Sulphate-rich wastewater is an increasing concern for industries as LKAB. The water chemistry of the LKAB Kiruna water system is characterized by high alkalinity, high pH (pH 7.5-9.0) and high concentrations of chemical species and soluble minerals. The sulphate content in the water system of Kiruna is associated with the dissolution of calcium sulphate as anhydrite (CaSO4) and gypsum (CaSO4 2H2O). However, the high concentrations of sulphate in the effluents from the LKAB Kiruna operation are unique for iron ore mining.    The aim of the thesis was to study and evaluate the behavior of sulphate in the process water system of the Kiruna concentrator plants. This was done by laboratory grinding (leaching tests), equilibrium calculations with the HSC software and mass balancing of the concentrator KA3 in Kiruna. The highest concentrations of sulphate have been detected in the process water of KA3, hence the focus has been on KA3 regarding sampling, evaluation and comparison. Water treatment technologies for sulphate and the effect of process water on ore processing have not been included in this project.   The laboratory grinding was done using process water and ore from the concentrator KA3. During the experimental work with laboratory grinding the parameters pH, temperature and operating times for primary- and secondary grinding, respectively, were varied. The observations from the experimental work were further confirmed by equilibrium calculations and mass balancing. The following conclusions were drawn.     Anhydrite/gypsum is not leached from the ore during ore processing with process water having concentrations of sulphate already close to the saturation point at approximately 1800 mg/L. If the process water is diluted with water with lower sulphate content, e.g. mine water or a diluted return water from the pond system (e.g. during spring flood), anhydrite/gypsum in ore will be dissolved until the sulphate concentration reaches the saturation point. The ionic strength of the process water controls the saturation point and thus the sulphate concentration. Leaching of anhydrite/gypsum in saturated process water, with respect to sulphate, is not affected by grinding time or adjusted conditions in the process water, such as temperature or pH value.    For further work, it is recommended to investigate the behavior of sulphate in the tailings pond system to increase knowledge of the overall behavior in the water system. In addition, a similar investigation of the behavior of uranium in the process water is recommended in order to face future environmental standards.

A run-of-mine (ROM) ore milling circuit is primarily used to grind incoming ore containing precious metals to a powder fine enough to liberate the valuable minerals contained therein. The ground ore has a product particle size specification that is set by the downstream separation unit. A ROM ore milling circuit typically consists of a mill, sump and classifier (most commonly a hydrocyclone). These circuits are difficult to control because of unmeasurable process outputs, non-linearities, time delays, large unmeasured disturbances and complex models with modelling uncertainties. The ROM ore milling circuit should be controlled to meet the final product quality specification, but throughput should also be maximised. This further complicates ROM ore grinding mill circuit control, since an inverse non-linear relationship exists between the quality and throughput. ROM ore grinding mill circuit control is constantly evolving to find the best control method with peripheral tools to control the plant. Although many studies have been conducted, more are continually undertaken, since the controller designs are usually based on various assumptions and the required measurements in the grinding mill circuits are often unavailable. / To improve controller performance, many studies investigated the inclusion of additional manipulated variables (MVs) in the controller formulation to help control process disturbances, or to provide some form of functional control. Model predictive control (MPC) is considered one of the best advanced process control (APC) techniques and linear MPC controllers have been implemented on grinding mill circuits, while various other advanced controllers have been investigated and tested in simulation. Because of the complexity of grinding mill circuits non-linear MPC (NMPC) controllers have achieved better results in simulations where a wider operating region is required. In the search for additional MVs some researchers have considered including the discrete dynamics as part of the controller formulation instead of segregating them from the APC or base-layer controllers. The discrete dynamics are typically controlled using a layered approach. Discrete dynamics are on/off elements and in the case of a closed-loop grinding mill circuit the discrete elements can be on/off activation variables for feed conveyor belts to select which stockpile is used, selecting whether a secondary grinding stage should be active or not, and switching hydrocyclones in a hydrocyclone cluster. Discrete dynamics are added directly to the APC controllers by using hybrid model predictive control (HMPC). HMPC controllers have been designed for grinding mill circuits, but none of them has considered the switching of hydrocyclones as an additional MV and they only include linear dynamics for the continuous elements. This study addresses this gap by implementing a hybrid NMPC (HNMPC) controller that can switch the hydrocyclones in a cluster. / A commonly used continuous-time grinding mill circuit model with one hydrocyclone is adapted to contain a cluster of hydrocyclones, resulting in a hybrid model. The model parameters are refitted to ensure that the initial design steady-state conditions for the model are still valid with the cluster. The novel contribution of this research is the design of a HNMPC controller using a cluster of hydrocyclones as an additional MV. The HNMPC controller is formulated using the complete nonlinear hybrid model and a genetic algorithm (GA) as the solver. An NMPC controller is also designed and implemented as the base case controller in order to evaluate the HNMPC controller’s performance. To further illustrate the functional control benefits of including the hydrocyclone cluster as an MV, a linear optimisation objective was added to the HNMPC to increase the grinding circuit throughput, while maintaining the quality specification. The results show that the HNMPC controller outperforms the NMPC one in terms of setpoint tracking, disturbance rejection, and process optimisation objectives. The GA is shown to be a good solver for HNMPC, resulting in a robust controller that can still control the plant even when state noise is added to the simulation. / Dissertation (MEng)--University of Pretoria, 2018. / National Research Foundation (DAAD-NRF) / Electrical, Electronic and Computer Engineering / MEng / Unrestricted

The aim of this thesis is to design a one-purpose machine for grinding concrete light-permeable bricks LiCrete. The bricks LiCrete are a new interior design component. The final step of manufacturing is wet grinding with high quality and accuracy. At the same time it is grinded the concrete and light-permeable parts made by polymethylmethacrylate (PMMA). It is important to keep size and quality appearance of the bricks. The research part contains description of the problems related to the grinding of the bricks LiCrete. The next part is about conceptual variants of the solution. The construction contains the complex solution of one-purpose machine with technical drawings. The last part include a conceptual design of continuous high-productive machine for grinding LiCrete bricks.

Layered double hydroxides (LDHs) are clay-like minerals commonly referred to as anionic clays" with a wide range of physical and chemical properties. LDHs often find application in pharmaceuticals, as polymer additives, as additives in cosmetics, as nanomaterial's and in catalysis. This is due to having variable layer charge density, reactive interlayer space, ion exchange capabilities, a wide range of chemical compositions and rheological properties (Forano et al., 2006). Various techniques exist for the synthesis of layered double hydroxides. These include co-precipitation, the urea method, induced hydrolysis, sol-gel and hydrothermal methods. Many of these produce environmentally unfriendly effluents or by-products, are energy intensive, make use of metallic salts or require inert synthesis environments (Rives, 2001). Limitations associated with these existing processes make LDH synthesis at an industrial level expensive or difficult to achieve. The need for 'green', affordable and repeatable synthesis methods are therefore often sought after. Recently the use of mechanochemistry as an alternative synthesis technique has gained wide-spread attention. Mechanochemistry involves the breaking and forming of chemical bonds due to an induced mechanical force. Various mechanochemical techniques for the synthesis of LDH materials exist or have been explored. These include methods such as single-step, two-step and mechano-hydrothermal grinding techniques. Grinding methods can be conducted dry, wet or collectively (Qu, Zhang, et al., 2015a). Mechanochemistry has further been used in conjunction with micro-wave energy and ultrasonic irradiation. The use of mechanochemistry as a synthesis method has proven to be promising with successful and unique LDHs produced. Intercalation of unique or complex anions within the interlayer has further been proven possible. The versatility and robust nature of this synthesis method makes it ideal for industrial application. Although many studies exist it was noted that limited research has been conducted on single-step wet grinding for LDH synthesis and warrants further investigation (Qu, Zhang, et al., 2015a) (Iwasaki,Yoshii, et al., 2012). This was due to factors such as incomplete conversion, difficulties associated with grinding and morphological imperfections. Single step wet milling could be benifi cial as a synthesis procedure as it eliminates hazards associated with dry powder, contains less process steps and is therefore possibly more cost effective and can be conducted batch, semi-batch or continuously due to fluid flow. Throughout the literature research conducted it was further noted that not many different milling devices have been explored. Ball mills, mixer mills and manual grinding were the most common methods used to supply mechanical energy to a system. The study therefore aims to expand on single-step wet synthesis of LDH materials by making use of a different milling device, namely a Netzsch LME 1 horizontal bead mill. The selected mill is designed for wet grinding application and can easily be up-scaled to a commercial batch, semi-batch or continuous process. Raw materials selected were a combination of oxides, hydroxides and basic carbonates. This would eliminate hazardous salt by-products and effluent, promoting 'green' synthesis of LDH materials. It was noted that the synthesis of LDH with the use of these materials have previously proven to be challenging (Qu, Zhang, et al., 2015a). The study was divided up into two sections namely a 'parameter study' and a 'versatility study'. The 'parameter study' involved exploring the in influence of milling and experimental parameters, such as rotational speed, retention time, solids loading, bead size and jacket water temperature, on the synthesis of Mg-Al LDH. The raw materials selected were MgO and Al(OH)3 combined at a divalent to trivalent cationic ratio of 2:1. The parameters were individually investigated, with the exception of jacket water temperature as it was varied with a change in retention time and a change in rotational speed. Unless stated otherwise or under investigation, parameters were investigated at a set speed of 2000 rpm, jacket water temperature of 30 °C, solids loading of 10 %, retention time of 1 h and with 2 mm yttrium stabilised zirconia beads. Therefore when investigating a specific c parameter, the others remained as stated above. Comparatively the 'versatility' study further explores the synthesis of Mg-Al, Ca-Al, Cu-Al and Zn-Al LDH by adapting optimal synthesis conditions, derived from existing mechanochemical techniques and methods, to the selected process. These were related to the divalent to trivalent cationic ratio and selected starting materials. Ageing of the samples obtained through the 'versatility study' were further explored to determine if the potential for a two-step commercial process exists. The study was investigated at a set speed of 2000 rpm, jacket water temperature of 30 °C, solids loading of 10 %, retention time of 1 h and with 2 mm yttrium stabilised zirconia beads. Half of the sample collected was subjected to ageing at 80 °C for 24 h under atmospheric conditions. / Dissertation (MEng (Chemical Engineering))--University of Pretoria, 2020. / This research was funded by Techsparks (Pty) Ltd and the Technology and Human Resources for Industry Programme (THRIP) administered by the Department of Trade and Industry, South Africa, (grant number THRIP/133/31/03/2016) / Chemical Engineering / MEng (Chemical Engineering) / Unrestricted

This master‘s thesis is presenting the way of the optimization of grinding characteristics when grinding cemented carbides by diamond wheels. There is described the theory of grinding, including grinding wheels and basic characteristics of cemented carbides in the theoretical part. There are defined experimental metering accomplished on the CNC grinding machine Walter Helitronic Power Mini in the practical part. There were tested eight grinding wheels. The grinding rate, surface roughness Ra, theoretic guaranteed storage period of grinding wheel in number of cuts, theoretical capacity of machined material, achievement of grinding machine and behaviour of the wheels when grinding ware evaluated from the reached results.

This work describes the construction of polymer - concrete frame of a machine tool. In particular it deals with the proposal of cast iron frame for the surface grinding machine BHP from the company KMS Brno, which should at all point replace the original cast iron frame of the same machine. The whole work is divided into two sections. First section consists of the research including a brief mention of the grinding technology in the reference to the construction of the frame of the grinding machine. Further the work deals with the theoretical knowledge regarding construction of frames of the machine. Finally it describes issues related to the technology of polymer – concrete and the production technology of parts from this material. Second section of the work consists of an engineering proposal of polymer – concreted frame considering the requirement of the main functional dimensions related from the structural measures. Subsequently the system approach and the principals for transition to the polymer – concrete construction of the grinding machine are made. The work concludes with the analysis and comparison of the two concepts (cast iron frame and polymer – concrete) in the terms of the Finite element method.

During machining play the size off component deciding role from the viewpoint of their behaviour. This is result of „size effect”, which turns common characteristic cutting process. The aim of diploma thesis was contribute piece of knowledge verification of this effect and the further exploit during machining. The main interest is directed to the relation between the cutting edge and depth of cut.

This diploma thesis presents theoretical possibilities of force/torque control algorithms for industrial robots equipped with force sensor so it deals with interaction between industrial robot and environment. The most important types of control schemes are presented. Practical part deals with design gripper for specific workpiece and for grinding using industrial robot with force feedback. For this operation is given force/torque control design, using industrial robot KUKA KR16, FTC sensor SCHUNK FTC 50-80V and PLC. Further deals with compensation of gravity and dynamics forces.

In the thesis is solved manufacturing technology of step drill from material of cemented carbide. At first is made review of existing shank cutting tool types, after that follows an analysis of cemented carbide tool material. In the next part of thesis is manufacturing technology of this tool, including review of grinding wheels, designed. Output of this work is procedure of program designing for manufacturing this tool in software Numroto. Next output is techno-economic evaluation of step hole manufacture with combined tool and comparison to conventional type of manufacture.

The goal of my thesis is to design a support for a CNC horizontal surface grinder, using the working area of grinding wheel circumference. The proposal is based on the client’s requirements for several variants of the propulsion drive and guide systems.