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By C. S. Chen, Y. J. Luo, M. W. Gao, B. Li, Z. F. Zhang

"To obtain large-sized billets with fine grains and homogeneous elements distribution, uniform direct chill (UDC) casting process, based on annular electromagnetic stirring coupling with intercooling, was employed to produce 7055 alloy billets with a size of F584 mm in this study. The results indicated that there were the coupled effects of annular electromagnetic stirring and intercooling on grain refinement and element homogenization, and also the billets produced by the UDC casting process showed excellent hot workability in comparison to the normal direct chill casting process.INTRODUCTION The high solute 7055 aluminium alloy has a wonderful combination of high specific strength and hardness, good resistance to stress corrosion cracking and high fracture toughness, which is very useful in aerospace application (Yan et al., 2013; Mondal & Mukhopadhyay, 2005). The production of large-sized 7055 alloy billets with high quality is the basic condition for the subsequent application of 7055 alloy to the aircraft. Inhomogeneous microstructures and performances of 7055 billets result from the high alloying element content and the inhomogeneous cooling condition in different regions of billets during the conventional direct chill casting (Paramatmuni et al., 2004; Lalpoor et al., 2011), which will bring bad influence to processing property, functional performance and utilization rate of materials. To alleviate segregation and obtain fine and uniform grains, some effective treatment methods were proposed including electromagnetic stirring (EMS) (Vives, 1989), ultrasonic vibrating (Zhang et al., 2011) and melt conditioning (Fan et al., 2013), on the melt to obtain fine and uniform grains. However, these methods could not effectively decrease the large temperature difference between central and periphery parts of the billet, because the solidification mainly depends on outside cooling including mould cooling and water spraying cooling. To change the heat extraction pattern of the billet functioned solely from the outer surface, based on annular electromagnetic stirring (A-EMS) invented by Xu et al. (2010), Luo et al. (2017) proposed uniform direct chill (UDC) casting coupling A-EMS with intercooling in the direct chill (DC) casting process. An in-mold cooler was inserted to the melt sump, and thus the alloy melt temperature and concentration at solidification front become more uniform."

Jan 1, 2018

By Donald F. MacDonald

WE are living in a mineral and technological civilization. The Encyclopedia Britannica defines civilization as follows: "It is the final test of a progressive civilization that a given effort shall produce a larger modicum of average individual comfort, and the pursuit of this ideal has been from first to last the impelling force which drives civilization onward". This "individual comfort" demands labour-saving machines and devices such as motor cars, radios, and thousands of other inventions, most of which require minerals and metals in vast quantity for their manufacture. In fact, more minerals and fuels have been used in the last third of a century than in all previous world history. Since 1800, the world's production of metals has increased more than a hundred fold (1). Scientific discovery is now advancing on a wide front, thanks to the research work that is being carried on in progressive countries. The world's work is now being done with very much less human drudgery than in the past. We do not have to toil for our living as our ancestors did, even if we follow their occupations. The average man has had many years added to his life-span, but, apparently, little to his spiritual stature and less to his common sense.

Jan 1, 1939

By H. S. Puttanna

Bound water plays an important role in the processing and utilization of numerous materials and mineral processing systems. The fundamental nature of this near surface bound (vicinal) water is yet to be understood in its complete detail. The objective of this paper is to use dielectric measurements to characterize the bound water near hydrophobic and hydrophilic oxide surfaces. It is anticipated that a combination of dielectric property measurements and characteristic relaxation times will allow for more effective analysis of the interfacial water.

Jan 1, 1992

By E. A. Córdova

Current methods for scratching a piece of rock to obtain or check the characteristics of its component material can sometimes be expensive and time consuming. Scratching a rock core requires an object with a point that it is capable of sliding along the surface of the rock while recording the response from the rock due to the sliding. With the idea of providing a cost efficient solution for a scratch device, a new generation turntable arm, composed of a cartridge with a diamond stylus and a USB output connection to the computer, was used to record the vibrations from the sliding of the stylus along a rock core surface. The output sound from the stylus was captured with the computer as an audio input signal. The raw sound data was recorded in a standard waveform audio format (wav) file, and post-processed using sound spectrum analyzer software (Spectra-Lab) to capture numerical data such as frequency, amplitude, and noise from the file. The results for frequency, amplitude, and noise were compared and plotted against the scanned surface of the rock core in the search for correlations that might represent specific characteristics of the surface being scratched.

Jan 1, 2010

By Donald G. Oss

The need for instrumentation and automatic control of the various parameters in the heavy media process of iron ore beneficiation has been apparent for some time. Continued demands for higher grade, competitive products from the Mesabi Range have made it necessary to increase the efficiency of the process in every possible way. A brief review of a typical heavy media flow scheme, as illustrated in. Figure l, might be in order for those not intimately associated with this process of iron ore beneficiation.

Jan 1, 1962

By L B. Sukla, V N. Misra

Microbial desulfurisation of coal has significant advantages over physicochemical desulfurisation processes since the former process selectively removes the inorganic sulfur compounds and heavy metals without significant carbon loss. The purpose of this study was to improve the desulfurisation yield of a coal sample from northeastern coalfields, Assam, India using microbial technique. The coal sample contained 2.13 per cent of total sulfur and 2.59 per cent of ash. Stirred tank reactors of 40 L capacity were operated in batch mode. Initially, the reactor was fed with 40 L of slurry containing ten per cent (w/v) coal, ten per cent (v/v) inoculum of mixed culture of mesophilic acidophiles, native to coal itself and the requisite amounts of constituents for 9K medium without added ferrous sulfate. The percolate of the reactor was then used to seed the medium for the next experiment. The purpose was to obtain a better adapted and more active biomass which would give a better desulfurisation yield for coal. Further studies were conducted in the bioreactor, fed with 40 L of slurry containing ten per cent (w/v) pulp density of coal, ten per cent inoculum (derived from previous studies) and the medium, supplemented with ferrous sulfate. Results showed an increased total desulfurisation yield of 43 per cent in the latter treatment in comparison to the previous one, where the desulfurisation yield was only 23 per cent. The findings also demonstrated the convenience of using inocula derived from coal, where 50 - 60 per cent of pyritic sulfur was removed, while chemical desulfurisation is of little significance with the majority of coal types. The ash content was also reduced to 1.74 per cent as the low pH of the process caused dissolution of a number of common minerals present in the coal.

Jan 1, 2004

By Gaom M. W.

The Mount Isa copper concentrator started operation in 1973. Its secondary grinding circuit consisted of two 5 meters diameter ball mills in closed circuit with 505 mm cyclones. At the design throughput of 800 t/h, the 80% passing size of the circuit product (P80) was about 140 µm. The then Mount Isa Mines Limited (?MIM?) installed two autogenous grinding (?AG?) mills in 1991 to replace two stages of crushing, a rod milling stage and one primary ball milling stage. One of the AG mills was later converted to semi-autogenous grinding (?SAG?) operation by the addition of a steel grinding medium to achieve the designed plant throughput of 800 t/h. The cyclone over-flow P80of the secondary ball mill circuit was reduced to 120 µm by the increased operating power in the AG/SAG mill circuits. The two secondary balls mills had a grinding power of 5.2 MW. A mineralogical study of the milled products indicated that half of this grinding power was sufficient for adequate chalcopyrite liberation. Eliminating one of the secondary ball mills could reduce energy and operating costs by more than A$2 million dollars per year. An optimisation project team was established to achieve the predicted power saving. Grinding circuit simulations were conducted for different circuit configurations. Ball mill parameters such as ball size, ball charge and feed slurry density were optimised. Cyclone body diameter, spigot and vortex finder sizes, and cyclone types were tested. The secondary ball mill circuit was redesigned and several proposed circuits were run as trial production campaigns to determine their operability and efficiency. The plant trials confirmed that one of the secondary ball mills could be decommissioned. Significant cost savings were achieved as a result. The success of the project demonstrates optimising grinding circuits can not only deliver the plant performance, but also a much lower unit operating cost through energy and maintenance savings.

Jan 1, 2014

By Y. H. Wang, S. Kou

"Three-dimensional weld pool convection was computer simulated using dimensionless variables. The electromagnetic force, the buoyancy force and the surface tension gradient on the pool surface were treated through the use of the dimensionless electromagnetic force, the Grashof number and the Marangoni number. Other typical dimensionless numbers such as the Prandtl number and the Peclet number were also used. The calculated and experimentally observed fusion boundaries were compared. The convection patterns were shown and the effect of the Marangoni number was demonstrated. IntroductionSeveral weld pool convection models have been developed by Oreper et al. (1,2), Chan et al. (3) and Kou et al. (4). These models describe two dimensional convection in stationary weld pools in a semi-infinite workpiece. Since the vast majority of arc welding practices involve a moving heat source and weld pool, and the workpieces are finite in thickness rather than semi -infinite, a 3-D convection model for a moving heat source and a workpiece of finite thickness is expected to be much more useful.Weld pool convection can strongly affect the structure and properties of the resultant welds. Variations in weld characteristics which are likely to occur from changes in weld pool convection are: weld penetration, macrosegregation, gas porosity, solidification structure, undercutting and surface smoothness. Apparently, the quantitative understanding of convection and heat flow in weld pools is of considerable practical interest. Mathematical models describing convection and heat flow in weld pools are essential, not only because of the quantitative understanding they provide, but also because of the difficulties associated with the experimental measurements of weld pool convection. These difficulties are mainly due to the fact that only surface flow, rather than the overall convection pattern in the weld pool, can be observed. In fact, due to arc glow even the observation of surface flow can be rather inconvenient."

Jan 1, 1986

By Z Tong, M Gao, X Wang

In response to the need for improved magnetic separators for beneficiation of fine grained iron ores that have been finely ground to liberate the iron minerals from the gangue, a series of high efficiency wet drum permanent magnetic separators (T-GCT) has been developed by Maanshan Tiangong Technology Co Ltd. These magnetic separators have high efficiency for separating superfine strongly magnetic minerals and the ability to produce high-grade concentrates with high recovery. They are ideal replacements for conventional drum magnetic separators, especially for treating superfine particles.

Jan 1, 2009

By Claudio L. Schneider, Peter R. King, Reiner Neumann

"Predicting the liberation spectra that are produced from breakage of two-phase ores under the random fracture assumption can be accomplished by measuring the conditional, on length, linear grade distribution directly from images obtained from a representative sample of the unbroken texture. The technique tremendously simplifies the prediction problem by avoiding the multiple convolutions that arise from the traditional method based on a description of texture from a measurement of the chord length distributions associated with each phase in the unbroken texture. For a 3-phase system, the phase transition probabilities associated with the textural information make the traditional calculation an almost insurmountable mathematical problem. The direct measurement procedure on the other hand can be expanded to three phases comparatively easily.A coal sample is used here to demonstrate the procedure. It is concluded that the conditional, on length, linear grade distribution can be predicted in the same fashion for multi-phase systems. Accurate stereological conversion is the practical hurdle to be overcome for multi-phase systems, but it is already a reality for 3- phase systems."

Jan 1, 2003

By Z. D. Tan

The continuous digestion technological conditions of phosphate tailings with high magnesium content in sulfuric and phosphoric mixed acid is studied in this paper. The influences of excess coefficient of sulfuric acid, weight liquid to solid, reaction temperature and time on conversion of P2O5 and MgO are discussed. The influence of infiltration capacity of phosphogypsum by the concentration of liquid-phase SO3 is discussed too. Under the optimal technological conditions, the conversion of P2O5 is 95.56% and MgO 98.63%, the filtration rate of phosphogypsum increases with the increasing of liquid-phase concentration of SO3, the optimal apparent concentration of SO3 is 0.135~0.14g? mL-1 in liquid-phase. The filtration rate of phosphogypsum is 1473kg? m-2? h-1. N-P-Mg compound fertilizer was produced by adding magnesia powder and inflating ammonia in filtering medium.

Jan 1, 2014

By Dr. -Ing. Wolfgang Pietsch

Many primary metallurgical wastes are in the sh.-ape of turnings; borings, chips, dusts, and other particuletes. While such. materials can be easily segregated and/or upgraded to yield high quality ?secondary metals with often known composition for easy recirculation into the production? process; their particulate nature results in various problems. Roller presses are used in an ever increasing number for size enlargement and densification of primary particulate metallurgical wastes for secondary metal recycling. The paper will mention the areas of application from A(luminum) to Z(ink), also including Brass; Cast Iron, lead, and Stainless Steel, as well as dusts from all types of melting and ladle furnaces or converters. Typical systems using roller presses for size enlargement. will be discussed.

Jan 1, 1995

By B. Devulapalli

A mathematical model of the industrial hydrocyclone based on fluid dynamics is a better alternative to the currently existing empirical models. The swirling-flow velocities are determined by solving the Navier-Stokes equations with an appropriate turbulence model. The solution of the momentum-balance equations yields the flow field inside the hydrocyclone which determines the particle trajectories, and subsequently the classification curve. The essence of the model is that the physical dimensions of the hydrocyclone and the slurry characteristics can be incorporated, and the influence of these parameters reflects on the flow predictions. The predicted tangential and axial velocities in a 250-mm hydrocyclone are in good agreement with the laser-Doppler velocimetry measurements. Finally, the predicted classification curves show good agreement with experimental data measured on a KREBS Dl0B hydrocyclone.

Jan 1, 1993

By Gregor Kücher

Lack of basic knowledge on the semi-direct recycling methods for hard metals hinders the application on an industrial scale. However, advantages like reduced expenses and lower environmental impact draw interest at future potentials. Consequently, this report aims to offer insight into the influence of varying bulky hard metal substrates during their lixiviation in acidic media with an oxidant. The statistical software Modde 11 assisted in the development of a design of experiments (DOE) for evaluation of the impact of average grain size, binder and tantalum carbide (TaC) content on the leaching characteristics. The other experimental parameters were constant. Among them were temperature, solution concentration and quantity, duration and substrate surface exposed to liquid volume. Eventually, prediction plots and factors of the computed model equation describe the effects of varying substrate qualities on leached binder metal and selectivity.

By Robert M. Becker

The evaluation of in situ rock stresses from measurements of the change in diameter of a borehole that is stress-relieved by overcoring has become a common practice. Generally the stress evaluation has been based on isotropic relations whereas rock in varying degrees is anisotropic. A plane elasticity solution for a circular hole along one axis of an orthotropic medium has been adapted to evaluation of in situ stress. The necessary elastic parameters for this evaluation may conveniently be obtained from static tests on the overcore in conjunction with a consistent orthotropic thick-wall cylinder solution. The method and equations for the laboratory and field evaluations are summarized and illustrated.

Jan 1, 1968

By C. Tong, B. Hilscher

"Sensor based ore sorting is being rapidly adopted by the mining industry. The ability to boost mill feed grade by rejecting waste grade rocks early in the process has proven revolutionary for some operations.This paper briefly reviews the current position of ore sorting in the industry, as well as abridged results from specific operations such as Barrick, McEwen, New Gold, and two others. The paper also introduces the concept of “Profit Recovery™”, the measuring of recovery based on rock profitability rather than just metal content.IntroductionSensor based ore sorting is being rapidly adopted by the mining industry. The ability to increase mill feed grade by rejecting waste grade rocks early in the processing stage is proving to be revolutionary for some operations. These potential outcomes have been too invaluable to be overlooked by both producing operations and prospective projects, thus leading to a wide range of studies on ore sorting. In addition, the advent of ore sorting has also called for a new standard of recovery analysis. The answer to this is the creation of a new term and concept - Profit Recovery™.This paper evaluates the most recent results of ore sorting in the mining industry, and presents the results from five different mining operations. Additionally, this paper will discuss and evaluate the Profit Recovery™ of each of these operations. The goal of this paper is to address common concerns regarding ore sorting rejects and their actual impact on project economics.State Of The ArtOre Sorting is a sensor-based sorting and pre-concentration technology implemented before the processing stage that is used to reduce the amount of waste reporting to the mill feed. This technology can also be utilized to recover ore from previously uneconomic waste, as well as reduce the mill energy and reagent consumption (Tong, 2012). In greenfield projects, sensor-based sorting can further provide value by reducing processing capital costs. The decline of available high grade orebodies and decreasing head grades has further increased the attractiveness of pre-concentration, and subsequently ore sorting (Lessard et al., 2014).There are currently two notable types of sensor-based sorting: bulk and rock-by-rock. Bulk sorting consists of live, high tonnage sorting that can be installed on a scoop or on a conveyor belt with a diverter. Rock-by-rock is a selective sorting method that scans and sorts individual rocks on a conveyor belt, and rejects rocks using air jets or mechanical levers. Figure 1 shows a diagram for a typical air jet sorter."

Jan 1, 2018

By X. L. Song, G. W. Zhang, F. Y. He, X. Xiao, L. L. Huang

This paper presents the design of a model and process simulation of a vertical mill based on a population balance model. The simulator, Simulink, which is a systematic modeling tool within MATLAB, was used for the simulation. The model will simulate the real time variation trend of each size fraction in the feed material to the vertical mill, as well as, the size distribution of the batch grinding products. Breakage distribution and selection functions are calculated based on batch grinding laboratory experiments using Back-calculation method. The simulated size distributions correspond with those in the actual mill operation having a relative error of less than 0.50%. This work lays the foundation for future research on modelling and simulation of a closed circuit grinding operation consisting of a vertical mill with hydrocyclone classifier.

Jan 1, 2016

By C. W. Overton

The operations of Bethlehem Copper are situated in the south-central interior of British Colombia at an elevation of 4900 feet above sea level. Main road and rail transportation systems pass through Ashcroft in the Thompson Valley, which is 28 miles by road from the minesite. The operation was the first low-grade open-pit porphyry copper mine in British Colombia. The minerals are chiefly chalcopyrite and bornite, while the rock is principally feldspar and quartz. In the outer fringes of the orebodies sane pyrite is present. Average grade of mill feed is 0.55% copper.

Jan 1, 1973

By Carlos A. Nunes

V-AI alloys have been used commercially to produce pure vanadium by Electron Beam Melting (EBM), as well as to obtain Ti-based alloys (ex. Ti-6AI-4V). The aluminothermic reduction of vanadium pentoxide (V205) is the primary method to obtain these alloys. Concerning the obtention of pure vanadium, earlier studies have indicated alloys presenting Al content between 10 and 15wt% as the most suitable alloys for direct EBM. In the present work we investigated the aluminothermic reduction of V205 in order to define process parameters for the obtention of V-AI alloys with composition in the previously mentioned range. It was studied basically the effect of excess AI, CaO addition and reaction atmosphere (air, argon) on the alloy composition (AI, 0, N). In addition, microstructural analysis of selected alloys by SEM (BSE images) and EPMA (WDX) were also performed.

Jan 1, 1996

By B. F. Westfall

Throughout the 1960's and 1970's world trade grew rapidly, reaching a peak of USS1.8 trillion in 1980. Since then the world recession of the early 1980's shrunk trade to about US$1.6 trillion. The reduced cash flow to developing economies made it difficult to service their huge international debts, Nowadays lenders are reluctant to grant Third World countries additional credit. The shortage of export financing, plus trade barriers set up by developed countries, is further inhibiting international trade. Therefore, countries are turning to new and creative alternatives to financing imports of consumer as well as of investment goods. Non-cash transactions, including different forms of countertrade, are rapidly growing alternatives to traditional trade financing patterns. In 1983 about 30% of international trade, or close to US$600 bill ion, were presumably done by non-cash transactions, up from barely 2% in 1976. By year 2000, half the world trade is likely to be conducted on basis of barter. As of mid-1984 some 88 nations used countertrade regularly and Governments of at least 15 Latin American countries had arranged or mandated commercial countertrade.

Jan 1, 1986