peng

Employing the combination of two types of polyelectrolyte might become necessary to enhance both settling rate of the flocs and water clarity of fine particle suspension in high capacity thickening process. The sequence of addition, mixing, type and dosage of polymer affect the overall performance and capacity of a thickening process. For the sedimentation of copper flotation tailings, the cylinder test results showed that two different techniques may be used to achieve the required performance including high settling rate of flocs, underflow density and overflow water clarity, by either adjusting pH prior to anionic polyelectrolyte flocculation, or using a combination of polymer flocculant and coagulant (dual polymer system). The dynamic thickening testing results showed that only the approach using a dual polymer system is able to meet the required performance. The effects of polyelectrolyte dosage, the sequence and numbers of polyelectrolyte addition, feed concentration, bed level and rake speed on the settling rate, underflow solid, and water clarity were studied in cylinder test and a laboratory dynamic thickening unit with various conditions related to the thickening process. The dynamic test is especially valuable in evaluating the addition and mixing of polymers. The results were evaluated quantitatively, using total suspended solids in supernatant, underflow density and capacity per unit settling area per unit time as the measure of effectiveness. The objective of this study is to quantify and explain some of the parameters involved in the sedimentation of copper flotation tailings.

Jan 1, 1997

By J. M. Davidson

The potassium mineral polyhalite (K2SO4.MgSO4.2CaSO4.2H2O) found in large deposits in western Texas and southeastern New Mexico is associated with varying amounts of halite (sodium, chloride, NaCl) and anhydrite (calcium sulphate, CaSO4). Although the anhydrite, because of its low solubility and slow rate of solution, is relatively inert, the halite is dissolved immediately in any process solution with which the polyhalite comes in contact. Limited quantities of sodium chloride in the liquors used for the hot extraction of polyhalite materially improve the results obtained, but only a very small sodium chloride content may be desired in the entering polyhalite in other procedures, such as Bureau of Mines process. In all of the processes suggested for the recovery-of potassium sulphate from polyhalite the control of the sodium chloride content will be desirable, if not absolutely essential to efficient operation.

Jan 1, 1934

By C B. Valentin

It is acknowledged that the analysis of iron ores using X-ray fluorescence (XRF) for major and minor elements is best carried out on fusion discs. This method of sample preparation eliminates mineral and particle size effects which can lead to biased results when using pressed powder pellets. However, the fusion disc method is costly as it requires a high capital investment in platinumware, requires experienced operators and uses expensive fluxes. Also, the dilution effect complicates the analysis of trace elements. For many applications, such as exploration and mining control, the method of XRF analysis of iron ores by pressed powder pellet probably provides data of adequate quality. Kumba Iron Ore, an iron ore producer in South Africa, recognises this and carries out most analyses of iron ore by pressed powder pellet and uses the automated fusion method mainly for certification of in-house calibration standards and quality control (QC) samples that are used for validation of pressed powder pellet method purposes. Automated fusion is also used for analysing the composite export shipping samples. All the other exploration, production, despatching and plant operation samples are done by the pressed powder pellet method. Automation of sample preparation procedures should improve the quality of data for pressed powder pellets. To compare the precision of the three methods of sample preparation and XRF analysis, 20 aliquots of a QC standard were prepared and analysed by each procedure/preparation method. The results and statistical data on the most important elements, Fe, K2O and P, are as shown later in Table 2.Clearly the precision is best for the auto prepared fusion discs, as expected, and worst for the manually prepared pressed powder pellets. However, the data generated from the auto prepared pressed powder pellets compare remarkably well against those from the auto prepared fusion discs.

Jan 1, 2007

By Ronald Molnar

"High demand for metals is driving the exploitation of lower grade and more complex orebodies. These projects are often the initiatives of junior mining companies with limited financial resources. In addition, existing operations seek to enhance revenue from their existing metal recovery operations, through the production of value-added by-product metals and chemicals. Typically, hydrometallurgical circuits, often with novel chemistry, are required to exploit these new ores, to produce the multiplicity of products that will make a marginal project economical, or to increase the product range of an existing operation. Often, the mineral processing engineer is given the task of coordinating the development of a back-end hydrometallurgical flowsheet for their mineral processing project. This paper discusses the objectives that companies have when they commission the operation of a hydrometallurgical pilot plant. The paper goes on to enumerate some of the principal differences between mineral processing and hydrometallurgical pilot plants and the effect these have on the design, operability and potential pilot plant outcomes. Important factors include working with chemically reactive solutions and pulps, elevated temperatures operation, changing rheological properties of slurries, the complexity of integrated circuit flowsheets with long hold-up times and multiple recycle streams, and the need in some cases for extreme attention to purity and cleanliness. Examples will be drawn from the extensive experience base of SGS Minerals Services at the Lakefield site, in piloting both mineral processing and hydrometallurgical process flowsheets.INTRODUCTIONWe are currently experiencing a period of strong growth in the demand for metals. This in turn is turning the spotlight on a great many smaller mining companies and mining promotion ventures trying to tap into the rising metal demand. Some of these companies want to develop their properties and recover metals while others want to develop to the point that a major company will take an interest, or in some cases buy them out completely.With the heightened interest in metals, many orebodies that have been known about for years are being reconsidered for exploitation. Often, the reason they have not been developed to date is because of difficult metallurgy and marginal grades leading to marginal economic viability. In both cases the key that unlocks the resources is often the application of a novel metallurgical flowsheet, often a hydrometallurgical flowsheet."

Jan 1, 2006

By R. S. Jurani

Sunshine Mining Co.'s Kellogg operation is the primary silver producer in the US. Maintaining a comfortable working environment in this deep underground mine historically has been a complex and costly problem. To improve the ventilation and cooling systems at a time of declining and un-certain silver markets, it was proposed to optimize the performance of existing facilities at minimum cost. This paper discusses a two-year, $400,000 optimization program that resulted in increased total mine airflow, cooler ambient temperatures, reduced compressed air usage, and lower energy consumption by primary fans, air compressors, and refrigeration plants. This saved the company about $650,000 per year.

Jan 1, 1988

By Murl R., Schrock

THE use of diamond-drill holes at the Moctezuma Copper Co., Pilares mine, Pilares de Nacozari, Sonora, Mexico, for the ventilation of raises has resulted from experiments that were made in an effort to secure continuous and efficient ventilation in hot and gaseous raises. The method is particularly applicable in long raises and in raises run from development levels where the source of fresh air is distant. In order that the CO, concentration shall not become excessive, 30 cu. ft. per min. per man must be supplied to a heading for breathing purposes:' The quantity of air that will pass through a diamond-drill hole by

Jan 1, 1929

By J. Laganiere

A considerable part of the sulphuric acid requirements of the Aluminum Company of Canada's Arvida smelter comes from the burning of 180-200 tons per day of zinc '"'sulphide concentrates in a 22-ft.-diam-eter fluidized bed roaster. The plant and its operation were fully de-scribed in a publication that appeared about ten year ago (1). A simplified flowsheet of the roasting and gas-cleaning sections of the plant is given in Figure 1. The wet zinc sulphide concentrates are un-loaded into a pug mixer, by means of a Pay loader, and mixed with water in a mixing tank to make a slurry of 80 per cent solids. The slurry is transferred to a .feed tank and then introduced into the roaster at a point four feet above the constriction plate, which is the height of the settled bed of zinc calcines. The roasting temperature is con-

Jan 1, 1963

By J. C. Nigro

The potential use of prereduced pellets in the burden of the blast furnace continues to be a topic of interest. Several excellent papers have been written describing the theoretical and experimental rewards. (1) (2) (3) (4) (5) (6) (7) (8) (9) Significant increases in iron output and substantial savings in coke consumption are major advantages over conventional iron oxide pellets. The savings are especially important in areas where good coking coal is at a premium. Lower handling and transportation costs may also be factors favoring prereduction. When considering the overall cost of making and smelting prereduced materials the optimum metallization level becomes significant. An analysis by Agarwal and Pratt of the thermodynamic aspects of blast furnace operation with all prereduced pellets shows that the criteria controlling coke consumption depends upon the degree of reduction and upon the percentage of oxygen (present as FeO) removed by solution loss.(8) The authors state that although the chances of obtaining large fuel savings are greatly improved when metallization is high, reduction to the highest degree, which is costly, may not result in the lowest energy requirement per ton of hot metal; thus, over reduction could possibly result in wasted energy in the blast furnace.

Jan 1, 1968

By C. Bryce

Rhenium is primarily recovered as a by-product from molybdenum roasting circuits. However, rhenium is also present in copper heap leach solutions at very low concentrations and represents a potential new rhenium source. Freeport-McMoRan Copper & Gold has developed a new process using carbon adsorption followed by ion exchange or solvent extraction to concentrate rhenium from less than 1 ppm to 15 g/L. The product is compatible as a feed to an existing rhenium processing plant. A pilot plant operated at Freeport-McMoRan?s Sierrita mine has demonstrated the technical and financial feasibility of this new process.

Feb 23, 2014

By S. Rajendran

Gas Hydrates (Methane Hydrates) are solid, ice ? like substances composed of water and natural gas. They occur naturally in areas of the world where methane and water can combine at appropriate conditions of temperature and pressure and are found in the ocean bottom sediments and in some permafrost areas. Besides temperature and pressure, factors like bathymetry, sediment thickness, sedimentation rates, and total organic carbon content (TOC) also control gas hydrate formation in the sea. The stability of gas hydrates depends on the critical high pressure ? low temperature combination (0-17 bars, 0-25ºC), which in turn dependent on the mix of gases from which the mineral is formed. As the critical parameters can be altered by deposition, erosion or slumping of sediments, formation or melting of ice cover, rise and fall of sea level and sudden temperature changes induced by tectonic activities, current flows or volcanisms, the gas hydrates tend to be very unstable. It is becoming increasingly evident that naturally occurring gas hydrates are significant component of the shallow geosphere and are of societal concern in at least three major ways: as an energy resource, a geologic hazard and a major contributor for climatic changes.

Jan 1, 2010

By McKee D. J

Much research is aimed at providing a revolutionary advance in technology that has the potential to render current mining and beneficiation problems obsolete. Such revolutionary advancements have been significant but few in number. Recent history shows that most improvement has been derived from a series of incremental improvements to the many processes that make up mining and beneficiation systems. Management approaches are changing to encourage this 'continuous improvement' and to support its implementation through the formal management of quality. This paper reviews some of the industry's priority R&D project areas and demonstrates that very significant opportunities are available to broaden the focus for improvement from individual processes to include the interaction between mining and mineral beneficiation systems.

Jan 1, 1994

By Goran Mathisson

PLASMARED is a process in which one well established and one new advanced technology have been merged into a practical tool for production of high quality direct reduced iron at lowest energy consumption and costs. Before describing the process, we have to reiterate the simple fundamentals of making metallized iron from iron ores: The main components necessary are: - Iron oxide - Carbon and/or hydrogen - Heat

Jan 1, 1982

By K. K. Clark, W. H. Somerton

The feasibility of reducing pressures needed to fracture formations by heating the borehole intensively has been investigated on a laboratory scale. Reductions in fracture pressures of heated Bandera, Berea and Boise sandstone cores were observed at various confining pressures, simulating reservoir stress conditions to a depth of 5,000 ft. Both permeable and impermeable borehole boundary conditions were tested. Three heating conditions were used in the tests. One group of samples was heated in a furnace to a temperature of 600C, cooled to room temperature., and then tested for fracture pressures. Two other groups of samples were heated with a borehole heater to maximum borehole wall temperatures of 625 and 792C, then cooled and tested. In all cases, heated samples showed substantial reductions in fracture pressures compared to unheated samples. The higher temperature borehole heated samples showed the greatest reduction, amounting to 70 per cent in the extreme case. In actual application to wells, it was concluded that fracture pressures may be reduced by 20 to 50 per cent by intensive borehole heating before fracturing. INTRODUCTION Hydraulic fracturing of oil and gas wells is an accepted and effective technique for increasing well productivity in many areas, but is notoriously unsuccessful in other areas. The technique becomes less interesting for production stimulation purposes when excessive fracture pressures are necessary. Formations which do fracture but require high pressures, probably form horizontal fractures. There is good evidence to indicate that some formations do not fracture at all, but yield plastically under high pressure. Thus, any technique which will make formations easier to fracture or will reduce fracture pressures is potentially interesting to petroleum producers. Horizontal fractures generally occur in planes of weakness, such as bedding planes, and at pressures equaling or exceeding the effective overburden stress. In the unusual case where planes of weakness do not exist, a slightly higher pressure must be applied to overcome the tensile strength of the rock. In general, high fluid-loss fracturing fluids are conducive to the formation of horizontal fractures.1 Vertical fractures, when they do occur, are initiated at pressures generally lower than overburden pressure and are favored by low fluid-loss fracturing fluids or impermeable boreholes. The pressure necessary to create a vertical fracture in an impermeable, elastic medium can be predicted from the so-called "thick-walled cylinder" equation: Pf = 2 or+ st.............(1) where pf = fracture pressure or = radial stress st = tensile strength of medium. This equation indicates that to fracture it is necessary to overcome a tangential compressive stress, induced by and equal to two times the radial confining stress, plus the tensile strength of the medium. If the above equation held strictly true for rocks, very little could be done to reduce fracture pressure. The tensile strength of the rock might be reduced somewhat, but any change in st would be small compared to the magnitude of the tangential stress at reasonable subsurface depths. Laboratory tests have shown that actual fracture pressures exceed values predicted from Eq. 1 by factors of 1.4 to 28.6.1,2 Eq. 1 thus does not properly describe the

Jan 1, 1966

By Kirsten Corin, Belinda McFadzean, Cyril O’Connor, Jenny Wiese

The Bushveld Complex of South Africa contains almost 90% of the world’s reserves of platinum group minerals (PGMs). In the flotation of PGMs, there are significant challenges arising from the need to treat ever-decreasing grades of the relevant ore deposits. The major challenge in the flotation of these ore bodies is the control and management of the gangue minerals, particularly silicates such as orthopyroxene, plagioclase feldspar, and pyroxene which are often rimmed with talc which makes them naturally floatable. It has been shown that various polysaccharide depressants such as CMC and guar have different properties in terms of depressing the gangue minerals. Since the PGMs are often associated with sulphides, copper sulphate is widely used as an activator in PGM flotation but can inadvertently activate the gangue minerals as well as reduce the recovery of PtTe2 which accounts for up to 40% of the Pt in the Platreef ore body. Depressants also reduce the mass of solids reporting to the froth and can thus destabilise the froth. This effect on the froth can be mitigated by using higher frother dosages or water of higher ionic strength. Reducing chromite recovery is of critical importance since high levels may negatively affect the downstream smelting process. Chromite recoveries can however be reduced through the application of gravity separation or reducing entrainment through reduced water recovery. In summary, due care needs to be taken to carry out site test work to develop an optimum ratio of collector, frother, activator, and depressant to ensure that the highest grades and recoveries of the PGEs are obtained while reducing depressant dosage as much as possible.

By Joseph J. Larry

In hard siliceous sandstone strata overlying coal seams, roof bolting is often the bottleneck in the coal production cycle. In the past, these strata have been drilled by pneumatically operated stopers. Although slow drilling is cumbersome and uncomfortably noisy, the stoper was the most effective drill in these harder strata. However, because of the (U.S.) Coal Mining Safety Act, which limits noise levels for operating drills, FMC Mining Equipment developed the water-through-the-drill-steel method of drilling high-compressive-strength strata. Although water-through-the-drill steel had been developed earlier, the real impact of wet drilling techniques surfaced when the dual-boom roof drilling machines were installed at the Virginia-Pocahontas Division, Keen Mountain, Virginia, in 1974. This paper covers some of the technical details of the water-through- the-drill-steel design and its application.

Jan 1, 1979

By Fabio Terzi

In this investigation some preliminary results are reported about the electrochemical oxidation of CO using goldbased encapsulated nanoparticles grafted on conducting substrate. The investigation has been planned in four steps: 1. production of Au(111) substrate and modification with self assembled monolayers; 2. synthesis and embedding of nanoparticles; 3. grafting of encapsulated nanoparticles on electrode substrates; 4. investigation of CO electroxidation on the modified electrode. The systems were characterized by means of various techniques (spectroscopic, microscopic, and electrochemical methods), obtaining information about SAM's structure and morphology, size and composition of nanoparticles and electrochemical behavior of modified electrodes.

Oct 1, 2003