Powder Metallurgy

The metal powders may be produced in a number of different ways. In metals where the intercrystalline material is brittle enough, they may be ground in a ball mill or eddy mill. The fineness of such a powder is more or less controlled by the grain size of the original metal.

Flotation of a Complex Sulphide Ore Containing Tetrahedrite

The ore investigated in this thesis is a zinc-copper-lead ore. Microscopic analysis of this complex sulphide ore showed it to contain pyrite, sphalerite, arsenopyrite, galena, chalcopyrite, tetrahedrite, and covellite, with quartz as the gangue constituent.

A Highly Efficient Solvent-Free Asymmetric Direct Aldol Reaction Organocatalyzed by Recoverable (s)-Binam-L-Prolinamides. ESI-MS Evidence of the Enamine-Iminium Formation

Recoverable (Sa)-binam-l-prolinamide in combination with benzoic acid is used as catalysts in the direct aldol reaction between cycloalkyl, alkyl, and α-functionalized ketones and aldehydes under solvent-free reaction conditions. Three different methods are assayed: simple conventional magnetic stirring, magnetic stirring after previous dissolution in THF and evaporation, and ball mill technique. These procedures allow one to reduce not only the amount of required ketone to 2 equiv but also the reaction time to give the aldol products with regio-, diastereo-, and enantioselectivities comparable to those in organic or aqueous solvents. Generally anti-isomers are mainly obtained with enantioselectivities up to 97%. The reaction can be carried out under these conditions also using aldehydes as nucleophiles, yielding after in situ reduction of the aldol products the corresponding chiral 1,3-diols with moderate to high enantioselectivities mainly as anti-isomers. The aldol reaction has been studied by the use of positive ESI-MS technique, providing the evidence of the formation of the corresponding enamine−iminium intermediates.

A liberation model for comminution based on probability theory

Mineral processing plants use two main processes; these are comminution and separation. The objective of the comminution process is to break complex particles consisting of numerous minerals into smaller simpler particles where individual particles consist primarily of only one mineral. The process in which the mineral composition distribution in particles changes due to breakage is called 'liberation'. The purpose of separation is to separate particles consisting of valuable mineral from those containing nonvaluable mineral. The energy required to break particles to fine sizes is expensive, and therefore the mineral processing engineer must design the circuit so that the breakage of liberated particles is reduced in favour of breaking composite particles. In order to effectively optimize a circuit through simulation it is necessary to predict how the mineral composition distributions change due to comminution. Such a model is called a 'liberation model for comminution'. It was generally considered that such a model should incorporate information about the ore, such as the texture. However, the relationship between the feed and product particles can be estimated using a probability method, with the probability being defined as the probability that a feed particle of a particular composition and size will form a particular product particle of a particular size and composition. The model is based on maximizing the entropy of the probability subject to mass constraints and composition constraint. Not only does this methodology allow a liberation model to be developed for binary particles, but also for particles consisting of many minerals. Results from applying the model to real plant ore are presented. A laboratory ball mill was used to break particles. The results from this experiment were used to estimate the kernel which represents the relationship between parent and progeny particles. A second feed, consisting primarily of heavy particles subsampled from the main ore was then ground through the same mill. The results from the first experiment were used to predict the product of the second experiment. The agreement between the predicted results and the actual results are very good. It is therefore recommended that more extensive validation is needed to fully evaluate the substance of the method. (C) 2003 Elsevier Ltd. All rights reserved.

Comparison of grinding media - Cylpebs versus balls

Cylpebs are slightly tapered cylindrical grinding media with a ratio of length to diameter of unity. The manufactures have made conflicting claims regarding the milling performance of Cylpebs in comparison with balls. One major point of interest is which one grinds finer at the same operating conditions. The difficulty in comparison is due to the shape difference. The two grinding media have different surface area, bulk density and contact mechanisms in grinding action. Comparative tests were conducted using the two types of grinding media in a laboratory Bond ball mill at various conditions of equality such as media mass, size distribution, surface area and input specific energy. The laboratory results indicate that at the same specific energy input level the Cylpebs produce a product with slightly less oversize due to their greater surface area, but essentially the same sizing at the fine end as that produced with the balls. The reason may be that the advantage of greater surface area is balanced by the line contact and area contact grinding actions with the Cylpebs. A new ball mill scale-up procedure [Man, Y.T., 2001. Model-based procedure for scale-up of wet, overflow ball mills, Part 1: outline of the methodology. Minerals Engineering 14 (10), 1237-1246] was employed to predict grinding performance of an industrial mill from the laboratory test results. The predicted full scale operation was compared with the plant survey data. Some problems in the original scale-up procedures were identified. The scale-up procedure was therefore modified to allow the predicted ball mill performance to match the observed one. The calibrated scale-up procedure was used to predict the Cylpebs performance in the full scale industrial mill using the laboratory tests results. (C) 2004 Elsevier Ltd. All rights reserved.

Effect of solute segregation on the strength of nanocrystalline alloys:Inverse Hall-Petch relation

We have used a high-energy ball mill to prepare single-phased nanocrystalline Fe, Fe90Ni10, Fe85Al4Si11, Ni99Fe1 and Ni90Fe10 powders. We then increased their grain sizes by annealing. We found that a low-temperature anneal (T < 0.4 Tm) softens the elemental nanocrystalline Fe but hardens both the body-centered cubic iron- and face-centered cubic nickel-based solid solutions, leading in these alloys to an inverse Hall–Petch relationship. We explain this abnormal Hall–Petch effect in terms of solute segregation to the grain boundaries of the nanocrystalline alloys. Our analysis can also explain the inverse Hall–Petch relationship found in previous studies during the thermal anneal of ball-milled nanocrystalline Fe (containing ∼1.5 at.% impurities) and electrodeposited nanocrystalline Ni (containing ∼1.0 at.% impurities).

Evaluation of double treated starches using thermal tools.

Starch is the main polysaccharide found in cereals, composed by amylose and amylopectin. Corn is the principal source of starches worldwide. Starches treatment, through physical, chemical and/or biological methods, can improve the applications range. Acid modification in alcoholic solution promotes minimally degradation in the granule. Ball mill is one physical method poorly explored. The aim was to treat the starches using HCl 0.5 mol L-1 for 1 hour in 100 ml of aqueous, ethanol or methanol solutions with subsequent ball milling processes. One sample was selected as native sample. The four others, one native sample and three acid modified samples, were treated by physical process with the oscillating ball mill. The DTG-60H equipment was used for the TG and DTA analysis. The TG curves showed three mass losses related to dehydration, decomposition and oxidation. The native sample without physical modification showed major resistance to total degradation. This occurs because the physical modification cleaves hydrogen bonds, leaving a weakened granule. The TGDTA results showed that the mass loss in the 2nd event was minor in the hydrolyzed samples compared with native samples. The acid modification can provide starch higher resistance to degradation up to 340 °C. These results showed that chemical and physical treatment changed the thermal behaviors of the starches.

Laboratory studies on ball wear in the grinding of a hematite-magnetite ore

Marked-ball grinding tests were carried out under different grinding conditions and environments. Three types of balls were used, namely, cast hyper steel, high chrome cast iron and EN-31 (forged), which cover a wide range of chemical composition, microstructure and media hardness. The effect of pulp density on ball wear and grinding efficiency was also studied. Relative pulp viscosities at different percent solids for the ore slurry were also determined. As the Kudremukh ore contained about 0.2% pyrite, the effect of addition of pyrite on ball wear was studied separately. Results of marked-ball grinding tests indicated that ball wear increased with time and showed a sharp increase for wet grinding over dry grinding. Ball wear under wet grinding conditions was also influenced by the gaseous atmosphere in the mill. At 70% solids, the best results in terms of reduced ball wear coupled with satisfactory grinding efficiency were obtained. The influence of oxygen on the corrosive wear of grinding balls was increasingly felt only if sulphide minerals such as pyrite were also present in the ore. The various ball materials could be arranged in the following order with respect to their overall wear resistance: high chrome cast iron > EN-31 (forged) > cast hyper steel.Possible ball wear mechanisms involved in the grinding of Kudremukh ore are discussed.

A new approach to the kinetics of size reduction in ball milling

The rate of breakage of feed in ball milling is usually represented in the form of a first-order rate equation. The equation was developed by treating a simple batch test mill as a well mixed reactor. Several case of deviation from the rule have been reported in the literature. This is attributed to the fact that accumulated fines interfere with the feed material and breaking events are masked by these fines. In the present paper, a new rate equation is proposed which takes into account the retarding effect of fines during milling. For this purpose the analogy of diffusion of ions through permeable membranes is adopted, with suitable modifications. The validity of the model is cross checked with the data obtained in batch grinding of ?850/+600 ?m size quartz. The proposed equation enables calculation of the rate of breakage of the feed at any instant of time.

Ball wear and its control in the grinding of a lead-zinc sulphide ore

Marked ball grinding tests were carried out in the laboratory with a lead-zinc sulphide ore under different experimental conditions using high carbon low alloy steel (cast and forged) and high chrome cast iron balls. Relative ball wear as a function of grinding period and milling conditions was evaluated for the different types of ball materials. The role of corrosion and abrasion-erosion in the wear of grinding media is brought out. Methods to minimise ball wear through control of mill atmosphere and addition of reagents are discussed.

Ball wear mechanisms and control in the grinding of sulfide and phosphate ores

Marked ball grinding tests were carried out in the laboratory using high carbon low alloy steel (cast and forged) and high chrome cast iron balls. Relative ball wear as a function of grinding period and milling conditions was evaluated for the different type of ball materials in the grinding of lead-zinc sulphide and phosphate ores. Results indicated that ball wear increased with time and showed a sharp increase for wet grinding over dry grinding. Ball wear under wet grinding conditions was also influenced by the gaseous atmosphere in the mill. The influence of oxygen on the corrosive wear of grinding balls was increasingly felt in case of sulphide ore grinding. The grinding ball materials could be arranged in the following order with respect to their overall wear resistance:

Laboratory studies on ball wear in the grinding of a chalcopyrite ore

Wear of high carbon low alloy (HCLA) cast steel balls during the grinding of a chalcopyrite ore was evaluated under different experimental conditions. The role of oxygen in enhancing ball wear during wet finding is brought out. The influence of pH on ball wear was also examined from the view point of acid production during grinding and reactivity of sulphides. Contributions from corrosion and abrasion towards ball wear are quantified in terms of ball wear rates as a function of time, particle size and gaseous atmosphere in the mill.

Highly accurate isotope composition measurements by a miniature laser ablation mass spectrometer designed for in situ investigations on planetary surface

An experimental procedure for precise and accurate measurements of isotope abundances by a miniature laser ablation mass spectrometer for space research is described. The measurements were conducted on different untreated NIST standards and galena samples by applying pulsed UV laser radiation (266 nm, 3 ns and 20 Hz) for ablation, atomisation, and ionisation of the sample material. Mass spectra of released ions are measured by a reflectron-type time-of-flight mass analyser. A computer controlled performance optimiser was used to operate the system at maximum ion transmission and mass resolution. At optimal experimental conditions, the best relative accuracy and precision achieved for Pb isotope compositions are at the per mill level and were obtained in a range of applied laser irradiances and a defined number of accumulated spectra. A similar relative accuracy and precision was achieved in the study of Pb isotope compositions in terrestrial galena samples. The results for the galena samples are similar to those obtained with a thermal ionisation mass spectrometer (TIMS). The studies of the isotope composition of other elements yielded relative accuracy and precision at the per mill level too, with characteristic instrument parameters for each element. The relative accuracy and precision of the measurements is degrading with lower element/isotope concentration in a sample. For the elements with abundances below 100 ppm these values drop to the percent level. Depending on the isotopic abundances of Pb in minerals, 207Pb/206Pb ages with accuracy in the range of tens of millions of years can be achieved.

Using DEM to model ore breakage within a pilot scale SAG mill

The best accepted method for design of autogenous and semi-autogenous (AG/SAG) mills is to carry out pilot scale test work using a 1.8 m diameter by 0.6 m long pilot scale test mill. The load in such a mill typically contains 250,000-450,000 particles larger than 6 mm, allowing correct representation of more than 90% of the charge in Discrete Element Method (DEM) simulations. Most AG/SAG mills use discharge grate slots which are 15 mm or more in width. The mass in each size fraction usually decreases rapidly below grate size. This scale of DEM model is now within the possible range of standard workstations running an efficient DEM code. This paper describes various ways of extracting collision data front the DEM model and translating it into breakage estimates. Account is taken of the different breakage mechanisms (impact and abrasion) and of the specific impact histories of the particles in order to assess the breakage rates for various size fractions in the mills. At some future time, the integration of smoothed particle hydrodynamics with DEM will allow for the inclusion of slurry within the pilot mill simulation. (C) 2004 Elsevier Ltd. All rights reserved.

Influence of charge size distribution on net-power draw of tumbling mill based on DEM modelling

Modelling and optimization of the power draw of large SAG/AG mills is important due to the large power draw which modern mills require (5-10 MW). The cost of grinding is the single biggest cost within the entire process of mineral extraction. Traditionally, modelling of the mill power draw has been done using empirical models. Although these models are reliable, they cannot model mills and operating conditions which are not within the model database boundaries. Also, due to its static nature, the impact of the changing conditions within the mill on the power draw cannot be determined using such models. Despite advances in computing power, discrete element method (DEM) modelling of large mills with many thousands of particles could be a time consuming task. The speed of computation is determined principally by two parameters: number of particles involved and material properties. The computational time step is determined by the size of the smallest particle present in the model and material properties (stiffness). In the case of small particles, the computational time step will be short, whilst in the case of large particles; the computation time step will be larger. Hence, from the point of view of time required for modelling (which usually corresponds to time required for 3-4 mill revolutions), it will be advantageous that the smallest particles in the model are not unnecessarily too small. The objective of this work is to compare the net power draw of the mill whose charge is characterised by different size distributions, while preserving the constant mass of the charge and mill speed. (C) 2004 Elsevier Ltd. All rights reserved.