Determination of critical state line(CSL)for silty-sandy iron ore tailings subjected to low-high confining pressures

The disposal of filtered tailings in high dry stacks can induce particle breakage,changing the material's behaviour during the structure's lifetime.The grading changes influence material properties at the critical state,and this is not mature for intermediate artificial soils(tailings)in a broad range of confining pressures.In this paper,it aims to describe the behaviour of iron ore tailings in a spectrum of confining pressures broader than the reported in previous studies.A series of consolidated drained(CD)triaxial tests was carried out with confining pressures ranging from 0.075 MPa to 120 MPa.These results show that the amount of breakage plays an essential role in the response of iron ore tailings.The existence of curved critical state line(CSL)in both specific volume(ν)-logarithm of mean effective stress(p′)and deviatoric stress(q)-mean effective stress(p′)planes,and different responses in the deviatoric stress-axial strain-volumetric strain curves were verified.An inverse S-shaped equation was proposed to represent the silty-sandy tailings'behaviour up to high pressures onν-lnp′plane.The proposed equation provides a basis for enhancing constitutive models and considers the evolution of the grading up to severe loading conditions.The adjustment considered three regions with different responses associated with particle breakage at different pressure levels.

Mechanism and kinetics of iron extraction from high silica boehmite−kaolinite bauxite by hydrochloric acid leaching

The chemical and mineral compositions of bauxite recovered from the Severoonezhsk Bauxite Mine(Arkhangelsk region,Russia)were studied by XRD,ICP-OES,TG/DSC,SEM,TEM,and Mössbauer spectroscopy.The iron-containing minerals of the bauxites were found to comprise alumogoethite(α-Fe_(1−x)Al_(x)OOH),alumohematite(α-(Fe_(1−x)Al_(x))_(2)O_(3)),alumoakaganeite(β-Fe_(1−x)Al_(x)O(OH,Cl)),and chromite(FeCr_(2)O_(4)).The efficiency of Fe extraction from the bauxite by HCl leaching was 82.5%at 100℃,HCl concentration of 10%,solid/liquid ratio of 1:10,and the process duration of 60 min,with aluminum loss from the bauxites below 4.5%of the total Al contents in the bauxite.Analysis of the kinetics of the iron leaching process proved diffusion to be the limiting stage of the process at 90−100℃.Bauxite residue after leaching presented traces of α-Fe_(1−x)Al_(x)OOH and β-Fe_(1−x)Al_(x)O(OH,Cl),and most of the iron content was in the FeCr_(2)O_(4).In bauxite residue after HCl leaching,in addition to iron oxide,the contents of chromium and calcium oxides significantly decreased.The iron chloride liquor after leaching contained the rare earth elements(REE)of 6.8 mg/L Sc,4.1 mg/L Ce and 2.3 mg/L Ga.

Sulfur phase and sulfur removal in high sulfur-containing bauxite

The sulfur phase in high sulfur-containing bauxite was studied by an X-ray diffraction analysis and a chemistry quantitative analysis.The methods for the removal of different shaped sulfur were also discussed.The results show that sulfur phases in high sulfur-containing bauxites exist in the main form of sulfide sulfur （pyrite） or sulfate sulfur,and the main sulfur forms of bauxites from different regions are not the same.Through a combination of an X-ray diffraction analysis and a chemistry quantitative analysis,the sulfur phases of high sulfur-containing bauxite could be accurately investigated.Deciding the main sulfur form of high sulfur-containing bauxite could provide theoretical instruction for choosing methods for the removal of sulfur from bauxite,and an oxidizing-roasting process is an effective way to remove sulfide sulfur from high sulfur-containing bauxite,the content of S^2-in crude ore in the digestion liquor is above 1.7 g/L,but in the roasted ore digestion liquor,it is below 0.18 g/L.Using the sodium carbonate solution washing technology to wash bauxite can effectively remove sulfate sulfur,the content of the total sulfur in ore is lowered to below 0.2% and can meet the production requirements for the sulfur content.

Enrichment and separation of iron minerals in gibbsitic bauxite residue based on reductive Bayer digestion

The mineralogical characteristics of three kinds of gibbsitic high-iron bauxite and the effects of various digestion conditions on the enrichment and separation of iron minerals were investigated. The results show that adding an appropriate organic reductant such as glycerol can promote the digestion of concomitant diaspore, boehmite and alumogoethite as well as the conversion of goethite to hematite in the reductive Bayer digestion. Processing Bauxite A with A/S of 25.41 can directly produce qualified iron concentrates(TFe>56%) by the reductive Bayer digestion, and thus realize the zero red mud discharge. For Bauxite B and Bauxite C with A/S of 7.82 and 3.35, the iron recoveries of 65.13% and 79.13% can be achieved with the corresponding TFe of 52.05% and 50.16% in the iron concentrates by gravity separation, respectively, resulting in the red mud discharge reduction of ~50% or above.

Effect of Bauxite Aggregate on Properties of Al_2O_3-SiC-C Iron Trough Castables

A1203-SiC-C iron trough castables were prepared using high alumina bauxite clinker GL-90 （ 〉 1 mm ） or homogenized bauxite GL-88 to replace the traditional brown corundum aggregates （ 〉 1 mm ） to reduce the cost of iron trough castables. Effects of the two bauxite aggregates on properties of iron trough eastables were investigated. The results show that the two kinds of bauxite affect flowability, bulk density, strength and slag corrosion resistance of trough castables differently. Compared with homogenized bauxite, high alumina bauxite clinker is more suitable to substitute brown corundum. The castables prepared from the bauxite clinker have similar performances with those prepared from brown corundum, especially used in medium or small blast furnaces with weak thermal impact and lower temperature hot metal. However, in large blast furnaces with severe thermal impact and high temperature hot metal, the performances of the two castables are significantly different. So it is suggested to use the brown corundum based castables in the front gyral zone of the slag skimmer.

pH variation mechanism of high sulfur-containing bauxite

In order to fundamentally solve the acidification problem of high sulfur-containing bauxite during storage, by simulating the environment of minerals storage in laboratory, the acidification mechanism and influencing factors of high sulfur-containing bauxite were studied and confirmed using the single variable method to control the atmosphere, water and other variables. The results show that the acidification is mostly caused by the oxidation of sulfur-containing bauxite, which is mainly the natural oxidation of Pyrite(Fe S2), then the alkaline minerals dissolute in the presence of water, leading to the acidification phenomenon, which is influenced by moisture and air flow. Finally, more acid-producing substances are formed, resulting in the acidification of high sulfur-containing bauxite. The acidification of high sulfur-containing bauxite results from the combined effect of the oxygen in the air and water, which can be significantly alleviated by controlling the diffusion of the oxygen in air.

Interface characteristics and wear resistance of Ni-B_(4)C plated ZTA reinforced high chromium cast iron composite

A chemical composite plating of Ni-B_(4)C was used to prepare the surface-modified zirconia toughened alumina(ZTA)ceramic particles.The ceramic preforms were prepared by the plated ZTA and sodium silicate solution binder,followed by casting infiltration to prepare the ZTA particles reinforced high chromium cast iron(HCCI)composites.The result reveals that a distinct interface layer forms at the ZTA/HCCI interface,which consists of phases of ZrB_(2),FeB,Fe_(2)B,and NaSiO_(4).The interfacial wettability between ZTA and HCCI is improved by the diffusion and reaction of Ni and B_(4)C.The wear test reveals that the Ni-B_(4)C plated ZTA particles can effectively improve the wear resistance of the ZTA/HCCI composite,and the wear rate of the composite is decreased to 11.6%of HCCI.

Effect of High Temperature Calcination on Structure and Properties of Bauxite-based Homogeneous Clinkers

In this paper,the effect of high temperature calcination on the structure and properties of bauxite-based homogeneous clinkers calcined at different temperatures for different durations was studied.The results show that with the rising of calcination temperature and the prolonging of holding time,the volume density of bauxite-based homogeneous clinkers increases and the apparent porosity decreases.After high temperature calcination,the linear expansion of bauxitebased homogeneous clinker is smaller than that of the non-calcined ones.Whether calcined at high temperatures or not,the thermal shock resistance of bauxite-based homogeneous clinkers is good.The crystalline phases of bauxite-based homogeneous clinkers are mainly mullite and corundum.There is more glass phase in the bauxite-based homogeneous clinkers without calcination.After calcination at high temperatures the glass phase content decreases significantly,and the mullite crystals develop better forming the cross-network structure.

Performing High Resolution Seismic Reflection for Mapping Bauxite Layers

The seismic method is able to produce highly accurate images of the Earth's subsurface. Having such detail is not only an important factor in mining, but also in civil engineering. Bauxite exploration attracts both government and industrialists to invest in it because of the high percentage of aluminum present. The economic importance of extracting aluminum from bauxite encouraged us to take this challenge;to image bauxite layers by using a high-resolution seismic reflection method at Al Qassim, Saudi Arabia. Since the subsurface structure of the area is complex, this high-resolution reflection method was carried out along a 2D line with geophone and source interval, with settings at 5 m. The result for the seismic section shows that the depth and thickness of the bauxite layer varied from 20 to 34 m, and 3 to 7 m respectively. In addition, the bauxite layer was sandwiched between clay layers. In order to achieve an even more precise depth than presented by seismic section alone, we tied the drilled wells to the seismic data and we accomplished a well match with an approximation error of 1 - 2 m, which may have been caused by the upper clay layer or by very shallow loose subsurface material. The seismic method thus applied shows the ability to detect significant details within the near surface of the earth, and considers more cost-effective than only drilled wells.

CUTTING FORCES IN HIGH SPEED TAPPING CAST IRON BY TUNGSTEN CARBIDE TAPS

The engineblock production lines need high speed tapping with tungsten carbide taps. In the tapping process, the machining precision and the tool life of taps are directly influenced by tapping forces. And the parameter optimization of tap structures is also correlated with the variation of tapping forces. Therefore, the study of tapping forces is necessary in developing new style taps. Several experiments about some novel carbide taps are performed on a vertical machining center by a Kistler dynamometer system in blind tapping both gray cast iron and ductile cast iron. And the variations of tapping forces are analyzed in tapping-in and tapping-out periods. It indicates that cutting forces hardly vary with the tap wear in tapping cast iron. Contrarily, tapping forces are closely correlated with the holding method. Besides, it also depends on the helix angle, the flute numbers and the plasticity of the work material to some extent.

Non-isothermal thermal decomposition kinetics of high iron gibbsite ore based on Popescu method

The thermal decomposition kinetics of high iron gibbsite ore was investigated under non-isothermal conditions.Popescu method was applied to analyzing the thermal decomposition mechanism.The results show that the most probable thermal decomposition mechanism is the three-dimensional diffusion model of Jander equation,and the mechanism code is D3.The activation energy and pre-exponential factor for thermal decomposition of high iron gibbsite ore calculated by the Popescu method are 75.36 kJ/mol and 1.51×10-5 s-（-1）,respectively.The correctness of the obtained mechanism function is validated by the activation energy acquired by the iso-conversional method.Popescu method is a rational and reliable method for the analysis of the thermal decomposition mechanism of high iron gibbsite ore.

Effects of electrolyte recycling on desulfurization from bauxite water slurry electrolysis

To lower the cost of bauxite electrolysis desulfurization using NaOH solution as the supporting electrolyte, effects of electrolyte recycling on bauxite electrolysis desulfurization were investigated. The results indicate that electrode corrosion, cell voltage, the desulfurization rate and the pH value of the electrolyte have no obvious changes with the increase of cycle times. Additionally, there were some transitive valence S-containing ions in electrolyte after the electrolysis, such as SO3^2-,S2O3^2- . However, most of the sulfur in bauxite was eventually oxidized into SO4^2- into the electrolyte, and these S-containing ions did not affect the recycling utilization for electrolyte.

High-temperature performance prediction of iron ore fines and the ore-blending programming problem in sintering

The high-temperature performance of iron ore fmes is an important factor in optimizing ore blending in sintering. However, the application of linear regression analysis and the linear combination method in most other studies always leads to a large deviation from the desired results. In this study, the fuzzy membership functions of the assimilation ability temperature and the liquid fluidity were proposed based on the fuzzy mathematics theory to construct a model for predicting the high-temperature performance of mixed iron ore. Comparisons of the prediction model and experimental results were presented. The results illustrate that the prediction model is more accurate and effective than previously developed models. In addition, fuzzy constraints for the high-temperature performance of iron ore in this research make the results of ore blending more comparable. A solution for the quantitative calculation as well as the programming of fuzzy constraints is also introduced.

Effect of Cryogenic Treatment on Property of 14Cr2Mn2V High Chromium Cast Iron Subjected to Subcritical Treatment

Effect of cryogenic treatment on the microstructure, hardening behavior and abrasion resistance of 14Cr2Mn2V high chromium cast iron （HCCI） subjected to subcritical treatment was investigated. The results show that cryogenic treatment after subcritical treatment can obviously improve the hardness and abrasion resistance of HCCI because abundant retained austenite is transformed into martensite and fine secondary carbides E（Fe, Cr）23 C6 ] precipitate. The amount of martensite and precipitated secondary carbide in HCCI experiencing subcritical treatment followed by cryogenic treatment was more than that experiencing the subcritical treatment followed by air cooling. When the abrasion resistance of HCCI reaches the maximum, its microstructure contains about 15 % retained austenite. Cryogenic treatment can further reduce the austenite content but the retained austenite cannot be transformed in to martensite completely.

Effect of Ti-V-Nb-Mo addition on microstructure of high chromium cast iron

The effects of trace additions of multi-alloying elements （Ti, Nb, V, Mo） on carbides precipitation and ascast microstructure of eutectic high chromium cast iron containing 2.85wt.%C and 31.0wt.%Cr were investigated from thermodynamic and kinetic considerations. The thermodynamic calculations show that Ti and Nb exist in the multi-alloying system in the forms of TiC and NbC. The formation of VC during the solidification is not feasible from the thermodynamic consideration. XRD analysis shows that the V exists in alloy compounds （VCr2C2, VCrFes）. The first precipitated high melting point particles （TIC, NbC） can act as the heterogeneous substrate of M7C3 carbides, which results in significant refinement of the M7C3 carbides. After the addition of alloying elements, C atom diffusion is hindered due to the strong affinities of the strong carbide forming elements for carbon, which decreases the growth rate of carbides. The combined roles of the increase of nucleation rate and the decrease of carbides growth rate lead to the finer microstructure.

Effects of Rare Earths and Al on Structure and Performance of High Chromium Cast Iron Containing Wolfram

Effects of RE and Al on the structure, impact toughness, hardness, and wear resistance of high chromium cast iron containing wolfram were investigated. The results show that without modification the volume fraction of austenite is high and the carbide appears to be thick lath and the grain size is relatively large; proper modification using RE combined with Al can reduce volume fraction of residual austenite in the as-cast structure obviously, refine grain size of primary austenite notably, and make the morphology of carbide changing from thick lath to thin lath, rosette, and feather-like modification can also increase hardness, wear resistance and impact toughness of cast iron.

A Fe-N-C catalyst with highly dispersed iron in carbon for oxygen reduction reaction and its application in direct methanol fuel cells

Exploring non‐precious metal catalysts for the oxygen reduction reaction （ORR） is essential for fuel cells and metal–air batteries. Herein, we report a Fe‐N‐C catalyst possessing a high specific surface area （1501 m2/g） and uniformly dispersed iron within a carbon matrix prepared via a two‐step pyrolysis process. The Fe‐N‐C catalyst exhibits excellent ORR activity in 0.1 mol/L NaOH electrolyte （onset potential, Eo=1.08 V and half wave potential, E1/2=0.88 V vs. reversible hydrogen electrode） and 0.1 mol/L HClO4 electrolyte （Eo=0.85 V and E1/2=0.75 V vs. reversible hydrogen electrode）. The direct methanol fuel cells employing Fe‐N‐C as the cathodic catalyst displayed promising per‐formance with a maximum power density of 33 mW/cm2 in alkaline media and 47 mW/cm2 in acidic media. The detailed investigation on the composition–structure–performance relationship by X‐ray diffraction, X‐ray photoelectron spectroscopy and Mo-ssbauer spectroscopy suggests that Fe‐N4, together with graphitic‐N and pyridinic‐N are the active ORR components. The promising direct methanol fuel cell performance displayed by the Fe‐N‐C catalyst is related to the intrinsic high catalytic activity, and critically for this application, to the high methanol tolerance.

Microstructure and wear resistance of highchromium cast iron containing niobium

In the paper, the effect of niobium addition on the microstructure, mechanical properties and wear resistance of high chromium cast iron has been studied. The results show that the microstructure of the heattreated alloys is composed of M7C3 and M23C6 types primary carbide, eutectic carbide, secondary carbide and a matrix of martensite and retained austenite. NbC particles appear both inside and on the edge of the primary carbides. The hardness of the studied alloys maintains around 66 HRC, not significantly affected by the Nb content within the selected range of 0.48%-0.74%. The impact toughness of the alloys increases with increasing niobium content. The wear resistance of the specimens presents little variation in spite of the increase of Nb content under a light load of 40 N. However, when heavier loads of 70 and 100 N are applied, the wear resistance increases with increasing Nb content.

Effect of tempering temperature on microstructure and mechanical properties of high boron white cast iron

The effect of different tempering temperatures on the microstructure and mechanical properties of airquenched high boron white cast iron was studied.The results indicate that the high boron white cast iron comprises dendritic matrix and inter-dendritic M 2 B boride;and the matrix comprises martensite and pearlite.After quenching in the air,the matrix is changed into lath martensite;but only 1-μm-size second phase exists in the matrix.After tempering,another second phase of several tens of nanometers is found in the matrix,and the size and quantity increase with an increase in tempering temperature.The two kinds of second precipitation phase with different sizes in the matrix have the same chemical formula,but their forming stages are different.The precipitation phase with larger size forms during the austenitizing process,while the precipitation phase with smaller size forms during the tempering process.When tempered at different temperatures after quenching,the hardness decreases with an increase in the tempering temperature,but it increases a little at 450 ℃ due to the precipitation strengthening effect of the second phase,and it decreases greatly due to the martensite decomposition above 450 ℃.The impact toughness increases a little when tempered below 300 ℃,but it then decreases continuously owing to the increase in size and quantity of the secondary precipitate above 300 ℃.Considered comprehensively,the optimum tempering temperature is suggested at 300 ℃ to obtain a good combination of hardness and toughness.

SPHERICAL MICROSTRUCTURE FORMATION OF THE SEMI-SOLID HIGH CHROMIUM CAST IRON Cr20Mo2

The nondendritic semi-solid slurry preparation of high chromium cast iron Cr20Mo2 has been studied in this paper. The experiments show that the proeutectic austenitic particles are more spherical under a larger stirring power condition, even if the stirring time is shorter, while the proeutectic austenitic particles are not very much spherical under a smaller stirring power condition and some proeutectic austenitic dendrites also exist, even if the stirring time is very long. The experiments also show that when stirred for 5-6 minutes under the test condition, the semi-solid slurry with 40vol.%-50vol.% solid fraction and spherical proeutectic austenite in the size of 50-80μm can be obtained.