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By C. J. Li, J. L. Feng

In the present study we focuses on developing the poroelasticity model that deals with adsorptioninduced permeability change mostly occurred in porous media constituted several phases such as coal. The underlying pressure induced by adsorption is obtained by Virial expansion form, which is substantially founded on statistical physics. The corresponding thermodynamic pressure applying on the pore surface is then used to detail the pore pressure and further to evaluate the macroscopic volumetric strain and the porosity. In the process of physical adsorption, the adsorbed phase is in thermodynamic equilibrium with the gas phase regardless of pore size, and the corresponding chemical potentials are all equal. The relationship between surface strain and volumetric strain is derived under infinitesimal deformation conditions to gain an explicit formulation of pore surface area with respect to volumetric strain and porosity. After the formulation of surface stress modified by the Langmuir isothermal adsorption is derived, the differential micromechanical constitutive equations of porous media are obtained. By supposing that the ratio of current permeability to initial is equal to the cubic ratio of current porosity to initial porosity, the differential equations for permeability change is consequently derived. The numerical simulations by the present model for permeability change of coal induced by adsorption of CO2 and CH4, respectively, are presented under confined stress conditions. The predictions from the model are good in agreement with the experimental data of sorption-induced permeability change of coals in the literature.

Jan 1, 2015

By A. Sand

Within stamp-charged coke making a large volume of coal is compacted to one single coal cake before entering the coke oven chamber. This is done by means of several falling stampers in a stamping machine having a mold nearly of the oven?s dimensions. Producing a high quality coke also from inferior coals requires a cake density of approximately 80% of the coal density. Besides that the industrial stamp-charging process demands a minimum mechanical strength of the coal cake to move it from the stamping mold into the oven chamber without failure. Densification and the build-up of cake strength were investigated earlier in stamping tests using a micro-stamping device. The quantities derived from these tests (as e.g. cake density or porosity) represent average values for the entire cake. Statements describing the local compaction state at different heights are difficult to achieve without destructing the cake. In order to gain better insight into the densification process and the inner structure of the coal cake a computational model based on the discrete element method (DEM) has been set up using 2 and also 3-dimensional simulation software. The stamper?s position and velocity as well as the force acting on the stamper were monitored and the model?s response was compared against measurement data from laboratory stamping tests. It was possible to reproduce the force and displacement pattern of the stamper in response to the viscoelastic properties of the cake using standard DEM bonding and contact models. Furthermore, the rearrangement of particles in response to the compaction by the stamper was tracked by calculating their displacement at the point the stamper hit the coal surface. The latter can also be used as indicators of particle deformation or breakage. By defining control points at different heights the particle displacement, stress and strain rates, porosity could be studied at different heights. Keywords: coke making, coal stamping, compaction, agglomeration, DEM, simulation

Sep 1, 2012

By Jared Ball, Darren Snashall, Paul Telford, Pengfu Tan, Ben Hogg

"The foamed converter charges were up to 3 8 per month in Xstrata Copper Smelter at Mount Isa. The issue of high converter foamover frequency had remained unsolved for many decades in Mount Isa. A thermodynamic model of copper P-S converter and a viscosity model of converter slag have been developed to simulate the slag blow and copper blow, in order to understand the mechanism of converter foamover. The model predicts the chemistry and viscosity of slag during slag blow and copper blow. The effects of oxygen potential, charge of dirty reverts, slag carryover, under-blowing, over-blowing, and temperature on the foamover and viscosity of slag in copper blow have been discussed. A theory has been developed to understand the mechanism of converter foamover. The practical solutions have also been developed and implemented in Mount Isa Copper Smelter. Some improvements of the industrial operations have been presented. After a series of improvements, the number of foamed charges per month in the converter operations has been decreased significantly from 35 in Aug 2008 to only one per month in 2009/2010.1. IntroductionThe Copper Smelter in Mount Isa receives the concentrate containing about 25% copper and produces anode copper that contains about 99% copper. There are several stages in the process. The first stage carries out in the ISASMELT™ furnace. The ISASMELT™ process produces a molten copper matte containing about 60% copper. An iron-silica slag and a sulfur dioxidebearing off-gas are the by-products of the process. The slag is taken to the slag dams for cooling before it is recycled through the Mount Isa Copper Concentrator.The matte is sent to Peirce-Smith converters. The converters further remove iron and sulphur to produce blister copper which contains about 97% copper. The anode furnaces remove any remaining sulphur and oxygen to produce anode copper that is about 99. 7% pure. This is cast into anodes and sent to the Xstrata Copper Refinery in Townsville for final refining.In the copper pyrometallurgical industrials, slag foaming is an important phenomena which occurs when the gas bubbles have stability and not rupture. Foaming greatly increases the interfacial area between matte, slag and gas and is essential for the operation of high intensity smelting processes. However, foaming or foamover is undesirable in P-S converter since it can damage the equipment and injure the operators. Figure 1 shows that the whole process of a foamover development in a converter."

Jan 1, 2011

By M. M. Botz

Cyanidation tailings which are disposed in a surface impoundment experience a loss of cyanide due to natural degradation, frequently reducing the cyanide concentration to very low levels. Quantifying cyanide losses in terms of pond geometry, local weather conditions and feed solution chemistry has been largely empirical though in many cases mining operations rely on surface impoundments to reduce cyanide to below an internally regulated concentration or an effluent limitation. To permit a more quantitative evaluation of cyanide losses in an impoundment, a computer simulation was developed to estimate the losses of free, WAD and total cyanide due to dissociation, photolysis and volatilization. Results of the model are compared against data collected for a North American tailings impoundment during 1998.

Jan 1, 1999

By Yaming Chen, Gerry Papini

This paper presents a case study of three-dimensional groundwater modeling of a proposed open pit at a gold mine project with historic flooded underground (u/g) mine workings in British Columbia, Canada. The modelling approach for dewatering the open pit included passive dewatering by draining water under natural hydraulic gradients and active dewatering by using active dewater wells, together with residual water drains. Target water level drawdowns behind the pit wall were used to determine the number and depths of dewatering wells to meet the slope stability requirements and in estimation of pit inflow rates. Conceptualizing the u/g mine workings and assigning appropriate flow boundary conditions throughout the life of the mine posed some unique challenges.

Sep 30, 2022

By Troy Williams, Chris Preston, Ian Lipchak

"Underground blasting operations are challenging from the standpoint of the distribution of explosivesenergy representative of ring blasting. Energy from both shock and pressure regimes of commercialexplosives may appear concentrated in the collar region of a typical ring blast and diluted at the toes of holes due to the oblique geometries of blastholes. The non-homogenous nature of ore in whichexplosives are distributed via drillholes, adds to the complexities of generating particulate profiles from fragmented material with consistencies that are predictable from blast pattern to blast pattern - well suited for specific underground handling equipment and mill processing. In an ideal world, it would be the blasting operations themselves that represent the primary crushing mechanism, or at least mitigate mechanical crushing that can comprise a large component of the cost in generating suitable muck. This paper presents a dynamic break view in 3D that allows a planner to visualize the potential break zone around a blasthole generated by an explosive load using a Kleine field. Simple as it sounds, this methodology provides information that can be used in conjunction with cavity monitoring surveys (CMS) to potentially judge dilution due to overbreak as well as recovery for a typical blast. As examples, there are two break geometries that are examined regarding circular breaks and elliptical breaks around blastholes. Using a Kleine field to define break, a planner generated isosurface can be generated and compared to CMS data for calibration and prediction, using AEGIS 3D ring design software."

Jan 1, 2016

By James P. Bennett

EAF slag chemistry and its control have been recognized as important in producing quality steel at a low price for a number of decades. EAF steel producers make lime and dolomite additions to furnaces, controlling the CIS ratios and sulfur pickup from the steel. Existing phase diagram data at 1600°C for CaO, MgO, FeO, SiO2, and Al2O3 was used to write a computer model optimizing slag chemistry for slag foaming and reduced refractory wear. The model, its development, and its use in an industrial steelmaking environment will be discussed along with how the model can improve energy efficiency. The importance of EAF mass balance to account for critical materials like Si in scrap and refractory wear using the model will also be emphasized.

Jan 1, 2003

By James P. Bennett

EAF slag chemistry and its control have been recognized as important in producing quality steel at a low price for a number of decades_ EAF steel producers make lime and dolomite additions to furnaces, controlling the CIS ratios and sulfur pickup from the steel. Existing phase diagram data at 1600°C for CaO, MgO, FeO, SiO2, and Al2O3 was used to write a computer model optimizing slag chemistry for slag foaming and reduced refractory wear. The model, its development, and its use in an industrial steelmaking environment will be discussed along with how the model can improve energy efficiency. The importance of EAF mass balance to account for critical materials like Si in scrap and refractory wear using the model will also be emphasized_

Jan 1, 2003

By M Reza Afshar

In this work a mathematical model was developed to study the effect of electromagnetic force on the magnesium melt containing nonmetallic inclusion in an electrical isolated channel. The electromagnetic force exerted on the inclusion induced by DC current field was calculated. A three dimensional turbulent flow equations were solved numerically to compute the velocity field within the channel. On the basis of computed velocity and magnetic fields, the trajectories of inclusions were calculated using the equations of motion for inclusions. Parametric studies were carried out to evaluate the effect of various parameters such as current density, channel diameter and particle density on the removal efficiency of inclusions from magnesium melts.

Jan 1, 2004

By Nagy El-Kaddah, T. T. Natarajan

This paper describes a novel approach for modeling three-dimensional electromagnetically driven flow in inductively stirred systems, and its application to modeling electromagnetic and flow phenomena in sub-mold rotary stirring of billets. It is based on a new T-\jf potential formulation of electromagnetic field, which does not require the calculation of the field in free space. A finite element algorithm has been developed for solving the electromagnetic field and Navier-Stokes equations in the fluid flow domain. The computed results have shown that the electromagnetic force field generates a strong rotational flow within the vertical section covered by the stirrer, and a relatively strong secondary flow beyond the stirrer. It has also been shown that the rotational and secondary flows were driven primarily by the vorticity of the force field at the billet corners. The induced flow in the molten pool was found to be turbulent and the effective mixing region in the molten pool was about three times the length of the stirrer. The mathematical approach presented in this paper provides the theoretical framework for quantifying these effects for any given stirrer configuration and operating parameters.

Jan 1, 1999

By Evgenii Pavlov, Ivan Tronin, Viktor Timofeev, Vladimir Kislov, Sergei Bogovalov

"Modeling of the magnetohydrodynamical (MHD) and thermodynamical processes during the industrial scale Direct Chill (DC) casting of aluminum slabs is performed using a combination of ANSYS/CFX and ANSYS/EMAG software. The electromagnetic field is modeled through ANSYS/EMAG, while hydrodynamic and thermodynamic processes are modeled through ANSYS/CFX. Both packages were modified in order to calculate MHD flows in the liquid pool that forms during aluminum DC casting, and they were unified into a software combination that provides simultaneous simulation of all the above processes. The simulation shows that the electromagnetic stirring of the molten aluminum changes the shape of the solidification front (solid-liquid interface) very dramatically, namely it becomes significantly flatter. This effect should improve the internal structure of aluminum DC slabs and allows us to increase the casting velocity.IntroductionProduction of Aluminum alloys with high mechanical properties and structural uniformity is one of the main goals of industry. The preferred production method of aluminum alloys in most modern plants is Direct Chill (hereafter DC) casting because it offers high productivity and commercial success. One important limitation of this technology is the development of centerline shrinkage in slabs larger than about 1 meter. The improvement of the internal structure of long DC cast slabs can be achieved by electromagnetic stirring (hereafter ES) of the liquid metal above the solidification front. This intensifies heat transport in the zone close to the solidification front and suppresses shrinkage formation."

Jan 1, 2013

By Shawn A. Cefalu, Matthew J. M. Krane, Kent J. VanEvery

"Segregation during electroslag remelting (ESR) of a nickel-chromium-molybdenum alloy (Ni-8 wt% Cr-25 wt% Mo) has been modeled. Features of the model include species transport and AC electromagnetic effects coupled with fluid flow, heat transfer, and solidification. The effect of varying ingot diameter and melt rate, on macrosegregation patterns, local solidification time, and liquid pool profiles obtained from this model are demonstrated. The results show that the macrosegregation in the ingots correlates to the filling velocity.IntroductionElectroslag remelting (ESR) is a secondary melting process used to refine the chemical composition and the microstructure of metals. Macrosegregation of solute elements causes defects in ESR ingots, including freckles and the maldistribution of phases. These defects are not correctable through heat treatment due to the large length scales over which they occur. However, the frequency and distribution of these defects may be minimized, or even prevented, through process control based on an understanding of the conditions that lead to their formation.In the past, studies have been conducted on the effect of the process parameters on the shape of the melt pool and the thickness of the mushy zone [1-7]. In these studies, the shape of the liquid pool is determined by consideration of the heat and fluid flow induced by electromagnetic (Lorentz) force and thermal buoyancy. The transport of solute and the resultant solutal buoyancy effects were not considered in these macroscopic models. Defect formation is tied to formation of secondary phases (e.g., freckling and white spots in nickel superalloys) [5,8]. In cases where secondary phase formation is calculated (e.g., [6]), phase fractions are determined using a micro-scale model given the local solidification time (LST) and local thermal history from the macroscale model.Using the local thermal history from the macroscopic transport model to predict microstructure increases the importance of the accuracy of those results. This investigation models the macrosegregation of molybdenum during the ESR of a Ni-Cr-Mo alloy. The effect of macrosegregation on pool shape and depth is demonstrated, along with its effect on the local solidification time. By comparing the relative effects of the melt rate and ingot radius, a better understanding of the factors that affect macrosegregation, and ultimately secondary phase formation may be obtained."

Jan 1, 2004

By R. Simon

Strain-burst phenomena are generally characterised by sudden releases of energy in a volume of highly stressed rock. Strain bursts are encountered in situations such as crown pillar bursts during cut-and-fill mining, face bursts at development headings cord floor bursts in deep shaft sinking. This paper describes a simple two-dimensional linear elastic FE modeling approach that leads to the calculation of the energy-release rate (ERR) and the total energy storage rate (TESR) in the rock-mass around the openings. The merits of using such energy parameters in the analysis of strain-burst problems for identifying areas of high energy release/storage are discussed through a case stud v. However, much site-specific back analyses are needed to better understand how strain bursts and energy parameters are interrelated.

Jan 1, 1999

Strainburst phenomena, generally characterized by a sudden release of energy in a volume of highly stressed rock, are often encountered in such situations like crown pillar bursts in cut-and-fill mining, face bursts at development headings and floor bursts in deep shaft sinking. This paper describes a simple FE modeling approach which leads to the calculation of the energy release rate (ERR) and the total energy storage rate (TESR) in the rock mass around the openings. The merits of using such energy parameters in the analysis of strainburst problems to identify areas of high energy release/storage are discussed. However, much site-specific back analyses are needed to better understand how strainbursts and energy parameters are inter-related.

Jan 1, 1998

By S. Esfahani, M. Barati

Heat recovery from blast furnace slags is often contradicted by another requirement, to generate amorphous slag for its use in cement production. As both the rate and extent of heat recovery and slag structure are determined by its cooling rate, a relation between the crystallization kinetics and the cooling conditions is highly desired. In this study, slags with different basicities were studied during non-isothermal cooling. Their continuous cooling transformation (CCT) diagram were plotted and compared with each other. Then, a mathematical model was developed that predicts the amount of crystallization during cooling. The results were validated by experiments performed by Single Hot Thermocouple Technique and image analysis. A second mathematical model that calculates temperature history of slag during its cooling was coupled with the above model, to allow optimizing the slag/air ratio for both heat recovery and slag glass content.

Jan 1, 2015

By Leslie C. Taylor, Anthony L. Kee

Computational modeling of explosively loaded saturated sand on a suspended plate is an inherently complex problem. In this study a computational method is used to predict the dynamic pressure load/impulse from a buried charge. A fully coupled code modeling the explosive charge, sand and air with a Eulerian mesh and the plate structure with Lagrange elements, such as Gemini-Dyna, is an appropriate computational tool. In water-saturated sand, the loadings are soil and water-transmitted shock and bubble or blast effects depending on the depth and the charge size. The computations provide the capability to determine the total impulse load placed on a horizontal plate on or above the soil due to an explosion in the saturated sand for different burial depths in saturated sand and different plate stand off distances. The following test case will be presented: (a) 4.5 Kg (10 lbs) TNT, 10.16 cm (4 in) depth of burial to top of charge, and 20.32 cm (8 inch) stand off distance (Test 4).

Jan 1, 2005

By C. Tan, C. Detournay

Wellbore stability is a major concern for drilling in naturally fractured formations. The infiltration of drilling mud into the fractures is a factor, which may compromise wellbore integrity due to the loss of strength experienced by the fractures. The reduction in the fracture frictional and cohesive properties is attributed to weakening of the infill materials and lubrication of fracture asperities by the mud filtrate. One way to investigate the influence of mud infiltration on wellbore stability in fractured formations is to use a numerical modeling approach. A requirement for the numerical model is the ability to predict the region of mud infiltration. This paper describes a numerical technique to model the extent of mud infiltration for application in coupled fluid-mechanical simulations in densely fractured rock masses using the computer code, UDEC. Several factors are considered including fracture pattern, in-situ stresses, reduction in joint frictional angle and cohesion, viscosity of the mud filtrate and fracture plugging. Results of numerical simulations are presented to illustrate the technique and show the influence of these factors on the extent of mud infiltration. Un des problèmes importants posés par le forage en milieu fissuré saturé, est celui du maintient de la stabilité du puit. L’infiltration de boue de forage dans le massif peut avoir pour effet de réduire les propriétés frictionnelles et cohésives des fractures et de compromettre ainsi la stabilité du puit de forage. Le radoucissement des propriétés des fractures est attribué à la dégradation du materiau de remplissage et au pouvoir lubrifiant des boues. L’analyse numérique offre un moyen d’investiguer l’influence jouée par l’infiltration de boue sur la stabilité du puit. Un des critères de sélection du modèle numérique sera son pouvoir de prédiction du domaine d’infiltration de boue. Cet article décrit une technique numérique permettant de modéliser l’infiltration de boue de forage dans le cadre de simulations hydro-mécaniques, en milieu à haute densité de fractures, effectuées avec le logiciel de calcul UDEC. Parmis les facteurs tenus en compte, on trouvera la nature du réseau de fractures, les contraintes in-situ, le radoucissement en friction et cohésion des joints, la viscosité de la boue et le bourrage des fractures. Des résultats de simulations sont présentés pour illustrer la technique et montrer l’influence de ces facteurs sur la taille du domaine d’infiltration de boue. Bohrlochstabilität ist ein wichtiger Aspekt für das Bohren in geklüfteten Gebirgsformationen. Das Eindringen der Bohrlochstützflüssigkeit in die Klüfte kann die Bohrlochintegrität wegen des Verlustes der Festigkeit des Kluftsystems gefährden. Die Reduktion der Reibung und kohäsiven Eigenschaften ist der Schwächung der Kluftfüllung und der Schmierwirkung der eingerungenen Stützflüssigkeit in Bezug auf die Kluft-Asperities geschuldet. Numerische Berechnungen sind ein Weg zur Untersuchung des Einflusses der Infiltration der Bohrlochstützflüssigkeit auf die Bohrlochstabilität in geklüfteten Gebirgsformationen. Eine Voraussetzung für numerische Modelle ist die Fähigkeit den Bereich der Infiltration der Stützflüssigkeit zu prognostizieren. Diese Publikation beschreibt ein numerisches Verfahren, um die Reichweite der Infiltration von Stützflüssigkeiten mittels fluid-mechanisch gekoppelter Simulationen im engständig geklüfteten Gebirge mit dem Programm UDEC zu modellieren. Verschiedene Faktoren, wie Kluftmuster, Gebirgsspannungszustand, Reduktion von Kluftreibungswinkel- und kohäsion, Viskosität der Stützflüssigkeit und Rissabdichtung wurden untersucht. Ergebnisse numerischer Simulationen werden präsentiert, um die Vorgehensweise zu illu

Jan 1, 2003

By Akul Joshi, Ming C. Leu, Robert Guttenberg, Susan L. Murray

The aerospace and automotive industries are facing a significant risk for cumulative trauma disorders from high-repetition, long-duration tasks. Additional risk factors such as shocks, vibrations and sustained uncomfortable postures oftentimes contribute to musculoskeletal, neurological injuries associated with the hand-arm system. The power tools used for the operation reduce the comfort and working efficiency of the operators, thus lowering their health and safety and the quality of operation. This paper investigates the fastening operation on the assembly line of a major aerospace company for quantifying hand-arm vibrations with the objective of developing a dynamic model of the hand-arm system. The model will be used to ascertain the effect of the various risk factors on the quality of the operation. Experiment Setup A system of three tri-axial accelerometers is used to collect vibrations entering the hand-arm system and their positioning follows the ISO-5349 standard. Reaction force during the operation is measured using a force sensor. The posture of the hand-arm system is measured using two goniometers and one torsiometer. The pilot study conducted has two subjects and one pistol-grip power tool. The experiment setup and positions of various sensors is depicted in Figure 1. [ ] Analysis Method The analysis consists of transmissibility of vibrations and frequency weighted acceleration based on the recommendations of the ISO-5349 standard [1,2]. The transmissibility [3] was deduced in frequency domain after measuring data in time domain from the

Jan 6, 2006

By Kenneth P. Michalek, James E. Kelly, Jonathan A. Dantzig

"Many investigations have been reported regarding the simulation of continuous casting with emphasis on in-mold heat transfer. These analyses have been limited, however, because they require either estimation or measurement of the characteristic heat transfer between the ingot and the mold. In this paper, a self-consistent model 'is presented for calculating the heat transfer between a solidifying continuous casting and the mold, in the context of the continuous casting of steel. Using both thermal and stress analyses, the air gap formed during continuous casting is calculated and used to compute the heat transfer coefficients. Iteration between the thermal and stress analyses is used to determine a self-consistent solution. IntroductionThe continuous casting process for steel is illustrated schematically in Fig. 1. Molten steel is tapped into a tundish from which it flows at a controlled rate into the continuous casting mold. The initial shell of the casting forms in the mold by transfer of heat from the metal through the mold wall to the cooling water. The remainder of the casting is solidified by application of water sprays, and/or radiation cooling below the mold.Heat transfer in the mold portion of the process is important because it controls the formation of various defects which are deleterious to subsequent processing. Examples of defects formed in this region are surface irregularities, such as cold folding and oscillation marks, and more serious defects, such as longitudinal or transverse cracks. A more catastrophic problem which may occur is a breakout, in which the shell ruptures and molten steel is discharged in an uncontrolled way."

Jan 1, 1986

By Mostafa O. El-Bealy

"To estimate the interdendritic cracking tendency in casting processes, a new model for interdendritic cracking criteria has been proposed. The model combines a concept of the alloying element effect on the interdendritic strain generation and therefore on the susceptibility of interdendritic cracking phenomena. A susceptibility of interdendritic cracking is modeled by using El-Bealy's interdendritic cracking susceptibility function ""BJCSF' and the opening displacement between the dendrites ""EIA "". These concepts are modeled based on the previous experimental observations and ElBealy' approach. The model is implemented numerically for a one-dimensional model problem with some similarities to the casting of steel. The variation of some key parameters that are known to influence the frequency and severity of the interdendritic cracking is then studied.I. INTRODUCTIONInterdendritic cracking ""hot tearing"" commonly encountered in both ferrous and nonferrous castings (1,2]. It is generally believed that interdendritic cracks start to nucleate and develop in the interdendritic strain region within the mushy zone [l-5]. The interdendritic strain region is then definitely coherent, but continuous films of liquid still exit (4,5]. This distinguishes interdendritic cracks from cold cracks forming during the casting process after complete solidification (6,7].Much effort has been put into the understanding of the interdendritic cracking phenomena, and several theories have been proposed. Fellini [8] stated that interdendritic crack ""hot tear"" will result if the material is subjected to too high of accumulated strain within so called vulnerable part of the solidification interval. Kinosita et. al. [9] and Campbell (10] also emphasized the role of tensile stresses in the forming of interdendritic cracks. Most interdendritic cracks criteria simply consider the size of solidification interval, stating that solidification range is associated with a lager interdendritic cracking susceptibility than a short range. Clyne and Davies (11] formulated a more refined such criteria based upon the time spent in different regimes of the solidification interval. They defined a vulnerable region in which thin continuous films of interdendritic liquid exist, and the permeability is low. When thermal strains are induced in this region, the film is not able to sustain the stresses, and an interdendritic crack will form."

Jan 1, 2001