BENEFICIATION OF HIGH-MgO SEDIMENTARY PHOSPHATE ORES

Dolomite [CaMg(CO3)2] is an intolerable impurity in phosphate ores due to its MgO content. Traditionally, the Florida phosphate industry has avoided mining high-MgO phosphate reserves due to the lack of an economically viable process for removal of dolomite. However, as the high grade phosphate reserves become depleted, more emphasis is being put on the development of a cost effective method for separating dolomite from high-MgO phosphate ores. In general, the phosphate industry demands a phosphate concentrate containing less than 1%MgO. Dolomite impurities have mineralogical properties that are very similar to the desired phosphate minerals (francolite), making the separation of the two minerals very difficult. Magnesium is primarily found as distinct dolomite-rich pebbles, very fine dolomite inclusions in predominately francolite pebbles, and magnesium substituted into the francolite structure. Jigging is a gravity separation process that attempts to take advantage of the density difference between the dolomite and francolite pebbles. A unique laboratory scale jig was designed and built at Michigan Tech for this study. Through a series of tests it was found that a pulsation rate of 200 pulse/minute, a stroke length of 1 inch, a water addition rate of 0.5gpm, and alumina ragging balls were optimum for this study. To investigate the feasibility of jigging for the removal of dolomite from phosphate ore, two high-MgO phosphate ores were tested using optimized jigging parameters: (1) Plant #1 was sized to 4.00x0.85mm and contained 1.55%MgO; (2) Plant #2 was sized to 3.40mmx0.85mm and contained 3.07% MgO. A sample from each plant was visually separated by hand into dolomite and francolite rich fractions, which were then analyzed to determine the minimum achievable MgO levels. For Plant #1 phosphate ore, a concentrate containing 0.89%MgO was achieved at a recovery of 32.0%BPL. For Plant #2, a phosphate concentrate containing 1.38%MgO was achieved at a recovery of 74.7%BPL. Minimum achievable MgO levels were determined to be 0.53%MgO for Plant #1 and 1.15%MgO for Plant #2.

Effect of microstructure and alloying elements on the resistance of fastener grade steels to hydrogen assisted cracking

Fastener grade steels with varying alloy contents and heat treatments were employed to measure changes in resistance to hydrogen assisted cracking. The testing procedure compared notched tension specimens fractured in air to threshold stress values obtained during hydrogen charging, utilizing a rising step load procedure. Bainitic structures improved resistance by 10-20% compared to tempered martensite structures. Dual phase steels with a tempered martensite matrix and 20% ferrite were more susceptible and notch sensitive. High strength, fully pearlitic structures showed an improvement in resistance. Carbon content, per se, had no effect on the resistance of steel to hydrogen assisted cracking. Chromium caused a deleterious effect but all other alloying elements studied did not cause much change in hydrogen assisted cracking susceptibility.

Spray characterization under flash boiling conditions of a DI multi-hole injector at high injection pressures in a combustion vessel

Spray characterization under flash boiling conditions was investigated utilizing a symmetric multi-hole injector applicable to the gasoline direct injection (GDI) engine. Tests were performed in a constant volume combustion vessel using a high-speed schlieren and Mie scattering imaging systems. Four fuels including n-heptane, 100% ethanol, pure ethanol blended with 15% iso-octane by volume, and test grade E85 were considered in the study. Experimental conditions included various ambient pressure, fuel temperature, and fuel injection pressure. Visualization of the vaporizing spray development was acquired by utilizing schlieren and laser-based Mie scattering techniques. Time evolved spray tip penetration, spray angle, and the ratio of the vapor to liquid region were analyzed by utilizing digital image processing techniques in MATLAB. This research outlines spray characteristics at flash boiling and non-flash boiling conditions. At flash boiling conditions it was observed that individual plumes merge together, leading to significant contraction in spray angle as compared to non-flash boiling conditions. The results indicate that at flash boiling conditions, spray formation and expansion of vapor region is dependent on momentum exchange offered by the ambient gas. A relation between momentum exchange and liquid spray angle formed was also observed.