This work is aimed at the analysis of the development of flotation technology by applying carrier minerals. Based on the concepts of continuum mechanics, a theoretical analysis of the influence of the carrier minerals (wall) on the motion of a single solid particle is provided, taking into account their hydrodynamic interaction (in the case of low Reynolds numbers). A correction was obtained in the form of a ratio of the particle size to its distance from the wall to take into account the influence of the wall on the hydrodynamic force acting on the particle. The influence of the wall is manifested through a rapid approximation of the liquid vortex flow in the gap between the solid wall and the particle to the steady-state mode, accompanied by the suppression of the transverse movement of particles. When the liquid slides along a wall-mounted gas–liquid layer with a reduced viscosity, the liquid flow increases in the interfacial gap, which can be analyzed by a dimensionless correction that includes values describing the properties of a continuous medium (dynamic viscosity) and a disperse phase (geometric particle size). The reason for the decrease in the induction time when gold grains adhere to each other is assumed to be due to the forces of hydrophobic attraction (when the grains have a mirror-smooth surface) and the sliding of the flow along the hydrophobic surface of the particles along the gas layer (when the grains have a rough surface). When polydisperse particles are aggregated, the threshold energy of the fast coagulation was established to be lower than that arising during the interaction of monodisperse particles, whose aggregation requires a large depth of the potential pit. Performing natural experiments on the ore using a rougher concentrate as a carrier material showed that the concentrate yield decreases by 20.52% rel. In the second case, the gold extraction was higher by 4.69% abs. While maintaining the achieved level of gold extraction, the double mixing of the rougher concentrate and the initial feed increased the gold content in the rougher concentrate from 4.97 to 6.29 g/t.

The effective development of modern welding technologies and the improvement of equipment and materials inevitably require deep theoretical knowledge about the physical phenomena occurring in the electric arc column and in the near-electrode region. However, there is still no convincing theoretical description of an arc discharge. This article demonstrates, through the generalization of known experimental facts and studies using a high-speed camera, that the conductive channel of an electric arc has a discrete structure, consisting of a set of thin channels through which the main discharge current passes. The cathode spot of an arc discharge is a highly heated and brightly glowing area on the cathode’s surface. Electron emission occurs from this region, which supports the discharge as well as the removal of the cathode material. We propose a new technique to study the reverse side of the cathode spot, revealing a structure consisting of individual cells or fragments of the cathode spot. For the first time, we present the anode spots captured by a high-speed camera. We carry out an analysis of the spots’ structure. We determine the parameters affecting the mobility of cathode and anode spots. We propose a hypothesis based on the obtained experimental facts about the heterogeneous structure of cathode and anode spots in an arc discharge and the existence of current filaments that affect the mobility of spots during arc combustion.

The reclamation of exhausted open-pit coal mines is an energy-intensive and costly process. Traditional methods offer no economic return. This study explores the feasibility of using autonomous electric dump trucks (EDTs) to fill the pit, leveraging regenerative braking during descent to generate energy and reduce operational costs. A comprehensive energy balance model was developed based on the operational cycle of the Komatsu HD605-7 (E-Dumper) in the unique downhill-loaded logistics of the Pery quarry. The model incorporates vehicle dynamics equations, including rolling resistance, gradient, and aerodynamic forces, to calculate net energy consumption per cycle. Three energy storage system (ESS) configurations were compared: NMC/NCA batteries, LiFePO₄ (LFP) batteries, and a hybrid LFP + supercapacitor (SC) system. Simulation results demonstrate that the net energy per cycle decreases with increasing payload capacity, even becoming negative (net energy generation) for loads above 110 tons due to powerful regenerative braking on the 13% descent grade. The hybrid LFP + SC system proved most efficient, achieving the lowest specific energy consumption (kWh/ton) by effectively capturing high-power regenerative currents. While LFP batteries have a lower energy density, their superior cycle life, thermal stability, and safety make them the optimal choice for the harsh mining environment. The proposed operation strategy, utilizing EDTs in a downhill-loaded cycle, transforms mine reclamation from a cost center into a potentially energy-neutral or even energy-positive process. A hybrid ESS with LFP batteries and supercapacitors is recommended as the most reliable and efficient solution for this specific application.

Depending on operating conditions, metals and alloys are exposed to various factors: wear, friction, corrosion, and others. Plasma surface alloying of machine and tool parts is now an effective surface treatment process of commercial and strategic importance. The plasma surface alloying process involves adding the required elements (carbon, chromium, titanium, silicon, nickel, etc.) to the surface layer of the metal during the melting process. A thin layer of the compound is pre-applied to the substrate, then melted and intensively mixed under the influence of a plasma arc, and during the solidification process, a new surface layer with optimal mechanical properties is formed. Copper-based alloys—Cu-X, where X is Fe, Cr, V, Nb, Mo, Ta, and W—belong to an immiscible binary system with high mechanical strength, electrical conductivity, and magnetism (for Fe-Cu) and also high thermal characteristics. At the same time, copper-based alloys have low hardness. In this article, wear tests were carried out on coatings obtained by plasma alloying of CuSn10 and CrxCy under various friction conditions. The following were chosen as a modifying element: chromium carbide to increase hardness and iron to increase surface tension. It is noted that an increase in the chromium carbide content to 20% leads to the formation of a martensitic structure. As a result, the microhardness of the layer increased to 700 HV. The addition of CuSn10 + 20% CrxCy and an additional 5% iron to the composition of the coating improves the formation of the surface layer. Friction tests on fixed abrasive particles were carried out at various loads of 5, 10, and 50 N. According to the test results, the alloy layer of the Fe-Cr-C-Cu-Sn system has the greatest wear resistance under abrasive conditions and dry sliding friction conditions.

This article identifies the main types of solid fluorine-carbon containing wastes which may be processed with obtaining aluminium fluoride AlF3. There was calculated the mass of excess electrolyte, forming in the conditions of use of electrolyzers with baked anodes and “dry” gas purification. Experimental data of aluminium fluoride obtaining from wastes are shown. Implementation of this technology may reduce the consumption of fresh AlF3 by 6–8 kg per a ton of metal, and scarce fluorite concentrate consumption. Ecological situation in aluminium smelter regions may be significantly improved. The main waste types in Soderberg aluminum technology are: gas purification dust and sludges, coal froth flotation tails, electrolyzer overhaul materials, nonprocessed part of coal froth, mechanical wastes (dust, etc.). Aluminum production in electrolyzers with baked anodes and “dry” gas purification form the following wastes: electrolyzer overhaul materials, small amount of coal froth and excess electrolyte (a new type of wastes). Sodium oxide (Na2O), contained in alumina, causes the formation of excess electrolyte.Authors used the results of the investigations, carried out within the Federal Target Program “Investigations and developments by the priority ways of development of scientific-technical complex of Russia for the period of 2014-2020”. Unique identifier of applied research and experimental developments is RFMEF I 5 7 7 1 5 X 0 1 9 0.

This article briefly analyzes the possible approaches to control the energy mode of electrolyzers and the electrolyte composition. There was made a review of literature, describing the control of energy mode of different types of electrolyzers. The advantages and disadvantages of the different ways used in the world practice were defined. A correct temperature of electrolyte and overheat size are the major factors, defining the achievement of high technical and economic indexes of electrolytic aluminium obtaining. The methods of development of low-cost and effective method of electrolyzer energy mode control were defined on the basis of the studied materials. Experiments were carried out on development of the formula for the calculation of liquidus electrolyte temperature. There were studied the effects of various factors on the electrolyte thermal response during aluminum production. This work objective is to determine optimal parameters and create an algorithm to control the electrolyzers' energy mode by monitoring and automated maintaining of the operation voltage and the electrolyte temperature structure within the specified limits. On the basis of the created control algorithm, the computer program was worked out and its industrial tests were conducted on an operating production. The study results can be used in developing and implementing the technology of electrolyzer automated control for aluminum production.