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By R J. Singh, E. Z. Chacko, Devilal, S. K. Jha, Rina Sahu, Sheshank Shekhar

"Breakouts are one of the biggest problems encountered during continuous casting of steel billets. Billets get cracked locally or break completely in two parts during solidification causing the liquid part of the partially solidified billet to empty inside the cooling chamber. Proper control of important parameters is necessary to avoid break outs during continuous casting. In the present work, the nature of the break outs at a billet caster at Tata Steel was studied. Data analysis was also done for certain casting parameters and the Sulphur tracer test was conducted to understand solidification in the mould. It was found that to reduce the occurrence of break outs, it was necessary to tune the operations based on the grade being cast and the design of the mould tube being used.IntroductionA break out during the continuous casting process is a rupture of the partially solidified shell inside the secondary cooling chamber, causing the contained liquid steel to spill out. In the mid 1970s while continuous casting technology was still in early stage of development, causes of breakouts was not well understood. Today, with technological development much has been understood about breakouts but, most of the understanding has been in the slab casting process wherein due to the higher level of instrumentation, a lot of information has been gained. In billet casting however, due to the geometry of the mould housing with the tube mould, multiplied by the complexity of the multiple strands, instrumentation has not been used and obtaining data for analysis has been difficult.Breakouts at billet casters are still the main hindrances to production. A break out results in a loss in production since the strand which has had a break out is now not available to produce and thus a six strand caster would be reduced to a five strand caster, increasing the time for casting the same tonnage. Additionally extra set up time is required as more often than not a mould change is required in order to have the strand casting again."

Jan 1, 2014

Jan 1, 1924

By R L. Cheesman

An extensive Precambrian iron-formation lies about 2,000 ft. beneath post-Precambrian rocks in the Fort a Ia Corne Forest Reserve, south of Choiceland, Saskatchewan. The geology, deduced from limited drill results and from some geophysical observations, indicates that the deposit is a characteristic magnetite iron-formation, not uncommon in the exposed Precambrian of Saskatchewan, but also shows certain interesting features of faulting and pre-Paleozoic weathering which have given rise to a pre-served detrital deposit of hematite. The body is of ore grade and of sizeable proportions. T HIS paper is presented in order to set forth the interesting geological features of a Precambrian iron deposit located beneath the cover rocks of the Great Plains region and to comment upon the methods of discovery and interpretation of the nature of the body. The Choiceland iron deposit is located in the Fort a Ia Corne Provincial Forest Reserve, some 15 miles south of the town of Choiceland, Saskatchewan. Choiceland is

Jan 1, 1964

By Daniel Saramak

"Issues concerning effectiveness of the high-pressure comminution process in technological circuits of copper ore treatment were presented in the paper. Crushing processes taking place in high-pressure grinding rolls devices (HPGR) are currently one of the most efficient methods of hard ore size reduction in terms of the energy consumption. The HPGR products are characterized by a fine particle size and the micro-cracks formation in individual particles, which appear in downstream grinding processes, decreasing their energy consumption. The purpose of this paper was to analyse the effectiveness of a ball mill grinding process depending on the changeable conditions of run for the HPGR crushing process. The research programme carried out included crushing tests in the laboratory scale HPGR device at various settings of the operating pressure volume and selected qualitative properties of the feed material (i.e. particle size distribution). Particle size distribution analyses of all HPGR products were performed and in the next stage the material was a feed to the ball mill grinding process. Grinding process kinetics were investigated through the determination of mass recoveries of individual particle size fractions after defined grinding time intervals. The models, defining the grinding process effectiveness as a function of changeable conditions of HPGR process run, were determined on the basis of obtained results. Based on these models the optimal grinding time in a ball mill was specified which is, in turn, the basis for optimization of operation of the technological comminution circuits for a given material type. The obtained results proved that the application of HPGR devices in a given copper ore comminution circuit may improve the effectiveness of the downstream grinding process which leads to improvement of the entire circuit work efficiency through decreasing the process energy consumption and enhancing product size reduction."

Jan 1, 2014

By John J. Dunkley

Recent years have seen the increased use of hydrometallurgy in the smelting and refining of metals. However this is often used as a final refining step, following an initial pyrometallurgical smelting process. Huge amounts of material are produced as melts which have to be cast, comminuted, and taken up into solution or leached. A common method is to granulate the melt and then grind it. In the case of metallic melts this can be difficult or unfeasible due to the ductility of the granulated particles. Water atomisation is capable of replacing the granulation and grinding stages with a single process step that can process in excess of 30tlhour of melt into particles as fine as 50 microns. Applications in operation in Co, Cu, Ni, Ag, Au, Pt and Rh refining are discussed together with potential applications in copper smelting.

Jan 1, 2003

By J. D. McCain

Magma's San Manuel smelter has adopted new operating techniques resulting in 21% increased productivity and 87% reduction in lost time accidents. Reverberatory furnaces were converted to coal firing from expensive natural gas and fuel oil. Slag and matte flow problems and safety were improved by implementing hydraulic slag stopping and matte tapping machines. Coordination of furnaces, converters and acid plant was improved by using a computer-aided converter controller/scheduler function. Manual mudding of converter lips after each collar pull was replaced with a gunning system for coating the mouth castings. One converter punch car was automated using robotic technology. An automatic anode take-off was installed with fewer moving parts and a mechanism for ear twisting one cell contact. Anode copper refining was improved by replacing propane/hydrogen mixtures with high pressure/velocity natural gas tuyeres. Improved converter scheduling increased acid plant production 43% with more autothermal operation time. Six dedicated computers/microprocessors are utilized for automation, data acquisition, process monitoring and on-line air quality information for the Supplementary Control System.

Jan 1, 1983

By M. T. Ityokumbul

The use of yield index, the product of the yield and gangue rejection, for the optimization of separation processes is presented. The characteristics of the yield index are contrasted with separation efficiency calculations and applied to laboratory froth flotation and washability data. Data from continuous froth flotation tests conducted to "optimize" froth flotation using process optimization software were also evaluated with the yield index procedure.

Jan 1, 1997

By M. Misra

The removal of lead and other heavy metals present in an active US Army small arms firing range soil was evaluated in a pilot scale test program at Ft. Polk, Louisiana. Two different acid based extraction processes in conjunction with conventional physical separation methods were used. Physical separation processes consisting of screening and gravity operations removed most of the coarse lead particulates and slugs. Hydrochloric acid leaching followed by precipitation of lead as hydroxide recycled clean soil containing less than 500 mg/L. total lead and less than 5 mg/L TCLP lead. Lead extraction efficiency with hydrochloric acid was 96 percent. The results of lead removal by physical separation in conjunction with acetic acid leaching were not consistent over the whole test period and the total soil processed.

Jan 1, 1998

By W. L. Price

I. INTRODUCTION Today, there are two conflicting trends facing the designer of the bulk material handling system. The first trend is the necessity to stockpile increasingly larger amounts of bulk material (coal, ore, stone etc.) as economically as possible. Fig. 1 illustrates such a typical large storage pile. The second trend is the increasing awareness of the ecological problems of today manifesting itself in a new concern over possible air pollution from storage pile surface particles. The conflict between these two trends can become dramatic when this bulk storage pile is located near a heavily populated area. Strong winds can easily create a severe local problem by blowing the particles from the pile surface toward residential and commercial areas, igniting a crisis in public relations. (2), (3), (4). To help define our combined subject and ecological culprit more accurately, Fig. 2 shows the commonly accepted size range of dust particles. A descrip¬tion of the present state-of-the-art of dust control for large storage piles is the intent of this paper. II. OPEN STORAGE PILE SYSTEMS - ALTERNATE CHOICES AND RELATIVE COSTS In discussing the open storage dust problem and possible solutions, one obvious question arises - what are the economics of placing large bulk storage under cover? Part or this answer will be found in Fig. 3 - an approximate unit capital cost comparison between several methods of storage. It will be noted that the cost curve(s) for the closed concrete silo storage illustrated in Fig. 4 is cheaper per ton at relatively small tonnage capacities, but as tonnage increases, the open pile storage unit cost (B) becomes more economical. Curve (T) covers the cost of open storage using the plow feeder arrangement shown in Fig. 5. A gravity draw-down pile with feeders at the base as shown in Fig. 6 represents yet another open storage choice.

Jan 1, 1972

By I Brandes de Roos

Water has played a key role in the Pilbara’s 60-year history of iron ore operations. In contrast to many of the current-day mining environments, iron ore mining was initially hosted by geological formations that were typically above the water table. Such mining operations required no dewatering or dewatering at rates that were less than mine and mining township requirements. The challenge for these operations was not pit dewatering but water supply for mining operations and municipal supply for nascent mining towns.The current industry sees new deposit styles being increasingly targeted, including channel iron and Marra Mamba Formation deposits. These deposits are often lower in the landscape and can require extensive dewatering. Furthermore, increased water demand for ore beneficiation has resulted in major programs of water-supply borefield development. Added to this is the emergence of magnetite projects and their significant levels of water use in ore beneficiation.The large volumes of water that are being extracted to support Pilbara iron ore mining is attracting attention. The Western Australian Department of Water has recently commissioned a study to assess the potential use of surplus mine water as a medium- to long-term supply for irrigated agriculture.This paper outlines the changing landscape of water management in Pilbara iron ore operations and explores strategies for maximising mining productivity. Water management is presented as an enabler for productivity improvements that can potentially provide long-lasting benefits post-closure.CITATION:Brandes de Roos, I, 2015. Shifting waters in the Pilbara’s iron ore industry, in Proceedings Iron Ore 2015, pp 507–510 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Stephen Krickovic

Air quantity-pressure and methane concentration surveys were conducted by the Bureau of Mines in accessible portions of an area being pillared in a Pittsburgh coalbed mine in West Virginia. These included two mined-out and three active butt headings and a bleeder system. The particular mine workings were started in virgin coal directly from a set of main headings; the main reason for the study was the difficulty usually encountered in adequately bleeding the gobs under such conditions. Although the two separate return airways in each active butt heading and the North and 1 Left bleeders contained acceptable methane concentrations (0.01 to 0.78 percent in the butts and 0.73 to 1.0 percent in the bleeders) with significant total methane removal (109 cfm in butts and 631 cfm in bleeders), there were relatively large areas in the gobs with possible minimal airflows. This condition appears to have developed from lack of systematic regulation of the airflow across the gobs and appears to indicate the existence of considerably more methane in the probably low flow areas in the gob.

Jan 1, 1973

By H. J. H. Pieterse

This paper highlights the mineralogy of the Barrick Goldstrike Mines Inc. area. The mine is located at the north end of the Tuscarora Spur and is part of the Bluestar/Goldstrike subdistrict of the Carlin Trend. The Betze, Post, and Meikle Mine are major deposits located in the area. The deportment of gold, its leachability, and various process options are also evaluated. Particular emphasis is given to the practical and economic considerations of ore control, and routing of ore to a process option.

Jan 1, 1993

By S. P. Fleming

An acid mine drainage sludge containing 0.26% nickel, 0.21 % cobalt and 4.5% manganese was leached in a one-liter reactor with sulfuric acid in the absence and presence of sodium sulfite. The effects of temperature (25°C and 52°C) and sodium sulfite concentration (up to 0.03 molar) on the leaching rate were particularly investigated. The leaching rates of nickel and cobalt with sulfuric acid have been determined to be controlled by diffusion through product layer. It has been found that effective leaching conditions to give more than 90% extraction of nickel, cobalt and manganese while keeping the iron extraction below 10% come with an elevated temperature and a low sodium sulfite concentration at pH 3; for example, 52°C and 0.01 molar sodium sulfite.

Jan 1, 1992

By J. O. Lewis

"The significant facts in the problem of the relation between the production of crude petroleum, and the ever-increasing demand for petroleum products are that in spite of continually increasing production, improvements in methods of refining and utilization, and heavy increases in imports, demands grow still more rapidly and we seem always faced with a shortage at hand or lust ahead. On the other hand, our foremost authorities warn um of entirely inadequate domestic reserves. Looking abroad we find some large fields and many of speculative promise, 'tut the situation is complicated by international relations and demands by other countries which promise to be even more insistent than oars. This is the situation, then. We can not rely upon our own Crude Petroleum to meet the Ever Increasing Demand for Petroleum Products.I wish to follow this somewhat alarming statement by saying at once that the Bureau of Mines is not pessimistic in facing this situation. To my mind those who discuss the oil situation may be placed in three categories; the pessimists, the optimists, and the super-optimists. The pessimists I call those who see darkly and will concede no possibility of solution. According to them a few years will see the automobiles piled in windrows of 'dilapidated junk, I have no sympathy with this point of view and deem it vicious and entirely unwarranted.The optimists I term those who believe that there is a solution and that we shall be able to meet all of our reasonable requirements for as far into the future as can be foreseen, yet who recognizes that this desired end can not be attained without prevision and energetic effort.The super-optimists are those who will say to you, ""There is nothing to this talk of shortage, whenever we have needed oil we have always found it and always will."" To these gentlemen the possibility of an inadequate supply of oil is as incomprehensible as the possibility of the extinction of the passenger pigeon was to the early settlers who saw flocks that hid the sun for days during their passage. The passenger pigeon disappeared within two generations thereafter, and I deem this point of view as being perhaps more vicious than that of the extreme pessimist. It seems to me it is nothing less than improvidence lulling us into a false sense of security. There is an old proverb to the effect that ""The Lord helps him who helps himself."" I believe that we shall solve the oil problem, but I do not think it will be solved by vague optimism. It is going to call for our most energetic efforts and I believe we shall have to do a lot of ""helping ourselves."""

Oct 1, 1920

By Petrus van Staden, Dragan Milanovic, Francisco Sánchez, Eero Kolehmainen, Carlos Frias

"Currently there is no economical and viable process for on-site metal extraction from Low Grade, Complex or Poly-metallic deposits, and even more, there is not any industrial process or technology able to deal with polymetallic or bulk concentrates containing Cu+Zn+Pb base metals and also precious metals. Traditionally, metals recovery from polymetallic sulfide deposits is performed by mining, selective flotation to separate Cu, Pb and Zn concentrates, and finally, smelting/refining of those concentrates to obtain the refined metals. In many cases, selective flotation of that kind of complex ores produces low metals recovery and low concentrate quality containing impurities such as Hg, As, Bi, etc., which results in high penalties in treatment and refining charges, and consequently, worsening the economy of the mining business. Recovery of the valuable metals from Polymetallic, Complex or Low Grade ores could then be maximised by producing bulk concentrates or middling flotation products to feed novel hydrometallurgical processes, like the integral metallurgical system that is currently under development within the INTMET project. For example, producing bulk concentrates would increase more than 100% Cu+ Zn+Pb cumulative recovery versus conventional selective flotation. Founded by the Horizon-2020 EU Programme, the INTMET Project was started in February 2016 and will be running over three years. The INTMET consortium is led by Cobre Las Cruces (Spain) and integrates twelve partners from seven EU countries, and including Serbia and South Africa as well. The INTMET project represents a challenging opportunity to develop suitable technological solutions to deal efficiently with difficult, polymetallic and complex sulphide ores that are abundant in Europe and worldwide. Main activities carried out during the first 18 months of the INTMET project development includes: (i) An atmospheric leaching pilot plant having a capacity of 300 kg/h bulk concentrate which has been installed and operated continuously for nine months at the Las Cruces mine; (ii) Pressure leaching test work developed by Outotec; (iii) Bioleaching test work performed by Mintek in collaboration with MMI Bor. Prior test work was applied on bulk concentrate samples supplied from Spain, Portugal and Serbia. Some of the results of these technological developments have been very positive and are presented in this paper."

Jan 1, 2018

By G. Kyle Green

Zirconium chlorinator residues contain an array of rare earths, scandium, unreacted coke, and radioactive thorium and radium. Because of the radioactivity, the residues must be disposed in special waste containment facilities. As these sites become more congested, and with stricter environmental regulations, disposal of large volumes of wastes may become more difficult. To reduce the mass of disposed material, the U.S. Bureau of Mines (USBM) developed technology to recover rare earths, thorium and radium, and unreacted coke from these residues. This technology employs an HCl leach to solubilize over 99% of the scandium and thorium, and over 90% of the rare earths. The leach liquor is processed through several solvent extraction stages to selectively recover scandium, thorium, and rare earths. The leach residue is further leached with an organic acid to solubilize radium, thus allowing unreacted coke to be recycled to the chlorinator. The thorium and radium waste products, which comprise only 2.1% of the original residue mass, can then be sent to the radioactive waste facility.

Jan 1, 1995

By R. R. Schehl

The Bureau of Mines analyzed the structure of a high-grade metallurgical coke, carbonized at different temperatures in the range 500° to 1,000° C, through X-ray diffraction studies. Growth in the crystallite size with increasing coking temperature was calculated from profile analysis and compared with values obtained from the radial distribution function. The carbonization temperature appeared to have little influence upon the stack height, whereas the layer diameters more than doubled in size between 500° and 1,000° C. These results are comparable to those obtained from other studies of poorer quality cokes.

Jan 1, 1974

By Jianhang Hu, Li Yang, Yonggang Wei, Kongzhai Li

"In this paper, the pyrolysis of biomasses including bamboo, sawdust and walnut shell were performed in a tube furnace under temperatures between 400? and 600? to obtain biomass carbon, gas, and tar. Textural parameters analysis revealed the caloric value of biomass carbons between 32 MJ/kg and 34 MJ/kg. It also indicated that the surface of biomass carbon consists of mesopore and macropore structures. By using GC analysis, it was determined the main ingredients of pyrolysis gas are CO, H2, CO2, CH4, C2H4 and C2H6. Calculation states that the density of pyrolysis gas is roughly between 1.0 kg/m3 and 1.7 kg/m3, while the calorific value of pyrolysis gas is between 12000 kJ/m3 and 16500 kJ/m3, illustrating that pyrolysis gas is a median gas. The calorific value of biomass tar was found to be between 32 MJ/kg and 34 MJ/kg, with more than 80 compounds in the biomass tar identified by GC-MS method.IntroductionBiomass as a renewable source is the world's largest and most sustainable energy resource [1].The conversion of biomass has the potential to be a renewable and carbon neutral method of producing fuels and chemicals [2-4]. Pyrolysis is a thermo-chemical process defined as applying heat to degrade biomass in an inert atmosphere. It transforms unstable biomass and other organic materials into biomass carbon, gas, and tar [5]. Biomass carbon can be stored or transported much easier as compared to parent biomass or be converted to value added products such as activated carbons[6]; gas is a relatively low-energy-density fuel; tar can be considered as a source of useful chemicals[7].The characterization of biomass pyrolysis will lead to its increased understanding and utilization as a source of solid, liquid and gaseous products which can be used as fuels and petrochemical feedstock[8,9].In recent years, many researchers studied the effect of temperature on biomass pyrolysis product distribution characteristics in a variety of pyrolysis reactor[10]. Ramin Azargohar's paper [11] presents the results of characterization for biomass and investigates the effects of pyrolysis temperature on the pyrolysis products obtained by fast pyrolysis of four different types of biomass."

Jan 1, 2014

It is widely accepted that the type of grinding media has an impact on the grinding chemistry and subsequent flotation behaviour of the sulphide minerals being separated. There are countless laboratory investigations demonstrating that inert grinding media produces more oxidizing pulp potentials, reduced levels of grinding media corrosion products, and superior concentrate grades and valuable metal recoveries. However, taking these results to industrial scale has proved difficult. This paper provides details of the protocol developed and used during a high-chrome grinding media plant trial. It describes the test regime employed to measure changes in pulp chemistry as well as concentrate grades and recoveries to produce a statistically meaningful result. The work also highlighted the need for close cooperation between the metallurgists on site and the researchers conducting the trial. To demonstrate the protocol, data gathered during a plant trail in a PGM concentrate will be presented describing the changes in pulp chemistry and metallurgical response observed.

Jan 1, 2012

By S. N. Yu

Tele-operation manipulators applied in this paper are systems for the remote handling and management of pyroprocessing related facilities in an Argon cell of the KAERI (Korea Atomic Energy Research Institute). Generally, these kinds of systems are composed of a master-slave system and its peripherals installed along the wall of the cell, with the master transmitting the user?s own motion to the gripper directly. This study introduced various considerations and modifications to improve the remote handling performance. The analysis of an operator's ability using his/her own upper arm motion range while manipulating the MSM, and considerations of its manipulation margin and the related tool modifications are also included. Finally, the test results of several remote handling tasks are presented, and an adequate operation strategy for the tele-operation system of hot-cell type facilities is proposed.

Aug 1, 2013