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Centralia?Mine Operations ?Centralia Mine ?Mountainous Terrain ?High rainfall (greater than 50 inches/yr) ?Multiple Pit/Multiple Seam ?Truck/Shovel Prestripping ?Dragline Overburden ?Coal Wash Plants

May 1, 2001

By F. Filzwieser, K. Gamweger

The process of gas purging in molten aluminium has been an industrial practice in Europe for many years. The advantages are a reduction in the hydrogen content and impurities in the melt, as well as a homogenisation of the temperature and chemical analysis in the molten metal. Formerly used lances or impellers are being replaced by porous plugs which are installed at the bottom of the furnace. This special product of RHI Refractories has proven its efficiency in primary melting as well as in die cast, sheet and extrusion plants.

Jan 1, 2004

Advanced high temperature electrochemical systems such as fuel cells, electrolyzers and ionic transport membranes are currently being developed for a wide variety of energy conversion, storage and gas cleanup applications. These systems offer high electrical efficiency, multi fuel capability, modular construction, no/negligible emissions (SOx, NOx, VOC, particulate matters) with capability to sequester green house gas emissions (GHG). Electrochemical processes and electrode reactions will be discussed. Cell and stack component materials and fabrication processes will be presented. Bulk, surface and interface degradation processes responsible for cell and stack performance degradation will be examined.

Jan 1, 2005

By S. M. Taghavi, M. Halali

This paper investigates the possibility of zinc oxide production from zinc ore concentration residues, and also the effect of temperature, time and depth of bed on waste materials reduction percents. The results obtained show a significant increase of the reduction percent as a function of time and temperature. With increasing in depth of bed, reduction percent will decrease. Maximum zinc oxide percent in products was 93.5%.

Jan 1, 2004

By M. Specht, D. Pörzgen, W. Lorenz, A. /. Buhr, R. P. Racher

The introduction of the near net-shape casting process at CORUS Staal IJmuiden in January 2000 required changes of secondary metallurgy processes including a development towards more aggressive slag compositions in the steel ladle. Therefore the steel ladle lining has been changed from fired andalusite bricks to magnesia-carbon bricks and, most recently, to fired spinel bricks to withstand the severe slag conditions. In comparison to the andalusite bricks the new steel ladle linings have a higher thermal conductivity. This requires the capability to keep the lining warm by ladle preheaters to sustain the overall thermal stability of the steel ladle in case of interruptions during hot cycling of the ladles.

Jan 1, 2004

By Yoshitaka Mitsuda, Masao Miyake, Masafumi Maeda

A leaching treatment was investigated to recover metals including rare earths from the mixtures of hydrogen storage alloys and nickel hydroxide. A potential-pH diagram of the La-Ni-H20 system including the domain of stability of LaNi5 was drawn to find appropriate leaching conditions. Alkaline solutions containing ligands that form complexes with nickel ions were supposed to be available to separate hydrogen storage alloys from the mixture. When the mixture was leached with ammoniacal alkaline aqueous solutions, the nickel hydroxide was dissolved and the hydrogen storage alloy was recovered as its original alloy.

Jan 1, 2004

By Douglas E. Wolfe, Jogender Singh, Robert Miller, Dong-Ming Zhu, Jeff Eldridge

This paper discusses microstructural changes produced by two novel approaches using electron beam physical vapor deposition (EB-PVD) in which periodic strain fields/microporosity was incorporated within the large columnar grains of Zr02- 8wt.%Y2O3 (8YSZ). The traditional columnar microstructure of partially stabilized zirconia has been slightly modified to produce a lower thermal conductive thermal barrier coating (TBC) by periodically interrupting the condensing vapor resulting in microstructural modifications with diffuse or sharp interfaces and morphological changes on the sub-micron scale without changing the composition of the TBC. These microstructural modifications resulted in a 20-30% reduction in the thermal conductivity, 28-56% increase in hemispherical reflectance, improved oxidation cyclic life (over 100%), and better strain tolerance as compared to standard ZrO2-8wt.%Y2O3 deposited on platinum-nickel-aluminide and CoNiCrA1Y bond-coated MAR-M-247 test samples. The TBC with tailored microstructures were examined by various techniques including scanning electron microscopy (SEM), x-ray diffraction (XRD), steady-state laser heat flux technique, and hemispherical reflectance.

Jan 1, 2004

By A. C. Atenas

The majority of refineries that operate with traditional starting sheet technology ?starting sheet- uses a relatively low current density of 250 A/m2. Industrial tests at high current density with conventional technology were carried out in Refinery of Potrerillos, getting satisfactory results that are similar the results obtained with permanent cathode technology. The series of copper refining electrolyses electrolysis trials were carried out between 300 to 325 A/m2. Electrolysis conditions, in accordance with industrial practice, were kept constant in all sets of experiments and were as follows; 45 g/L Cu 2+, 210 g/L H2SO4, 62 °C, electrolyte circulation of 14-18 L/min. The same Dosing dosing of Additives additives used in permanent cathode technology was required in these tests. In general, only not importantminor operational modifications were necessary in comparison to normal practice in the Refinery to assure the good results. Different quality of starting sheet and anodes were examined. The test included starting sheets from smelter and laminated process. Results indicate that the charge physical quality of the electrodes and the control of the process during the two first days of operation are the keys to get the best results.

Jan 1, 2007

By Renaud Cousin

Supported gold catalysts were prepared by Direct Anionic Exchange on an alumina support and tested during the reaction of CO oxidation and of saturated and unsaturated hydrocarbons (C1 to C3). The catalysts showed high activies over a range of concentrations and temperatures compatible with an application to automotive exhaust cleaning. Furthermore, a complete resistance to thermal ageing at 600°C in the absence or presence of water was observed due to the obtention of strongly anchored nanosized gold particles during the preparation step.

Oct 1, 2003

By Erol Yilmaz

This poster presents results obtained from an experimental test set-up called CUAPS (curing under applied pressure system) allowing to assess the performance and quality of cemented paste backfill (CPB) materials. CUAPS can be used for carrying out a series of tests: one-dimensional consolidation, saturated hydraulic conductivity, pore-water pressure dissipation, and curing under uniaxial stress. The poster presents CUAPS testing preliminary results including uniaxial compression tests (UCS) and mercury intrusion porosimetry (MIP). It was demonstrated that CUAPS-consolidated CPB materials cured under time-dependent stresses provide higher UCS values than standard mould (undrained and unconsolidated) CPB samples. This may be explained by the release of excess pore water within backfill that gives rise to a significant reduction in the total porosity of fresh CPB materials prior to hardening and thus, to higher mechanical strength (UCS) gain. The results obtained from MIP highlighted a good correlation between CUAPSconsolidated and mould-unconsolidated CPB samples. MIP results were also related to UCS values in order to predict the final CPB mechanical strength.

Nov 1, 2008

By E. Ferguson

In evaluating refractory designs for cast house applications, thermal calculations are frequently performed to determine cold face shell temperatures, temperature profiles and metal freeze plane locations within the refractory layer, and heat loss in the steady state condition. A problem arises when looking at molten metal transport crucible designs in that these structures are usually operating under non-steady state conditions throughout their production cycle. Because the molten metal temperature varies with time, and material properties such as thermal conductivity are temperature dependant, mathematical solutions are at best... complicated. This paper presents a relatively simple, iterative solution, that can be set up on a standard computer spreadsheet program, to calculate heat transfer in non-steady state conditions. These calculations can provide curves for (1) molten metal temperature vs time and (2) cumulative heat loss vs time, given variable starting conditions, to aid in the evaluation of molten metal transfer crucible refractory designs.

Jan 1, 2004

By J. H. Baek, S. Alexandrovskii, D. W. Lee, B. K. Kim

Nano-phase titanium carbide was synthesized by Mg-thermal reduction process using a novel route of Mg-thermal reduction. The processes are based on I) feeding of TiC14+CxC14 x = 1, 2 ) solution into liquid magnesium, 2) Mg-reduction of metal chlorides, 3) TiC formation by the reaction of released Ti and C atoms, and 4) vacuum separation of residual liquid phases of Mg and MgCl2. In this study, the process for titanium carbide production with composition close to stoichiometry and the minimum content of impurities was optimized with the various process parameters such as concentration of initial solution, its feeding rate and reaction temperature, as well as a kinetic study.

Jan 1, 2004

By Y. C. Kim

This paper discusses Air Liquide's patented SPALTM (Surface Protection Air Liquide) technology and process for the inerting of coreless induction furnaces using cryogenic liquid gas. Air Liquide Canada Inc., in collaboration with Riverside Brass and Aluminum Foundry Limited (Riverside Brass), conducted plant trials to demonstrate the applicability of the SPALTM technology for copper-based alloys. Results showed that with SPALTM, Riverside Brass benefited from a significant increase in metal yield as the level of dross formation was drastically reduced. Together with the many other benefits of this technology, SPALTM demonstrated to be a non-negligible cost-effective solution to reduce metal production costs. In an effort to optimize the argon flow, different flow rates were used and the oxygen level above the metal bath was measured to pinpoint optimal flow. The results of metal yield, charge mix, dross formation, and melt temperature are compared with and without argon. The metal yield improvements are dramatic and calculated net savings are presented hereunder.

Jan 1, 2007

By Amin Jafari

Macrosegregation has always been an important issue with the solidification processes, particularly in Direct-Chill Casting of Aluminum alloys, where uneven properties, surface and bulk defects and limitations in productivity can be arisen due to macrosegregation in the cast product. Following the global attempts to practically predict the macrosegregation, in the present work, a numerical model was developed based on an industrial scale DC casting process to simulate the solidification and macrosegregation in an Al-4.5%Cu billet. Interesting aspects of this investigation are concerned with an efficient numerical scheme to keep simplicity, consistency and desired physical resolution of the solidification phenomena together. In the mathematical model, coupled conservation equations of mass, momentum, energy and species were solved numerically using finite volume method. A different numerical scheme, called SIMTLE, was introduced to link the energy and species equations with the phase diagram of the alloy. Calculations were performed on an industrial case and obtained results were compared to available experimental data to assure the performance of the model. Different macrosegregation features were predicted and discussed on the solidifying Al-alloy billet.

Oct 1, 2011

By M. Kalin

Tailings deposits are frequently the source of ground water contamination due to the transport of contaminated tailings pore-water. If amendments to tailings covers could be made to facilitate a precipitation reaction and halt or reduce the generation of acid in pyritic tailings, the quality of pore-water quality would be improved which would in turn reduce the production of contaminants. The effects of phosphate wastes, added to base-metal mine tailings in Newfoundland, Canada, were tested. Laboratory and field experiments determined the effects of different mixing ratios of phosphate wastes to tailings volume (1:4, 1:8, 1:12 and 1:20, dry weight) for a total period of 3.2 years. The addition of phosphate at ratios of 1:4 to 1:12 substantially increased the pore water pH, and reduced both acidity and Zn concentrations. These results suggest that addition of phosphate wastes to tailings covers can reduce acidity generation and improve tailings pore-water quality.

Jan 1, 2004

By K. Murase

Potentiostatic electrodeposition behavior of dendritic copper from acidic copper(I) chloride (cuprous chloride) baths containing sodium chloride and sodium bromide was investigated. The morphology, or appearance, of copper dendrite and the sodium content in the dendrite as an impurity were both influenced by deposition potential (0 to ?150 mV vs. SHE) and bath temperature (R.T. to 60 C), while the current efficiency for the deposition was 99% or more irrespective of the deposition conditions examined. The bath pH did not affect the deposition behavior in the pH range of 0 to 2. Bath temperature was found to be the most important factor influencing the deposition current. The current density of the dendrite deposition on a titanium cathode was lower than that onto a copper cathode with the same substrate surface area. The reproducibility of the current for the dendrite deposition was poorer when an as-polished titanium cathode was used, although it was improved by surface treatment of the cathode with an HF-HNO3-H3PO4 solution before electrodeposition. The deposition behaviors were discussed with the potential-pH diagram of the Cu-Cl-H2O system.

Jan 1, 2007

By Marta Polgari, Eva Surova, Bohumil Molak

Abstract -The Ûrkút rhodochrosite deposit and Branisko Mn showings (rancieite, manganiferous calcite), located in Lower Jurassic marine sedimentary rocks with black shale, were studied by organic­ geochemical methods. Both depositionallocalities were affected by the Lower Jurassic Toarcian anoxic event. Ûrkút shales are rich in organic matter (av. 2.94 wt% total organic carbon), the composition of which indicates derivation mainly from marine sources, with some terrigenous component. The shales matured in a bacterially active environment under reducing conditions of diagenesis-catagenesis. Branisko shales (?0.2 wt% TOC) with lenses of Mn oxide ore were weakly metamorphosed and their organic matter thermally degraded. The model for Mn carbonate ore formation envisages reaction of Mn derived from sediments, with carbonate generated by a bacterially mediated process of decom­ position of organic matter that also involved Mn reduction.

Jan 1, 1992

By W. Wallace

The aerospace industry celebrated 100 years of powered flight in 2003, and the remarkable achievements that have occurred during the past 100 years are in no small way due to major developments in materials. Modern alloys for airframes, engines and other major sub-systems have evolved through the intelligent application of new processing concepts involving melting, casting, hot and cold working, heat treatment and more recently vapour phase processing. Alloy design has evolved in parallel to allow maximum benefits to be achieved from these processing advances. However, the pace of development seems to be slowing and future gains are likely to be made by learning how to extract major value from aerospace assets. Understanding the modes of deterioration and establishing cost effective lifetimes by holistic life cycle management seem to be the way of the future. Extending component lifetimes by repair, rejuvenation and refurbishment are all viable possibilities and they offer great opportunities for Canada, which, traditionally, has been a major user of modern aerospace materials rather than a supplier. The challenges for metallurgist, physicists and engineers will be no less than in the past and should create new business opportunities for Canada. The scenario described above will be developed by calling upon examples drawn from the author's experience.

Jan 1, 2004

By D. Allen

Faced with decreasing ore grades and harder ores, many mines today are forced to become more efficient with their approach to processing. Variability in ore hardness, mineral liberation, reagent consumption, sliming, and leach responses are all a function of the minerals present and their concentration. Modern semi-automated X-ray Diffraction (XRD) analyses using Rietveld refinement techniques, in conjunction with high speed quantitative Near Infrared (NIR) analyses, provide reliable quantitative mineralogical ore profiling. By the implementation of XRD with NIR, mining, milling and leaching operations no longer need to be dependant on visual estimates for GeoMetallurgical Modeling and are provided with a valuable forecasting and production control tool. This paper will illustrate the development, plant implementation and application of XRD and NIR at several copper operations.

Jan 1, 2007

By J. R. Perumareddi, V. S. Sastri, M. Elboujdaini

Economics of corrosion, the corrosion modes and causes, corrosion control methods to combat corrosion, along with a summary of issues and their implementation in the aerospace industry are briefly discussed.

Jan 1, 2004