In the casting process, as a mould is filled with molten metal, air escapes through the vents. Air pressure in the mould cavity has serious effects upon the filling behaviour such as surface profile of the molten metal and filling time. In this project a computational model was developed for calculation of air pressure during the mould filling. A 3D single phase code based on the SOLA-VOF algorithm was used for the prediction of the fluid flow. The ideal gas assumption, conservation of mass equation and Bernoulli law were used for the calculation of air pressure. A new algorithm was developed to interpolate air pressure on the surface cells. The creation of air pressure was correlated with the sizes of the vents and their locations. An experimental test was designed to verify the modelling results. Comparison between the experimental data and simulation results has shown a good agreement.

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Although the operating properties of Galvanox TM leaching have been widely studied in the literature, several factors concerning chalcopyrite passivation during the process remain unknown so far. The present work hence aims at investigating the significant effect of externally added pyrite features with a particular focus on its particle size (d80 of 0.52, 20, 45 and 2000 µm) through a series of experiments performed in a 2-L stirred-tank electro-reactor. To this end, the role of pyrite: chalcopyrite ratio (0.49:1, 2:1 and 4:1) and presence of electrical current were examined while the rest of the parameters kept constant (80 °C temperature, 400-500 mV (Ag/AgCl) redox potential, pulp density of 10% (w/v), and stirring rate of 1200 rpm). Plus, kinetic models of the leaching tests were studied based on the diffusion and chemical controlling concepts. It was found that the coarser the pyrite particles, the more favorable the copper extraction from the concentrate due to acceleration of reactions in the cathodic electrode and high mass transfers. However, this was in contradiction with the existing reports in the literature. Moreover, galvanic interactions became intensive in the presence of pyrite meaning extensive chalcopyrite dissolution with significantly reduced passivation. Ultimate copper extraction values of 24.17±1.25%, 55.79±0.91% and 57.26±1.59% were resulted at Py:Cp ratios of 0.49:1 (natural), 2:1 and 4:1, respectively. The results showed that maximum copper recovery of 67.32±2.34% was obtained at an optimum condition of pyrite grain size=2000 µm, Py:Cp=4:1, current application=500 mA, 8 h and 80 °C. Finally, detailed kinetic modeling indicated that the chemical control mechanism was dominant in the early reaction stages (t<3.5 h) concerning the availability of fresh surface for chemical agents; however, the second half of the process (8.0 h>t>3.5 h) was controlled by the diffusion control.

In this investigation the effect of interaction between aqueduct and tunnel on the ground settlement has been examined using PFC3D. At first, the calibration of PFC3D was conducted based on UCS test results rendered from three different ground layer. Then intact model with dimension of 70 m × 20 m × 34.5 m (x × y × z) was built. These models are consisted of 8 layers with different mechanical and geometrical properties. Four different configurations for aqueduct were created in four models. Diameter of aqueduct was 2 m and its depth was different in four models. After aqueduct generation, tunnel with diameter of 9 m and length of 20 m was drilled in depth of 22 m. After tunnel drilling, the settlement data of ground surface were picked up. After tunnel simulation, the effect of support lining was investigated on the ground settlement. For this purpose, after each step of tunnel drilling, lining support with diameter of 35 cm was performed. The results show that the maximum value of settlement occurred when aqueduct reach to head of tunnel. Also the safety has maximum value when the distance between aqueduct and tunnel wall was 4.5 m. the ground settlement before and after support lining shows that ground settlement reach to zero by support application.

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