The Western Power and Smelting Company Tramway System
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Effects of Varied Process Parameters on Froth Flotation Efficiency: a Case Study of Itakpe Iron Ore
Nigerian Journal of Technology (NIJOTECH) Vol. 39, No. 3, July 2020, pp. 807 – 815 Copyright© Faculty of Engineering, University of Nigeria, Nsukka, Print ISSN: 0331-8443, Electronic ISSN: 2467-8821 www.nijotech.com http://dx.doi.org/10.4314/njt.v39i3.21 EFFECTS OF VARIED PROCESS PARAMETERS ON FROTH FLOTATION EFFICIENCY: A CASE STUDY OF ITAKPE IRON ORE S. Akande1, E. O. Ajaka2, O. O. Alabi3 and T. A. Olatunji4,* 1, 2, DEPARTMENT OF MINING ENGINEERING, FEDERAL UNIV. OF TECHNOLOGY, AKURE, ONDO STATE, NIGERIA 3, 4, DEPT. OF MET. & MATERIALS ENGINEERING, FEDERAL UNIV. OF TECHNOLOGY, AKURE, ONDO STATE, NIGERIA Email addresses: 1 [email protected], 2 [email protected], 3 [email protected], 4 [email protected] ABSTRACT The dire need for Itakpe iron ore concentrates of appreciable iron content meets for smelting operation necessitated this study. Core samples of the iron ore sourced from Itakpe, Kogi State, Nigeria were prepared for petrological analysis followed by chemical and particle size analyses. Froth flotation was done using different collectors at varying particle sizes and pH values. Characterization studies carried out revealed that Itakpe iron ore is a lean ore assaying 36.18% Fe2O3 and contains predominantly quartz, sillimanite, and haematite. Its liberation size lies favourably at 75 µm. Processing the ore by froth flotation yielded appreciable enrichment. Optimal recovery (~92%) was achieved using potassium amyl xanthate (PAX) at pH 11 for fine feed sizes (<125 µm) yielding iron concentrate assaying 67.66% Fe2O3. Thus, processing at this set-of- conditions is recommended for the industrial production of more enriched Itakpe iron ore concentrates. -
Principles of Extractive Metallurgy Lectures Note
PRINCIPLES OF EXTRACTIVE METALLURGY B.TECH, 3RD SEMESTER LECTURES NOTE BY SAGAR NAYAK DR. KALI CHARAN SABAT DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING PARALA MAHARAJA ENGINEERING COLLEGE, BERHAMPUR DISCLAIMER This document does not claim any originality and cannot be used as a substitute for prescribed textbooks. The information presented here is merely a collection by the author for their respective teaching assignments as an additional tool for the teaching-learning process. Various sources as mentioned at the reference of the document as well as freely available material from internet were consulted for preparing this document. The ownership of the information lies with the respective author or institutions. Further, this document is not intended to be used for commercial purpose and the faculty is not accountable for any issues, legal or otherwise, arising out of use of this document. The committee faculty members make no representations or warranties with respect to the accuracy or completeness of the contents of this document and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. BPUT SYLLABUS PRINCIPLES OF EXTRACTIVE METALLURGY (3-1-0) MODULE I (14 HOURS) Unit processes in Pyro metallurgy: Calcination and roasting, sintering, smelting, converting, reduction, smelting-reduction, Metallothermic and hydrogen reduction; distillation and other physical and chemical refining methods: Fire refining, Zone refining, Liquation and Cupellation. Small problems related to pyro metallurgy. MODULE II (14 HOURS) Unit processes in Hydrometallurgy: Leaching practice: In situ leaching, Dump and heap leaching, Percolation leaching, Agitation leaching, Purification of leach liquor, Kinetics of Leaching; Bio- leaching: Recovery of metals from Leach liquor by Solvent Extraction, Ion exchange , Precipitation and Cementation process. -
Chapter 11: Beneficiation
CHAPTER 11 Beneficiation – Comminution Sponsored by: SPONSOR PROFILE Through pioneering the introduction of modern process • project controls and reporting plants and associated technologies to remote and logistically • contract management challenging locations, Lycopodium Minerals Pty Ltd has • procurement and logistics management developed a successful track record in developing and • inspection and expediting commissioning major resource projects worldwide. • quality assurance/quality control Since its establishment in 1992, Lycopodium has become a • financial evaluations leading international engineering and project management • client representation. consultancy, with an enviable reputation for providing Engineering technically innovative and cost-effective engineering solutions. They are focused on the evaluation and development of projects • Conceptual through to detailed design in the fields of minerals processing, materials handling and • across all disciplines: earthworks, civil infrastructure. • structural, mechanical, piping • electrical, instrumentation, control Lycopodium Minerals has undertaken studies and projects across a broad range of commodities including gold (free, • systems, automation and infrastructure. gravity, refractory, preg robbing), base metals (concentrators, Process hydrometallurgy), iron ore, uranium, rare earths and industrial minerals. Their resume of projects reflects diversity in not • Metallurgical test work design only commodity, but client background, technology, scale of • management and interpretation -
Sand, Gravel, and Crushed Stone On-The-Job Training Modules
SAND, GRAVEL, AND CRUSHED STONE ON-THE-JOB TRAINING MODULES Module 17 - “Primary Crushing Operation” UNITED STATES DEPARTMENT OF LABOR ELAINE L. CHAO SECRETARY MINE SAFETY AND HEALTH ADMINISTRATION DAVE D. LAURISKI ASSISTANT SECRETARY Originally Published AUGUST 2000 INSTRUCTION GUIDE SERIES MSHA IG 40 MODULE NUMBER 17 OF INSTRUCTION GUIDE NUMBER 40 ON-THE-JOB TRAINING FOR THE SAND, GRAVEL, AND CRUSHED STONE INDUSTRY PRIMARY CRUSHING OPERATION This module describes basic job steps, potential hazards and accidents, and recommended safe job procedures for primary crushing operations. This job is normally done by the crusher operator, but may be done by other occupations. Crusher operators must protect themselves, and other people in the area, from accidents and injuries resulting from operation of the crusher and associated equipment. There are several different types of primary crushers, however, there are many similarities in the job clxii procedures followed by crusher operators. Crushing is the first step in converting shot rock into usable products. Essentially, crushing is no more than taking large rocks and reducing them to small pieces. Crushing is sometimes continued until only fines remain. At some operations, all the crushing is accomplished in one step, by a primary crusher. At other operations, crushing is done in two or three steps, with a primary crusher that is followed by a secondary crusher, and sometimes a tertiary crusher. Raw material, of various sizes, is brought to the primary crusher by rear-dump haul units, or carried by a wheel front-end loader. Primary crushing reduces this run-of-mine rock to a more manageable size. -
Effect of Comminution Method on Particle Damage and Breakage Energy
EFFECT OF COMMINUTION METHOD ON PARTICLE DAMAGE AND BREAKAGE ENERGY Michael Moats, Jan Miller, Chen-Lun Lin and Raj Rajamani Department of Metallurgical Engineering University of Utah Outline • Our Department • High Pressure Grinding • Particle Damage Characterization • Breakage Energy • Application to Simulant Development Department of Metallurgical Engineering • University of Utah is located in Salt Lake City along the Wasatch Mtns. • Only stand alone Metallurgical Engineering department remaining in the U.S. • Traditional curriculum with critical mass of professors – Mineral Processing – Chemical Metallurgy – Physical Metallurgy High Pressure Grinding Rolls (HPGR) HPGR consists of a pair of counter rotating rolls, one fixed and the other floating. The feed is introduced to the gap in between the rolls and they compress the bed of particles. The grinding force applied to the crushing zone is controlled by a hydro-pneumatic spring on the floating roll. Speeds of the rolls are also adjustable to obtain optimum grinding conditions. Comparison of HPGR and AG/SAG Mills Aspect HPGR AG/SAG Mill Grinding Mechanism Inter-particle compression Impact, attrition and compression Residence Time Low-single pass High (feed migrates through length of mill) Wet/Dry Grinding Dry-Low moisture Predominantly wet milling Availability >90% -2-4 change outs pa >90% -1-2 change outs pa Size regulated feed Required Yes-strongly affects stud breakage AG-No, SAG-Sometimes Critical material size Not required Required Product particle Yes (beneficial for downstream Negligible micro-cracking processes Maximum Throughput 2000tph 4000tph Footprint Small Large Specific power 1-5kWh/t 5-12kWh/t Operating cost Overall plant 20% lower Overall plant 20% higher Capital Cost 25% lower 25% higher Delivery time Substantially faster Substantially longer Variation in feed hardness Single parameter variable High losses •Reference: Koenig, R.L. -
Redesign and Fabrication of Hammer Milling Machine for Making Pasta
International Journal of ChemTech Research CODEN (USA): IJCRGG, ISSN: 0974-4290, ISSN(Online):2455-9555 Vol.12 No.03, pp 202-218, 2019 Redesign and Fabrication of Hammer Milling Machine for Making Pasta Workalemahu Manaye1, Beruk Hailu1,T Ashokkumar1*, 1Department of Mechanical Engineering, Institute of Technology, Haramya University, P.O Box 138, Dire Dawa, Ethiopia. Abstract : This study Aimed to redesign a Hammer mill machine for grinding,owing to the inability of existing mill to meet the demand of waste pastaflourin Dire Dawa food Complex. Rational design by drawing and calculations and Simulation in solid works. CAD software were used to bring this milltoreality. The modified pasta grinding milling machine efficiency will be 90%..Waste of Pasta, Macaroni, Biscuits, or Breads and there by impact cost of production through minimizing waste as well as inquests safe, hygienic & efficient way of grinding these by products at Dire Dawa food complex. Key words : Pasta Grinding, Solidwork, Belt Drive, Design. 1.Introduction Hammermills are more widely used in feed mills because they are easier to operate and maintain and produce particles spherical in shape (Kim et al., 2002; Amerah et al., 2007). To increase production capacity of hammer mills, they are equipped with an air-assist system that draws air into the hammer mill with the product to be ground, thus allowing particles to exit through screen holes (Kim et al., 2002).Hammer mills have been reported to produce a wide range of particle sizes compared to roller mills (Seerley et al., 1988; Douglas et al., 1990; Audet, 1995). During roller milling each grain passes through the mill independently of surrounding grains (Campbell et al., 2001). -
Crushing Resource Book
Metalliferous Mining - Processing Crushing Resource Book C R U S H I N G Table of Contents TABLE OF CONTENTS............................................................................................................................2 INTRODUCTION TO CRUSHING .....................................................................................................................3 What is this module about?.....................................................................................................................3 What will you learn in this module? .......................................................................................................3 What do you have to do to complete this unit? .......................................................................................3 What resources can you use to help?......................................................................................................3 INTRODUCTION TO COMMINUTION ................................................................................................4 CRUSHING THEORY ...............................................................................................................................5 CRUSHING EQUIPMENT AND CRUSHING CIRCUITS.................................................................... 9 CRUSHING EQUIPMENT ...............................................................................................................................9 CRUSHING CIRCUITS AND STAGING .......................................................................................................... -
In the United States District Court for the Southern District of Indiana
Case 1:15-cv-00433-TWP-TAB Document 1 Filed 03/16/15 Page 1 of 20 PageID #: 1 IN THE UNITED STATES DISTRICT COURT FOR THE SOUTHERN DISTRICT OF INDIANA UNITED STATES OF AMERICA ) and the ) STATE OF INDIANA, ) ) Plaintiffs, ) ) ) Civil Action No. 15-cv-433 v. ) ) ) EXIDE TECHNOLOGIES ) (d/b/a EXIDE TECHNOLOGIES, INC.), ) ) ) ) Defendant. ) ) COMPLAINT The United States of America, by the authority of the Attorney General of the United States acting at the request of the Administrator of the United States Environmental Protection Agency (“EPA”), and the State of Indiana (“Indiana”), by the authority of the Indiana Attorney General, acting at the request of the Indiana Department of Environmental Management (“IDEM”), hereby file this Complaint and allege as follows: NATURE OF ACTION 1. This is a civil action brought against Exide Technologies (referred to herein as “Exide” or the “Defendant”) pursuant to the Clean Air Act, 42 U.S.C. § 7401 et seq. and the laws of Indiana. This action seeks civil penalties and injunctive relief for violation of certain requirements under the Clean Air Act and its implementing regulations, as well as corresponding requirements of Indiana law, at a secondary lead smelting facility that Exide owns and operates at 2601 West Mount Pleasant Boulevard, Muncie, Indiana (the “Facility”). Indiana’s authority to Case 1:15-cv-00433-TWP-TAB Document 1 Filed 03/16/15 Page 2 of 20 PageID #: 2 seek injunctive relief and civil fines with respect to the Facility derives not only from the Clean Air Act, but also Indiana Code (“Ind. -
A Study on Reduction of Copper Smelting Slag by Carbon for Recycling Into Metal Values and Cement Raw Material
Preprints (www.preprints.org) | NOT PEER-REVIEWED | Posted: 17 January 2020 doi:10.20944/preprints202001.0177.v1 Peer-reviewed version available at Sustainability 2020, 12, 1421; doi:10.3390/su12041421 Article A Study on Reduction of Copper Smelting Slag by Carbon for Recycling into Metal Values and Cement Raw Material Urtnasan Erdenebold and Jei-Pil Wang* Department of Metallurgical Engineering, School of Engineering, Pukyong National University, Busan 608- 739, Korea * Correspondence: [email protected]; Tel,: +82-51-629-6341 Abstract: Copper smelting slag is a solution of molten oxides created during the copper smelting and refining process, and about 1.5 million tons of copper slag is generated annually in Korea. Oxides in copper smelting slag include ferrous (FeO), ferric oxide (Fe2O3), silica (SiO2 from flux), alumina (AI2O3), calcia (CaO) and magnesia (MgO). Main oxides in copper slag, which iron oxide and silica, exist in the form of fayalite (2FeO·SiO2). Since the copper smelting slag contains high content of iron, and copper and zinc. Common applications of copper smelting slag are the value added products such as abrasive tools, roofing granules, road-base construction, railroad ballast, fine aggregate in concrete, etc., as well as the some studies have attempted to recover metal values from copper slag. This research was intended to recovery Fe-Cu alloy, raw material of zinc and produce reformed slag like a blast furnace slag for blast furnace slag cement from copper slag. As a results, it was confirmed that reduction smelting by carbon at temperatures above 1400°С is possible to recover pig iron containing copper from copper smelting slag, and CaO additives in the reduction smelting assist to reduce iron oxide in the fayalite and change the chemical and mineralogical composition of the slag. -
Nickel Laterite Smelting Processes and Some Examples of Recent Possible Modifications to the Conventional Route
metals Review Nickel Laterite Smelting Processes and Some Examples of Recent Possible Modifications to the Conventional Route Ender Keskinkilic Department of Metallurgical and Materials Engineering, Atilim University, 06830 Ankara, Turkey; [email protected]; Tel.: +90-533-302-9510 Received: 16 July 2019; Accepted: 1 September 2019; Published: 3 September 2019 Abstract: The treatment of laterites has been a research hotspot in extractive metallurgy over the past decades. Industrially, the pyrometallurgical treatment of laterites is mostly accomplished with a well-established method, namely, the rotary kiln–electric arc furnace (RKEF) process, which includes three main operations—calcination, prereduction, and smelting—followed by further refining for the removal of impurities from the raw ferro-nickel. As indicated in many studies of the RKEF process, the major downside of this method is its high energy consumption. Efforts have been made to lower this consumption. Furthermore, several new processes have been proposed. Among these, low-grade ferro-nickel production is regarded as the most widely and industrially used process after traditional RKEF operation. Although not widespread, other alternative processes of industrial scale have been generated since the start of the millennium. Recently, certain innovative processes have been tested either in the laboratory or at pilot-scale. In this paper, a literature review related to the smelting of laterites is made, and an emphasis on new processes and some examples of new developments in the RKEF process are presented. Keywords: laterite; smelting; RKEF process; low-grade ferro-nickel 1. Introduction According to a review published by Diaz et al., oxide-type nickel ores accounted for 64% of land-based nickel ores, but more than 60% of nickel production was based on the matte smelting of sulfide ores in 1988 [1]. -
Integral Management of Arsenical Sludge, Treatment and Recovery of By-Products of Acid Waters from Smelter Plants
MILAF: INTEGRAL MANAGEMENT OF ARSENICAL SLUDGE, TREATMENT AND RECOVERY OF BY-PRODUCTS OF ACID WATERS FROM SMELTER PLANTS ULRIKE BROSCHEK, CECILIA VIDAL, LUIS BRAVO and GILDA ZUÑIGA Environmental Program, Fundación Chile Parque Antonio Rabat Sur 6165, Vitacura, Santiago, Chile; E-mail: [email protected] ABSTRACT Currently, the copper mining industry produces high amounts of sulfuric acid with low purity and high concentrations of arsenic and other metals. Most of these acid waters are neutralized in the copper smelting plants by using lime to raise the pH from 1 to 12 generating high amounts of arsenical sludge that has to be disposed on safety landfills because of its high toxicity. This has forced the mining companies to pay large sums of money for the disposal of significant volume of solid waste. Each copper smelting plant produces in average during this specific process more than 18,000 tons of arsenical sludge yearly, spending on the treatment and disposal stage more than US 2.8 million dollars per year where a 70 % of this cost corresponds to the disposal costs of the solid waste [1,2,3]. Different technologies for treating these acid wastewaters have been developed and patented worldwide. However, these treatments have focused on obtaining the separation of the arsenic from the effluent through physical-chemical precipitation using different basic components and cations that reacts with the contaminants and then precipitates in the solution [4]. These technologies have not been able to solve the problem because they are expensive, complex, not always efficient and still generates high amounts of arsenical sludge requiring high disposal costs; hence, mining companies have not implement them. -
Milling Studies in an Impact Crusher I: Kinetics Modelling Based on Population Balance Modelling
minerals Article Milling Studies in an Impact Crusher I: Kinetics Modelling Based on Population Balance Modelling Ngonidzashe Chimwani 1,* and Murray M. Bwalya 2 1 Institute of the Development of Energy for African Sustainability (IDEAS), Florida Campus, University of South Africa (UNISA), Private Bag X6, Johannesburg 1710, South Africa 2 School of Chemical and Metallurgical Engineering, University of the Witwatersrand, Johannesburg 2050, South Africa; [email protected] * Correspondence: [email protected]; Tel.: +27-731838174 Abstract: A number of experiments were conducted on a laboratory batch impact crusher to investi- gate the effects of particle size and impeller speed on grinding rate and product size distribution. The experiments involved feeding a fixed mass of particles through a funnel into the crusher up to four times, and monitoring the grinding achieved with each pass. The duration of each pass was approximately 20 s; thus, this amounted to a total time of 1 min and 20 s of grinding for four passes. The population balance model (PBM) was then used to describe the breakage process, and its effectiveness as a tool for describing the breakage process in the vertical impact crusher is assessed. It was observed that low impeller speeds require longer crushing time to break the particles significantly whilst for higher speeds, longer crushing time is not desirable as grinding rate sharply decreases as the crushing time increases, hence the process becomes inefficient. Results also showed that larger particle sizes require shorter breakage time whilst smaller feed particles require longer breakage time. Keywords: impact crusher; comminution; milling parameters; population balance mode Citation: Chimwani, N.; Bwalya, M.M.