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By J. Kempken, R. Degel, J. Kunze, R. König

The FeNi technology is currently dominated by high-power submerged arc furnaces, often designed as smelter as "two-inline-solution". To achieve the intended high efficiency, state-of-the-art design in good correlation with ores and reductants and an integrated layout of the whole plant is of great importance. An introduction will be given to general aspects in the production FeNi, plus a detailed overview of design principles for large FeNi smelters and finally some examples of innovations and research projects concerning Fe-Ni.

Jan 1, 2007

By H. Melama

The primary grinding stage in the Vuonos concentrator comprises a rod mill in open circuit and a semi-autogeneous mill in closed, circuit with a hydrocyclone classifier. The instrumentation of the grinding circuit is displayed in Fig. 1. All the measurements have computer interfaces and all the control circuits have been implemented by the process control computer. The crushed ore feed to the rod mill is measured by a belt-weigher and controlled by a belt-feeder. The pulp density in the rod mill is stabilized by proportioning the waterfeed at the mill inlet to the crushed ore feed. The slurry level in the pump sump is measured by a pressure transducer and it is controlled by charging the speed of the direct-current drive pump.

Jan 1, 1984

By S. Lim, G. Walsh, V. Romero

The cable television show, Mythbusters, contacted the New Mexico Institute of Mining and Technology requesting a pressure gauge to be used in underwater testing. The requirements for the gauge were: it must be passive (i.e. require no power to function), it must indicate when a certain, pre-determined pressure was reached, and that indication was to be visual. A pressure gauge was developed, using standard, commercially available rupture discs, set to burst at 500 psi. Underwater testing was conducted using a 400 lb Pentolite charge. Test devices were set out at ranges from 50 to 200 feet from the seat of the blast. The rupture discs showed a lethal range up to 100 feet, but not at 150 feet. This result matched well with the behavior predicted through modeling and simple shock physics calculations. Additionally, the geometry between the incoming shock and the pressure gauge did not seem to have a strong effect on gauge performance.

Jan 1, 2009

By Eduardo Lozano, Vilem Petr

The use of explosives brings countless benefits to our everyday lives in areas such as mining, oil and gas exploration, demolition, and avalanche control. However, because of the potential destructive power of explosives, strict safety procedures must be an integral part of any explosives operation.

Jan 1, 2017

By Lucie Spencer, Craig Butterworth

"This paper presents the design of a raft enhanced pile group recently constructed for a hotel development in Perth, WA. At the time of construction in 2016 the hotel was the tallest prefabricated hotel in Australia.The structure covers the entire 12 m by 32 m development footprint, located in an inner city environment, and directly surrounded by existing structures. The small site and lack of space required innovative thinking in terms of the substructure design.The ground conditions comprise a layer of medium dense sand underlain by variable layers of stiff clay, silts and sands. Groundwater was around 1.5 m below ground level.The substructure design was carried out on the basis of a raft enhanced pile group. This allowed the use of much shorter piles than a conventional pile solution, thereby permitting the adoption of CFA piling techniques. This also allowed the raft thickness to be reduced to such that the substructure works were maintained above the groundwater level.The design was carried out in general accordance with the Australian Standard AS 2159 and using conventional piled raft design techniques involving iteration between elastic soil settlement software and structural analysis software until spring reactions were obtained with convergence of the two models. Following this springs were introduced to model piles in the structure.Due to the variable nature of the ground and resulting uncertainty in pile base capacity it was not considered appropriate to design the system as a pile assisted raft with piles loaded beyond their ultimate geotechnical design strength. As a result, all piles were designed based on a maximum load maintained within the elastic response region, with the majority of the load taken by the piles. However, the combined capacity of the raft and the piles allowed for a saving in pile lengths and numbers of around 40%, when compared to a conventional pile group designed in accordance with the Australian Standard AS 2159.The raft slab was monitored during construction in order to check the actual displacements against the design displacements. At the end of construction, the settlements were found to be within 2 mm of the design values.INTRODUCTIONThe Wellington Street area of Perth in the CBD is undergoing recent regeneration which includes the King’s Square development, Perth Arena and the Wellington Street Bus Station. The proposed hotel development is close to the recent developments on a Lot previously occupied by a low rise development. Due to the small size and constrained nature of the site, the substructure design for the tower needed to take into account available space and the impact of the works on adjacent properties. This paper presents reasoning for the choice of substructure design, details of the design methodology adopted, results from limited post construction monitoring and potential improvements that could be considered for similar future developments."

Jan 1, 1900

By T Takayama, M Matsumura, Y Konno

The steel industry accounts for 14 per cent of domestic CO2 emission in Japan, and iron ore sintering process occupies approximately three per cent. While Fe content in iron ore is gradually decreasing. So, the amount of concentrated iron ore will increase in the future. We have focused on magnetite concentrate as sinter materials, because magnetite can be easily magnetically beneficiated. However, it is experienced that blending magnetite ore resulted in increasing Fe2+ component in the iron ore sinter, which results in lower reducibility. Therefore, promoting the oxidation reaction from magnetite to hematite in the sintering process is countermeasure for reducibility. In addition, this promotion causes increase of oxidation heat, which results in high sinter strength and reduction of coke. It is assumed that the oxidation of magnetite tends to proceed in the cooling stage, where the oxygen partial pressure increases after the combustion of fine coke, but there are few studies on the effect of heat profile, especially cooling path. The purpose of this study is to design the effective sintering heat profile to promote oxidation of magnetite ore, especially, to investigate the effect of cooling path on sintered ore microstructure. In this study, magnetite ore and magnetite reagent were respectively mixed with calcium carbonate reagent. Then the mixed samples were pressed and formed into cylindrical tablets for simulating the adhesive layer of a pseudo particle. Through examining influence of maximum temperature and cooking rate on oxidation reaction of magnetite, we confirmed that the oxidation reaction of magnetite is suppressed at above 1350°C for maximum temperature, compared to 1300°C. Sintering at lower temperature is desirable because hematite is stable below 1350°C in the Fe2O3-CaO phase diagram.

Nov 8, 2021

By M. Kamyab

Transportation of fluid and slurry (fluid and solid particle mixtures) in a pipe and annulus space has been the focus of numerous studies. There are different parameters to be considered when studying slurry transportation. These include slurry velocity or flow rates; fluid properties such as density and rheology; and solid particle properties including concentration, density, shape and size. Also the angle of the flow conduit, rotation of the pipe and possible eccentricity of the annulus are other factors which influence slurry transport characteristics. Although a number of analytical, numerical and empirical equations as well as numerical simulations have been developed for studying the flow and slurry transport characteristics, the results need to be validated against either field or lab data. As performing field tests is costly and time consuming, conducting simulations at the laboratory scale appears as a good alternative. Different flow loops have been designed to study slurry transport behaviour in different science and engineering disciplines including oil and gas and mining. However, few of these consider, in particular, cuttings transportation in small size annulus space. The flow characteristics appear to be very different when slurry travels within a small size annulus, in particular when the fluid velocity is high. In this study, a review of some of the existing slurry flow loops will be conducted. Then the details of a slurry loop, which has been designed and commissioned for the purpose of studying cuttings transport in a small size annulus space for applications in drilling mineral exploration wells using coil tube technology, will be presented.

Aug 1, 2013

By Boris Broere, Wiebe Boomsma, Pieter Lucieer

"The Blue Nodules project started February 2016 as part of the EU Horizon 2020 subsidy program. Blue Nodules aims at developing a sustainable deep sea mining system for the harvesting of polymetallic nodules from the sea floor. Blue Nodules is closely related to the Blue Mining and Midas projects, both EU subsidized projects. Blue Mining mainly concerned the development of technical capabilities to adequately and cost-effectively discover, assess and transport deep sea mineral deposits up to 6,000 m water depths. The MIDAS project - Managing Impacts of DeepseA reSource exploitation - was a multidisciplinary research programme investigating the environmental impacts of extracting mineral and energy resources from the deep-sea environment.The Blue Nodules project is divided in seven work packages defined to develop mining equipment and process equipment, to assess and integrate environmental, economic and technological aspects and to assess and minimize the environmental impact of mining polymetallic nodules.This abstract will address part of the work performed in the second work package called: ‘Subsea harvesting equipment and control technology’. The main topic addressed will be the development of a propulsion system to manoeuvre the harvesting system. The propulsion system will be developed with full incorporation of economical and compliance requirements and to have a minimal environmental impact.SummaryBased on information gathered in the 70’s during the first studies into polymetallic nodules mining and more recent data and developments, an initial full scale design of the propulsion system is developed. The largest challenge for the propulsion of a deep sea mining vehicle is to drive on the soft sediments associated with these deep sea environments. A short summary of the initial design criteria is given below."

Jan 1, 2017

By Jérôme Boutin, Rémy Oddo, Sylvain Ouellette, Paul-Émile Boileau, Gilles LeBlanc, Pierre Marcotte

ackleg rock drills are widely used in the mining industry and are known to generate high levels of hand-arm vibration which contribute to the development of the hand-arm vibration syndrome for exposed miners.1-3 To reduce the vibration levels, a prototype of an antivibration handle was developed as part of a previous study.4 To provide some bench marking for this handle prototype and to follow the evolution of its performance over time, a test bench was developed to characterize the vibration emission values of jackleg drills under controlled operating conditions. As the current ISO 8662 series of standards could not apply directly to this type of tool, there was a need to design and validate a test bench to evaluate the vibration emission values of jackleg drills, while taking into account the conditions specific to the operation of this type of tool. Methods A test bench including an energy absorber, was developed for testing jackleg drills based on the ISO 8662-3 standard 5. The energy absorber was bolted to a 3300 kg concrete block to ensure tool stability. A pictorial view of the device is given in Figure 1. For validation purposes, acceleration measurements at the handle of a conventional jackleg drill were taken simultaneously along the three axes (xh, yh and zh) in an underground rock drilling operation as well as on the test bench. The handle accelerations were measured for three different jackleg angles (13º, 28º and 43º) determined with respect to the floor. Moreover, each measurement was repeated at least three times to asses the data repeatability. [ ] Results As a preliminary validation of the test bench, Figure 2 provides a comparison of the frequency weighted rms acceleration spectrum measured along the zh-axis, for both underground drilling and operation on the test bench (28º jackleg angle in both cases). It is shown that the vibration measured on the handle of a jackleg drill operating on the test bench is representative of that recorded during typical rock drilling operations, despite the fact that some harmonics of the percussion frequencies are generated with a higher amplitude on the test bench. Table 1 provides

Jan 6, 2006

By J. Jung, W. Keller, N. Rohn

In hydrometallurgical minerals processing slurries are often processed at very small grind sizes and high solids concentrations. This normally results in flow anomalies of such slurries. Due to flow limits or yield stress the slurry tends to stagnate close to the vessel bottom, the walls and at any internals. The main mixing task therefore generally is not suspending of the solids but the homogeneous blending of the entire vessel volume. If not considered during the agitator design only a fraction of the vessel contents will be mixed. Therefore the knowledge of the slurry rheology as well as the variations in process parameters is vital to design e.g. storage or surge tanks. The integral mixing solution considers the motor power, the choice of the impeller type and number, the impeller diameter as well as the design of the baffles and feed and discharge positions.

Jan 1, 2014

The Telfer Underground sublevel cave (SLC) Operation is located approximately 850 m below surface. The cave was designed to propagate through an old decline which was initially used to monitor the cave. There was a requirement to install air blast plugs at two locations in the old decline in order to isolate any potential air-blasts from the active workings in the event of the rock mass collapsing into the cavity. There was a further requirement for an air-blast plug in another section of the mine where there was a risk of the cave intersecting an old workshop and providing an air-blast pathway through an abandoned incline. The design criteria for the plugs was that they should withstand the design air blast loading, be free draining, cost effective and easily constructed with the mining expertise available on site. A plug consisting of grouted mullock was considered robust and least challenging to construct. For the purpose of estimation of maximum air pressure on plugs, it is supposed as a worst case that the rock above a cave falls as an airtight piston onto the top of a muck pile, forcing air into it and also mine workings intersected by the cave. Airflow through the muck pile is governed by Ergun's equation for turbulent flow. In a time-stepping integration scheme, transient air pressures and velocities are calculated according to equations of thermodynamics, in the cave and at intervals along intersected drives by means of a finite difference spatial discretisation. The ability of plugs to withstand computed pressures is assessed by finite element elastoplastic analysis. This paper outlines the rationale for potential air blast loading, calculation of transient air pressures, plug design and analysis of plug behaviour. The plug construction method is also discussed.

Nov 25, 2010

By Mario H. Castro-Cedeno

"A design for a handheld MEMS chemical detector is proposed. The detector will be used to detect trace amounts of chemicals in air. It can detect drugs, toxic chemicals and/or explosives. The proposed detector will use ion mobility spectrometry (IMS), a technique that is well known for accuracy and has been used in the past in suitcase sized chemical detectors. The separation and detection of the chemicals occurs in the drift channel and the process was modeled using the finite element method and CoventorWare modeling software. A manufacturing process sequence for the drift channel is proposed and was demonstrated.IntroductionThe goal of this effort is to design, mode~ and prototype a MEMS chip that will be the key component in an ion mobility spectrometer (IMS). This technique uses and asymmetric potential to separate the various ion species in a stream of incoming air [1-4]. One advantage of IMS is its ability to separate chemical species from air at atmospheric pressure and temperature. This is a requirement for a simple to use handheld drug or chemical detector. IMS can be used to detect drugs, toxic chemicals and explosives and it is well known for accuracy in detecting very small amounts of chemicals. This chemical detection technique has been used in the past, but not in handheld detectors.One variant of IMS is the high-field asymmetric waveform ion mobility spectrometry or FAIMS [3]. The FAIMS process, shown in Figure l, works as follows: a gas sample is admitted into the instrument where gas molecules are ionized, typically by a weak radioactive isotope source, ultraviolet light source; and more recently through field emission. The ions move along the length of a channel while they are separated in the transverse direction by an asymmetric electrical potential. The potential, in the form of an asymmetric waveform, causes relative motion between the various chemical species. The species that hit the charged top and bottom plates are neutralized and only those ions that move along the center are detectable as charged chemical ions at the end of the channel."

Jan 1, 2004

By A. H. Onur

Spontaneous combustion of coal is a significant hazard in underground coal mines. It causes serious problems for miners for many years after the fact. It threatens workers? lives and causes economic losses for companies. It disrupts coal production and makes it necessary to abandon the main drift where the spontaneous combustion occurred. Coal fires have to be prevented before they occur; otherwise they are very hard to control. Precautions thus have to be taken in potentially risky areas. For coal to spontaneously combust, it needs 3 elements: fuel, oxygen and heat. If one of them is missing, the fire cannot occur. The best way to prevent spontaneous combustion is to prevent contact between coal and air. Coating of the coal surface with an air-proof lining material would be a practical and useful solution to prevent spontaneous combustion of coal. In the scope of this study, a lining material for coating the coal surface was designed at laboratory conditions. Lining material to be used for preventing coal fires should be airproof, cheap, sufficiently strong, have low rebound, be water- and heat-resistant, and easily obtained and applied. It should also be safe for human health when in contact with mine ventilation. By considering these obligations, 3 kinds of gypsum (plaster, satin plaster, molding plaster), as well as lime, cement and fly ash and different mixtures of these materials were applied in laboratory conditions to form a lining material. Samples of lining material were subjected to uniaxial compressive strength tests to determine their behavior against roof loads. Although there is no need to carry any roof load, the lining material has to be sufficiently strong to stay in place on the applied surface. If the lining material is broken, coal and oxygen can react again. Air permeability and curing time of the mixtures were also tested in laboratory conditions. Then the tested mixtures were applied on a wall with a pump to test the applicability of mixtures. After all tests were performed in laboratory, the most suitable mixture was determined as the optimal lining material to prevent coal fires.

Aug 1, 2013

By Nabeel Khan

Annual oil production from the Canadian Oil Sands in Northern Alberta has been rising for several decades, and more ore and overburden are excavated each year from an increasing number of open pit mines. Overburden meeting certain specifications will be used to dam tailings and fill open pits, but the remaining material must be stored in overburden storage structures (OBSS). Well-designed overburden storage structures are more stable and cost less in the short- and long-term. The purpose of this paper is to explore OBSS designs that will be stable yet economical in the short- and long-term. The geological background of the site is briefly discussed, including the effect of each of the main geologic layers (recently deposited till and muskeg, Clearwater Formation clay shales, McMurray Formation oil sands, and the Devonian limestone) on the slope stability of the OBSS. Cost is considered in the analysis when balancing between minimizing costs (steeper slopes) and acceptable factors of safety (flatter slopes), all the while considering the financial consequences of failure. Potential failure planes are identified and probabilistic analysis is conducted on the critical failure surface. The variations in the factor of safety caused by varying pore water pressure, friction angle, and cohesion, are plotted and discussed.

Jun 1, 2012

Drilling is a common process in mining and petroleum engineering applications which have different objectives. For example, drilling deep boreholes in tight gas formations and gas shales is becoming more popular in the oil and gas industry. By contrast, drilling deep small sized holes for mineral exploration in hard rocks is performed to obtain samples for grade analysis purposes. In both applications optimising the drilling process includes using the most effective operating parameters such as rotation speed and weight-on-bit in order to maximise the rate of penetration. Obtaining the optimum drilling parameters requires sensitivity analysis over a range of data, which would be costly and time consuming during real field operations. Therefore, conducting several experimental simulations in the lab would be very beneficial before field operations begin. A drilling rig was designed and developed to simulate various drilling scenarios. The rig works in conjunction with an existing true triaxial stress cell (TTSC) which is in use for different petroleum related applications. The rig allows drilling into a cubic rock sample of up to 300 mm size. Three independent stresses can be applied to the sample to simulate real in-situ field stress conditions while the sample may be saturated with fluid. A significant feature of the rig is its ultra-high speed rotation which can rotate up to 8000 rpm: this is to simulate hard rock drilling for mineral exploration applications where large weight-onbit could damage the bit cutters. With the proposed design, a drilling fluid of any type can be circulated in the simulated borehole similar to the real situation, to study its effect on drilling performance. The TTSC drilling lid is equipped with torque and drag measurement systems which are two important drilling parameters to be recorded during drilling operation. It is believed that this new drilling rig will open opportunities for performing major new applied research in the area of more efficient drilling in both oil and gas bearing formations and mineral exploration applications.

Aug 1, 2013

By Gordon Chen

As part of a value engineering envisioned by East Coast Slurry, Weidlinger Associates, Inc. designed a unique elliptical slurry wall cofferdam for construction of the 65 ft. deep MWRA North Dorchester Pump Station. A conventional rectangle cofferdam with multiple levels of bracing would have been time consuming and costly and imposed a significant obstruction to the pump station construction. A circular slurry wall, while eliminating the bracings, conflicted with adjacent structures and required excessive backfilling around the final pump station structure. The ellipse shaped cofferdam fit the needs of the project well; however, it created a significant design challenge without the use of bracings. Unlike a circular cofferdam which primarily only has hoop stresses, the ellipse still has to be designed for horizontal bending moments in each panel because of the non-axial symmetric conditions. The more eccentric the cofferdam shape; the higher the horizontal bending. The challenge was to develop a three dimensional finite element model that could analyze both the hoop stresses and horizontal bending stresses above and below the bottom of excavation induced by soil and water pressure and unbalanced construction surcharge loads. This paper discusses the techniques used to model the soils and structure interactions and results of stresses on this challenging unbraced configuration.

Jan 1, 2010

By R. F. Harig

Designing an underground nuclear waste repository is a complex process. Although many decisions are involved before the design is complete, the first three--what the target horizon is, what the underground boundary is, and where the entry point will be located--are important because they establish the basis for the entire repository design. Even more important than these decisions, however, is the data on which the decisions are based. Because the current data are limited, an aggressive data gathering program is needed during the next design phase to augment information about the intricate interplay among all facets of the repository design and the geologic medium in which the proposed repository is to be developed. Although unique to modern engineering enterprises, the challenges involved in designing a repository in the unsaturated zone are within current technology and engineering practices.

Jan 1, 1991

By L. Cheng

Almost all modern cutting bits use a cemented tungsten carbide tip to provide adequate hit life against wear. Laboratory tests by the US Bureau of Mines have indicated that the number of strikes for ignition increased by a factor of three with a new non-rotating bit impacting a sandstone block when the clearance angle was increased by 10°, and that carbide-tipped bits allowed more strikes before ignition than steel-tipped bits by a factor of 7 to 10. Recent field tests in an operating coal mine indicate a dramatic reduction in the frequency of frictional ignitions and improvement in hit life by using a mushroom-shaped hit cap and a larger initial clearance angle. The latter was achieved by increasing the hit attack angle. Improved hit performance through selection of the grade of tungsten-carbide is a com¬promise between fracture resistance and wear resistance. A large clearance angle should he maintained by various techniques, such as a variable attack angle holder, or a reusable hit that can he reground.

Jan 1, 1990

By Michael McVay

The use of augered cast-in-place piles has seen tremendous growth under commerical structures in the past twenty years. Problems with vibration, soil densification and/or heave associated with driven piles do not occur with properly installed augered piles. Augered cast-in-place piles were originally constructed (1950s) with diameters of .31 m (12 in.) and lengths up to 6.1 m (20 ft); however with the advent of better drilling equipment, diameters varying from .41m(16 in.)to .61 m (24 in.) and typical depths ranging from 18.3 m (60 ft) to 24.4 m (80 ft) are achievable. Reinforcement may vary from a single high strength rebar (Grade 60) at the top of the pile to a continuous steel cage depending on loading (compression, tension-uplift, and lateral). Typical axial design loads (compression) for a single augered cast-in-place pile are in the 445 kN (50 tons) to 890 kN (100 tons) range.

Jan 1, 1997

By Bauduin C. Besix

The Eurocode 7 "Geotechnical Design" is based on "Limit State Design", tackling the uncertainties as much as possible at their source through: - selection of characteristic values of variables (loads, soil properties, pile resistance,...); - partial factors applied on the characteristic values; - model factors to account explicitly for uncertainties of the calculation rule if necessary. Eurocode 7 will propose three "design approaches". The selection of one of them will be by National Determination. For pile design, the approaches are: - approach 1 is a "material factoring approach" at load side and a "resistance factoring approach" at resistance side. The structural and geotechnical design are checked for both of two separate sets of partial factors. - approach 2 is a "load and resistance factoring approach" and is in several aspects close to a deterministic approach. The design is checked for one set of partial factors. - approach 3 is a material factoring approach, at load as well as at resistance side. The design is checked for one set of factors. The aim of this paper is to introduce to the design of pile foundations based on pile load tests and on ground test results (semi-empirical and analytical methods) in the frame-work of the three design approaches. Detailed attention is devoted to: - the selection of the characteristic value of the pile resistance, accounting for spatial variability and stiffness of the structure; - the reliability of the prediction of the pile resistance using analytical or semi-empirical methods which may be accounted for through a "model factor". The results of a large test campaign on screw piles in OC Clay and a calculation example illustrate the proposed procedure when calculation rules using CPT results are used.

Jan 1, 2002