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Mining > Metallurgy > Flashcards

Metallurgy Flashcards

1
Q

3 branches of Metallurgy

A

1) Extractive
2) Physical
3) Adaptive

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2
Q

Preparation required before the extraction process

A

Ore Dressing

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3
Q

A localized plastic deformation

A

Necking

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4
Q

Minimum strength that will promote plastic deformation

A

Yield strength

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5
Q

Capacity to absorb energy when it is deformed elastically

A

Resilience

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6
Q

How is a Rockwell Hardness Test performed

A

find difference in depth of penetration bet a minor and a major load using diamond cone

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7
Q

How is Brinell Hardness test done

A

w. a Hard spherical indenter and measure indent for a specified load and time

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8
Q

Izod Impact test is done by

A

placing specimen vertically and 167 J impact

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9
Q

Charpy impact test is done by

A

hor specimen, 300 J load

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10
Q

Knoop and Vickers is done using a

A

diamond indenter for brittle materials only

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11
Q

Fatigue def

A

metal’s response to cyclic loading

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12
Q

Creep def

A

time dependent deformation under constant load and/or high temp

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13
Q

3 types of Extractive processes

A

1) Pyrometallurgy
2) Electrometallurgy
3) Hydrometallurgy

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14
Q

Ore type where pyro met is easiest

A

Oxide minerals

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15
Q

How is smelting done

A

1) Use carbon as a reducing agent
2) Convert oxide to molten state
3) Alllow SG for metal to separate from the slag

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16
Q

How are Carbonate ores treated

A

by separating into metallic oxides and CO2 thru heating

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17
Q

How are Silicate ores treated

A

same for oxide plus removal of silica

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18
Q

How are Sulfide ores treated

A

for matte in smelting operations

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19
Q

How are Sufide ores prepared

A

by adding elemental sulfur to molten metal

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20
Q

How is sulfur removed

A

by oxidizing to sulfur dioxide gas

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21
Q

Treatment of metal product to remove impurities

A

Refining

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22
Q

What is a Shaft furnace and its efficiency

A

charge in contact with fuel (thermal efficiency of 60-70%)

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23
Q

Reverbatory furnace is a

A

Heat from firebox passes to the charge then is exhausted

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24
Q

Describe Muffle, Crucible, and Retort

A

heat is conducted through wall, low thermal efficiency

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25
Q

Pyrolysis means

A

destructive distillation of coal in the absence of air

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26
Q

What is Calcination process

A

process of heating the ore at a temp not suff to melt ore, in absence of air

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27
Q

When is Calcination done

A

Covert carbonate ores into oxide and CO2

CaCO3 —> CaO + CO2

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28
Q

What is Roasting

A

heating of ore in presence of excess air

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29
Q

When is Roasting done

A

convert metal sulfides into metal oxides and sulfur dioxide

2Cu2S + 3)2 —> 2Cu2O + 2SO2

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30
Q

What is sulfatizing roast

A

Oxide is turned into metallic sulfate

CuO + SO3 —> CuSO4

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31
Q

What is blast roasting

A

air is supplied by fan or blower

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32
Q

What is flash roasting

A

used in very fine sulphide material (flot concentrates)

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33
Q

What is smelting

A

process of melting and separating into two immiscible liquids

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34
Q

Converter process

A

presurized air is blown through molten charge

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35
Q

Molten solutions of sulfides

A

Matte

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36
Q

Molten solution of arsenides

A

Speiss

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37
Q

What is dross

A

Collective term for Sollid impurities floating on molten metal

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38
Q

What are refractories

A

Accepts molten charge

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39
Q

2 types of Heat Exchanger

A

Recuperators (continuous transfer) and Regenerators (stores heat)

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40
Q

Why is Roasting done

A

to convert metal into soluble form and remove volatile impurities, and to weakn bonds

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41
Q

What is used to leach Cu-Zn, and gold- silver allow

A

Sulfuric Acid

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42
Q

Base NH4OH used to leach what

A

Copper

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43
Q

NaOH is used to leach what

A

bauxite

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44
Q

NaCN or KCN is used to leach what

A

Au and Ag

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45
Q

Vat or Percolation leaching is used for

A

5 mm diameter material, lasts days

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46
Q

Fastest type of leaching (hours)

A

Agitation leaching

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47
Q

Why is Pressure leaching done

A

for minerals difficult to dissolve at ordinary temp and pressure

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48
Q

SPC means

A

Separation - Purification - Enrichment

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49
Q

What is SPC by Ion exchange

A

used of polymeric resin to exchange ions

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50
Q

Steps in Ion-Exchange

A

1) Sorption - pregnant soln passed thru resin column to exchange ions
2) Elution - ions are removed from resin by passing eluan or renerant which has excess electrolyte

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51
Q

What is Adsorption process

A

use of activated carbon to takeup ionic or molecular substances preferentially

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52
Q

Explain Solvent Extraction

A

partitioning of metal into immiscible phase - aqueous and organic (aqueous w/ valuable)

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53
Q

Metal winning precipitation is done by

A

formation of solid product from solution using reagents

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54
Q

Electromet is done by

A

deposition of metals at cathode

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55
Q

Cadmium is precipitated using

A

Zinc dust

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56
Q

Zinc purification is done by

A

Neutral circuit leaching

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57
Q

Zinc dissolution is done by

A

Acid circuit leaching

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58
Q

Explain Amalgamation

A

1) Mercury leaches Gold to form Amalgam
2) Retort furnace is used to vaporize Mercury and condensed for reuse
3) Gold Amalgam is left in the furnace

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59
Q

Furnace using electricity for heat

A

Arc furnace

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60
Q

Explain Oxidation

A

involves loss of electrons

Fe0 ->Fe2+ + 2e-

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61
Q

Explain Reduction

A

involves gain in electrons

Cu2+ + 2e- -> Cu0

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62
Q

Oxidation occurs here

A

Anode

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63
Q

reduction and deposition occurs here

A

Cathode

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64
Q

Electrolyte is the

A

aqueous medium thru w/c ions move from one electrode to another

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65
Q

Explain Electrowinning

A

1) Anode site provides the electrons

2) The cathode uses electron to recover metal

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66
Q

Explain Electrorefining

A

Anode is dissoved into solution

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67
Q

Betts process means

A

Crude lead is refined (only if Bismuth is present)

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68
Q

Process to remove Silver and Gold from lead bullion

A

Parkes process

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69
Q

Nickel is is prod electrolytically by

A

Bessemer matte using a nickel sulfate solution w/ boric acid

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70
Q

Silver bullion is refined electrolytically by

A

Thum or Moebius process

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71
Q

Wohlwill process is

A

Electrolytically refining Gold bullion

Selective deposition of Gold using REDOX reactions

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72
Q

What is electroplating

A

surface coating of metal on metallic object thru cathodic depostion

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73
Q

Used to refine Al

A

Bayer Process

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74
Q

Define Isotopes

A

same number of protobs, diff number of neutrons

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75
Q

Explain allotropy

A

Change in structure when heated

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76
Q

What is metallic bond

A

all positive cores share electrons

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77
Q

Metal which is non-crystalline at room temp

A

Hg

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78
Q

Liquid w/c is non-amorphous

A

Crystalline polymer

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79
Q

3 Principal metallic structure

A

BCC
FCC
HCP

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80
Q

How many Bravais lattice

A

14

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81
Q

What is Diffraction

A

Constructive interference of scattered x-rays

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82
Q

Alloying is done by

A
  1. Metal base is melted

2. Additive are added as solids to be dissolved

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83
Q

2 common types of Metal Fabrication Processes

A
  1. Forming

2. Casting

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84
Q

Forming operations

A

F orging
R olling
E Extrusion
D rawing -

85
Q

Casting operations

A

D ie - force molten material under pressure
I nvestment - Wax is molded, ceramic mold takes its place as wax melts, molten material poured
C ontinuous - cast into continuous strands
S and - as mold material
L ost Foam Casting - Foam is replaced with hardened metal

86
Q

2 Miscellaneous operations

A

Powder metallurgy

Welding

87
Q

Hot Working use

A

Large strains can be achieved

88
Q

Forging def

A

use of compressive stress to deform metal

89
Q

Rolling def

A

Reducing of thickness and change in shaped using pair of revolving rollers

90
Q

Extrusion def

A

Forcing hot block of metal thru a die orifice under high pressure

91
Q

Drawing def

A

Pulling metal thru exit side of die

92
Q

Casting def

A

Molten metal solidify in mold

93
Q

How is Powder met done

A
  1. Powder is prod by mech, electro, chem, atomization process
  2. Compacted using punches
  3. Heat for inter-particle weld
94
Q

Mechanical joining

A

Bolts, Rivets, Screw, Snap fit

S

95
Q

Soldering def

A

Bonding sep pieces by melting metal

96
Q

Most common bonding material

A

60-40 lead-tin

97
Q

Brazing def

A

similar to soldering but using Ag or Cu alloys

98
Q

What is CIP/CIL

A

Selective dissolution of Gold using cyanide for >3% Au feed

99
Q

What is Miller process

A

Chlorine gas is passed thru molten gold to ppt other metals

100
Q

What is HPAL and MOA Bay process

A

Use of Sulfuric acid leaching of Ni into Sulfate

101
Q

What is Sherritt Gordon Process

A

Ammonina (NH3)leaching of Ni

102
Q

Mitsubishi Process is the

A

Continuous Furnace smelting of Cu into copper matte

103
Q

Flash smelting is

A

under Mitsubishi Process, Autogenous fine particle smelting of Cu

104
Q

Blast furnace smelting is used to extract what

A

Iron

105
Q

What is Midrex/COREX process

A

Direct Iron Oxide Reduction

106
Q

5 Unit Operations in Ore Dressing

A 
Comminution
Sizing 
Concentration
Dewatering
Auxilliary Operations
107
Q

2 Means of Liberation

A

Size reduction and detachment

108
Q

When is “Grain” used

A

for Uncrushed rock

109
Q

When is “Particle” used

A

Crushed rock

110
Q

Reaction that reduces iron to pig iron

A

Boudard reaction

111
Q

Two types of Liberation due to fracture

A

Intergranular

Transgranular

112
Q

4 types of middlings

A

Rectilinear
Vein
Shell
Occlusions

113
Q

Rittinger’s formula (Surface area)

A

E = K(Final area - Initial area)

114
Q

Kick’s Energy Law (Change in size)

A

E = K*ln(Initial Diameter / Final Particle Diameter)

115
Q

Bond’s Energy Law (Crack length)

A

E = K * (1/sqrt(Final diam) - 1/ sqrt(Initial Diam))

116
Q

Reduction ratio (Rr)

A

feed opening/ product opening

117
Q

Geometry factor for Kick’s

A

n = 1.0

118
Q

Geometry factor for Bond’s

A

n = 1.5

119
Q

Geometry factor for Rittinger’s

A

n = 2.0

120
Q

Rod mill L:D

A

1.5-2.5 : 1

121
Q

Ball Mill L:D

A

1-1.5 : 1

122
Q

AG/SAG L:D

A

0.5 : 1

123
Q

SAG volume ball mill charge %

A

6-10%

124
Q

Mass Balance Eqn

A

F = C + T

125
Q

Elemental Balance equation

A

fF = cC + tT

126
Q

What is MOG

A

Size to w/c ore is ground to ensure sufficient liberation

Normally 80% passing

127
Q

Mesh no. equals

A

of square apertures/in^2

128
Q

GGS formula

A

Cumulative passing vs LOG(passing size)

129
Q

Concentration ratio in terms of assay

A

K = (c-t)/(f-t)

130
Q

Recovery in terms of assay

A

R = c(f-t)/f(c-t)

131
Q

Enrichment ratio

A

Er = c/f

132
Q

2 methods of Sizing

A

Screening - Use of physical barriers

Classification - diff’l movement of solid particles thru fluid

133
Q

2 Screen movements

A

Frequency - hor’l movement

Stroke - Vertical movement

134
Q

Limit of Industrial screening

A

Mat’l over 250 microns

135
Q

Dual Vibrating screens has how many products

A

3 (2 over size, 1 under size)

136
Q

Terminal velocity meaning

A

Equilibrium attained bet gravitational and fluid resistance forces.

Bouyant force + Drag force - Gravitational force = 0

137
Q

Free settling is the

A

settling in a vol of large fluid vol wrt total vol

138
Q

Effect of flowing film wrt to SG and Diameter

A

the high SG low D is less affected than high SG high D,

139
Q

What is High-tension separation done

A

Uses diff in electrical conductivities to sep feed

140
Q

Theory behind froth flotation

A

Driving force for attachment of part’s to bubbles is the REDUCTION OF SURFACE ENERGY of the system

141
Q

Allotrope of Sphalerite

A

Wurtzite

142
Q

What are Surfactants

A

Surface active chemicals that affect dynamics at interface

143
Q

What do collectors do

A

makes surface hydrophobic

144
Q

What is the Polar group and Hydrocarbon chain

A

Polar group attaches to mineral while Hydrocarbon chain makes it hydrophobic to water

145
Q

What do Frothers do

A

Control stability of bubbles

146
Q

What do Conditioners do

A

Control pH w/c in tur dictates the surface charge

147
Q

What do Modifiers do

A

affect adsorption efficiency of collectors on min surface

148
Q

2 types of Modifiers

A

Activators - adsorbent to collector

Depressants - suppresses adsorption of collector

149
Q

Working slope for Chutes

A

45-55%

150
Q

What are tensioning devices

A

to prevent undue sag on conveyor belt

151
Q

What are snub pulleys

A

to increase tension

152
Q

What are drive pulley

A

receives torque from motor to move belt

153
Q

What is a counter-weight in conveyors

A

To add tension in conveyor

154
Q

Interlock systems are used to

A

stop preceding conveyors when one fails

155
Q

What do belt-loading systems do

A

Load ore same speed as belt

Centers ore on belt

156
Q

Elliptical Bar feeder advantage

A

Move large rocks along while letting thru smaller ones

157
Q

Most widely used feeder for coarse materials

A

Apron feeder

158
Q

What is a live storage stock pile

A

There is a draw bell and a conveyor under the stockpile

159
Q

How are orebins used

A

intermediate bet crushing and grinding

160
Q

When are sloping bottom ore bins used

A

for easily oxidized ore

161
Q

Slurry/Conditioning tanks are used

A

Store suspensions of fine solids

162
Q

Non-white or nearly white metals

A

Au and Cu

163
Q

Ferromagnetic mineral

A

Fe, Ni, Co

164
Q

What is toughness

A

ability to absorb energy up to fracture

165
Q

Reagnet which lowers surface tension; reagent conc at bubble

A

Organic frother

166
Q

Reagent increases surface tension; reagent conc away from surface

A

Inorganic frother

167
Q

Effect of electrolyte ph in frothing

A

Acids - dec froth

Alkali - inc froth

168
Q

Collector for most sulfide minerals

A

Xanthates

169
Q

Other name for “Aeroflot” a collector for sulfides

A

Dithiophosphates

170
Q

Collector for alkali earth metals,some carbonates, and oxides

A

Carboxyl

171
Q

Collector Applied for silicates

A

Cationic

172
Q

Depressants fxn

A

Make hydrophobic to hydrophilic

173
Q

Activator fxn

A

To help adsorb collector making it hydrophobic

174
Q

What do regulators do

A

pH modification

175
Q

pH of flotation slurry for all sulfide ores

A

alkaliine

176
Q

Column flotaion descrp

A

Feed at top
Air sparger makes bubble at bot
Cleaning zone at top
Conc output at top

177
Q

Net downward flow of water maintained inColumn flotation

A

Positive Bias

178
Q

Jameson Cell fxns by

A

Feed and air slurry jet is injected
Wash water at top removes entrained tais
Conc at top
Tails at bot

179
Q

Adv of Jameson

A

Fast, bc contact dependent not residence time dependent

180
Q

Denver flotation cell works by

A

Impeller at bot sucks in slurry and pressurized air from top

181
Q

Most widely used flotation machine

A

Wemco cell

182
Q

Wemco feature

A

rotor-disperser, no need for pressurized air

183
Q

Outokumpu Cell feature

A

Impeller design
There is an impeller surrounded by vert slots called diffuser
Air is pumped also

184
Q

Particle size range for flotation

A

10 to 150 microns

185
Q

carat to mg

A

1 carat = 200 mg

186
Q

Pa to Bar

A

100,000 Pa = 1 bar

187
Q

Hp to kW

A

1 Hp = 0.746 kW

188
Q

cal to kJ

A

1 cal = 4.184 kJ

189
Q

Relation of attachment porbabitlity to diameter

A

inversely proportional

190
Q

Pulp density must be kept:

A
  • As dense as possible, so coarse can sep from fines

- but dilute enooguh for particle rearrangement

191
Q

Effect of temperature in flotation

A
  • Increased flotation room

- inc solubility of reagents

192
Q

DMS is most effective for

A

Metalliferous ore with light gangue

193
Q

What is a LARCODEM

A

Large Coal Dense Medium Separator

194
Q

Energy law: >1 cm

A

Kick’s

195
Q

Energy law: 10 - 1000 microns

A

Rittinger’s

196
Q

Energy law: 1 cm - 10 microns

A

Bond’s

197
Q

Measures or energy nec to break an ore

A

Work Index

198
Q

Net profit =

A

Revenue - Cost - Deductions

199
Q

Roughing descrp

A
  1. Uses mod seperating force to rem liberated minerals

2. Rec of bulk of conc

200
Q

Scavenging Descrp

A
  1. Receives tailings from rougher

2, Strong sep force for incompletely liberated minerals

201
Q

Receives rougher concentrate

A

Cleaning

202
Q

When to use Rougher-Scavenger

A

If Recovery is more important than grade

In pyritic gold, transport cost is less than add’l cleaning

203
Q

When is Rougher - Cleaner used

A

When Conc. grade is important

for easily recoverable ores

204
Q

Feed Character for impactor

A

Soft feed

205
Q

Why are Rod mills run in open circuit

A

due to evenness of product

206
Q

What are reclaimers

A

Stockpile with conveyance at bottom

207
Q

Bayer process

A
  1. Al2O3 dissolve is in molten cryolite
  2. Carbon anodes electrolytically collect O2 ions
  3. Molten Al is left
208
Q

Gangue Mineral for Lead zinc complex

A

Siderite

Mining (14 decks)

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