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By Cesar Giron Camerini

Os aços inoxidáveis bifásicos superduplex estão presentes em diversos setores da engenharia devido a versatilidade oferecida em termos de propriedades mecânicas e resistência à corrosão. Para garantir a qualidade destes aços, avaliar o teor de ferrita presente na microestrutura é de grande relevância para indústria uma vez que diversas propriedades do material dependem do controle deste teor. Durante a fabricação de equipamentos ou inspeções de campo uma das formas mais viáveis de monitorar o teor de ferrita é através do ferritoscópio, dada sua portabilidade e fácil interpretação. No entanto, observou-se que a forma usual de calibração do ferritoscópio pode levar a medidas imprecisas, principalmente na avaliação dos aços superduplex. A fim de analisar esta influência, foram realizados diferentes testes de caracterização microestrutural através de microscopia ótica, difração de raio-x e o magnetômetro de amostra vibrante, para confrontar com medidas obtidas com ferritoscópio. Conclui-se que para elevados teores de ferrita, a calibração do ferritoscópio realizada a partir dos padrões fornecidos pelos fabricantes apresentam desvios significativos dos teores encontrados a partir da caracterização com equipamentos de laboratório. O presente trabalho apresenta uma solução para utilização do ferritoscópio para uma quantificação mais acurada do teor de ferrita nos aços inoxidáveis superduplex.

Oct 30, 2017

The 105th Annual General Meeting of The South African Institute of Mining and Metallurgy was held in the J.C. Lemmer Auditorium, SA National Museum of Military History, 22Erlswold Way, Saxonwold, Johannesburg on Thursday, 8thAugust, 2002. Welcome The President extended a special welcome to the guests and representatives of our sister institutes and other associations. Also to recipients of awards, senior members of industry, Honorary Life Fellows, Past-presidents, our Members and other guests, among them the following: Mzolisi Diliza, Chief Executive, Chamber of Mines of South Africa Dawie van Wyk and Rod Tucker, Vice-presidents, The Geological Society of South Africa Vaughan Townsend, President, Institute of Certificated Mechanical and Electrical Engineers, South Africa Karel Landman, President, Institute of Mine Surveyors of South Africa Frik Grobbelaar, South African Colliery Managers? Association Pierre Ballot, President, South African Institute of Electrical Engineers Trueman Goba, President, South African Institution of Civil Engineers

Jan 1, 2002

By Ding Xu Chu

There are many methods developed for measuring the crustal stress in China. Among them only two methods have been adopted in practice, i.e., overcoring method (for which the sensors include: Piezo-magnetic stress gauge, steel-ring strain cell, 3-dimensional hollow-inclusion stress ,gauge, and Leeman's-like stress gauge) and hydraulic fracturing method. For the former method, one of those sensors is installed in a borehole, 36 mm in diameter, then prestressed, and finally overcored with a drill bit of 130 mm in diameter. After that the deformation of the borehole wall is measured, from which the in-situ stresses are determined. In order to avoid the errors resulting from the difference in elastic modulus for various kinds of rocks as well as from the installment of the cells, we have developed a technique to calibrate the sensor on-spot using a confining pressure calibrator and produced a very good result. For the later method, the measurements are achieved by isolating a certain section of a borehole and then injecting water to pressurize it till a tensile break is induced. It is identical to the typical technology used internationally. For many years, through field observations and a large number of laboratory experiments, we believe that the most efficient way of stress measurement for engineering purposes is the overcoring method using Piezo-magnetic stress gauge. It is characterized by stable and reliable measurement values, high accuracy and high adaptability. Taking the measurements in the intact rock mass as an example, the measured stress magnitudes are within accuracies of 8% and the errors in orientation are about 5 degrees. It can even be used perfectly in deep water. Up to now, we have performed in-situ stress measurements in more than 70 sites and obtain more than one thousand sets of data. The deepest depth used in the overcoring method is 80 m in vertical borehole and 780 m in tunnels.

Jan 1, 1987

Incomplete liberation of mineral particles is one of the key factors limiting the performance of industrial flotation circuits. This work aims to quantify the relationship between different breakage modes and how these affect mineral liberation properties. A copper porphyry (bornite) ore sample was subjected to breakage using a piston-die compression unit and an impact mill. The particles produced as a result of each mode of breakage were then characterised using Mineral Liberation Analysis (MLA) to quantify the mineralogical and liberation properties of the progeny particles. The impact mill was found to produce bornite that was finer grained relative to the host particles. In con-trast, bornite discharged from the piston-die unit closely followed the size distribution of the host particles and was retained to a greater extent in the larger/intermediate size fractions. The results provide insight into what breakage methods are optimal for the purposes of downstream separation.

Jan 1, 2014

By S. F., French

IN reviewing the design of the ore haulage system for the Morenci project, the reader should bear in mind that the railroad and its equpiment cannot be considered as an independent railroad provided only for the purpose of transporting ore from one point to another, but as an integral part of the operation which begins at the electric shovels loading ore at the mine, and ends where the ore, after having been crushed in the primary crushing plant, is deposited in the bins at the secondary crushing plant. Obviously then, the problem consisted of designing a system that would function to the best possible advantage in complete co-ordination with the other units.

Jan 1, 1942

Accounting for borehole damage in analytical modelling of explosively generated stress waves is important for predicting the finer details of the stress wave patterns observed in the field. The classical Sharpe's [19421 concept of an effective borehole larger than the initial borehole diameter has been widely accepted to explain material damage around a borehole. A new analytical model based on dynamic compaction is advanced to predict far-field stress wave patterns. This model supports field data corresponding to reduced frequency of oscillations and increased damping. The present model recovers the earlier result when compaction around the borehole representing borehole damage is ignored.

Jan 1, 1990

By Marvin S. Seppanen

Computer programers are often required to make modifications to unfamiliar Fortran routines. This Bureau of Mines report describes a computer program designed to aid the programer in such a situation by reorganizing: Fortran routines. This reorganization includes a sequential renumbering of the routine's statement numbers, a sequential renumbering, and relocation of format statements, an alphanumeric reordering of dimensioned and typed variables, a uniform pattern of text spacing, and a sequential numbering of the records in the final Fortran routine. The computer program has been extensively tested by the author and has proved to be a valuable tool for reorganizing Fortran routines developed under contract and later utilized by the Bureau, and for preparing routines for publication.

Jan 1, 1975

By M. C. Malamphy

A general description of the activities and results of bauxite investigation by the Bureau of Mines at its bauxite project in Saline and Pulaski Counties, Ark., has been given in Report of Investigations No. 4251. The factual data obtained during the project are reported in a series of Reports of Investigation beginning with No. 4251, of which this is the sixth. The data are accompanied by maps showing the loca.ion of holes, drilled and the deposits developed. Each area upon which work was done is reported by half townships. Each bauxite deposit investigated was assigned a name and a number for ready reference and identification, and its location and name are shown on the appropriate half-township map. The description of each half township is followed by a description of each deposit developed in that half township. The 14 half-township maps and 77 detail maps of the bauxite deposits in this series of reports give the locations and numbers of all the holes drilled on the project except the deep holes drilled to test geophysical anomalies. The locations of those holes are shown on figure 13 in Volume I. The descriptions of the deposits developed are followed by complete detailed logs of the drill holes. Many of the widely spaced exploratory holes did not discover bauxite of minable thickness and grade. The pertinent information obtained from the widely spaced exploratory drill holes has been summarized and tabulated, and a table for each half township is given with the discussion covering that area.

Jan 1, 1948

By B. K. Parekh

Sludge obtained during production of magnesium (Mg) metal from electrolyzing of molten MgCl2 contains entrapped magnesium particles. The sludge material containing the magnesium particles is a friable, continuous matrix of frozen salt mixture which may also contain some oxides and impurities. A dry process was developed for recovery of magnesium metal from the sludge, utilizing minerals beneficiation unit operations. The steps included selective comminution, screening, attritioning and tabling. Recovery of the high grade (+90 percent) metal was in the 70 percent range. The process is being commercially used in the U.S. The novel process was also successfully applied to a magnesium-alloy for recovery of metal from the sludges.

Jan 1, 1995

By James S. Graham

Foundation pile driving hammers used in New York City in the past 100 years have been drop, steam, compressed air, diesel, and hydraulic. In 1992, the first hydraulic hammer in the New York City area was purchased by Norwalk Marine Contractors, Inc. from Junttan in Finland. It was bought because of its variable energy and ease of mobilization, not because of its higher transferred energy. Heller and Johnsen engineers instrumented hydraulic hammers on nine jobs. The measured transferred energy for the nine jobs was found to average approximately 80 percent. There is no clear consensus regarding the reasons for the hydraulic hammer being more efficient in delivering energy to the pile as compared to single-acting steam/air impact hammers. To minimize pile damage during installation, and to minimize footage overruns, an up-to-date version of the wave equation software that includes an efficiency value of 0.95 for hydraulic hammers is now used.

Jan 1, 2000

This paper outlines the mechanism of Stress Corrosion Cracking (SCC) and how it can cause premature failure of rock bolts. SCC occurs due to the progressive development and growth of cracks in the surface of a metal, and it is caused by the combined effects of stress and a corrosive environment affecting susceptible metals and alloys. It can occur in most metals including stainless steel. It is not a new phenomenon, but its effect on rock bolts has only been recognised recently.Rock bolt failures caused by SCC appear to be brittle failures which occur at less than the ultimate tensile strength of the bolt. In the mining industry, SCC failures of rock bolts can occur a few months, or after many years of exposure to stress and a corrosive environment. If SCC of rock bolts is suspected, then the rock bolts should be examined by a metallurgist, and steps should be taken to reduce the problem.

Jan 1, 1998

By Matthew John M. Krane

"The macrosegregation patterns and convective behavior of a Pb-5wt%Sb-35wt%Sn alloy are studied using new numerical treatments of solid particle motion and of transport phenomena occurring during the solidification of ternary metal systems. At this composition, the solidification which occurs while the local liquid composition is in the (Pb)-(SbSn) binary eutectic trough has a significant effect on these phenomena. The effects of this solidification path on fluid flow and macrosegregation are compared to the more familiar binary alloy patterns and the effect of solid particle transport is evaluated. The final predictions of macrosegregation are compared to measured composition profiles. IntroductionThe macroscopic maldistribution of alloy constituents during solidification, commonly called macrosegregation, is a defect which occurs in real metal processing systems. This nonuniformity of species distribution, especially when it forms a high composition gradient or a poor distribution of secondary phases, can lead to areas of high stress concentration, which contribute to cracking during extrusion or forging of wrought alloys or when an as-cast piece is severely loaded in service [1, 2]. Macrosegregation studies in binary systems have become quite common since the introduction of single-domain numerical models which feature one set of conservation equations and boundary conditions for an entire, fixed computational domain containing solid, liquid and multiphase regions. A complete review up to 1995 has been presented by Prescott and Incropera [3]. However, most commercial alloys generally have more than two species in amounts significant enough to affect the convective flows which lead to macrosegregation and other defects. The formation of secondary solid phases, including eutectic and peritectic reactions, also may occur in commercial metal alloys and should be treated using appropriate thermodynamic models."

Jan 1, 1999

By Lewis C. Karrick, Martin J. Gavin

"Introduction.The theory of fractional ""education"" of oil from oil shale has been used by several inventors as the basis for the design of retorts for the production of oil from the oil shales of the United States. The term fractional ""education"" gives expression to the rather common belief that when an oil shales is heated it produces light, low-boiling oils as low temperatures, and increasingly heavier, higher-boiling oils as the temperature of retort¬ing rises. The theory evidently had its origin in the fact that crude petroleum may be fractionally distilled, yielding light oils at low distillation temperatures, and heavier oils as the distillation temperature increases is as, gasoline is produced from petroleum at relatively low temperatures, kerosene at higher temperature, and heavier products such as gas-oil and lubricating distillation at still higher temperatures.The writers have examined several oil-shale retorts designed to take advantage of the belief that crude, and in some cases refined, gasoline can be recovered from the shale at low temperatures; kerosene at higher temperat.res, and so on. Such retorts are usually designed to operate continuously and have several vapor-pipes lending from them at differing intervals and passing to separate condensers. Designers of such retorts repeat that the distillate from the low-temperature parts of the retort will be gasoline, and that as the shale passes to zones of increasingly higher temperatures, the vapor lines lending from these zones rill remove increasingly heavier products such as kerosene, gas-oil etc."

Mar 1, 1924

Controlled blasting experiments in small development drifts were conducted at CANMET's Experimental Mine, from August 1992 to November 1993. The objective of these experiments was to develop suitable controlled blasting techniques for small development headings drilled by jackleg with 32 mm diameter holes. The experimentation also aimed to provide insight into blast damage mechanisms. Particular attention was given to the physical-mechanical properties of the rock and the rockmass structural data in order to make the results applicable to other geological environments. The drift faces were approximately 2.4 m by 2.4 m with 36 to 43 holes drilled to a depth of 2.4 m. Cartridged water gels, emulsions and semigelatin dynamite were used in the cuts and as primers, ANFO as the main explosive and decoupled 19 mm diameter semigelatin dynamite charges were used in the perimeter holes. Smooth blasting techniques and pre-splitting were tested in the underground mine. All the blasts were monitored with a multi-channel blast vibration monitor to which was attached sets of high frequency geophones and accelerometers. This first set of experiments has illustrated the efficiency of con-trolled blasting techniques to reduce blast damage and demonstrated the need for further research to improve the safe and efficient use of explosives.

Jan 1, 1995

By John A. Organiscak

The Bureau of Mines conducted a survey of eight shearer longwall operations to identify factors that affect respirable dust generation from longwall roof supports. The longwalls surveyed were in coal seams located in different geographic regions of the United States. Data were collected on mining (geologic) conditions, support design, operational characteristics, and amount of respirable dust generated from roof supports. Analysis indicated that mining conditions are the main factors that affect the generation of dust during roof support movement. Both roof strength and depth of cover above the coal seam showed relationships with the amount of support dust generated. Several practices are currently employed to effectively control roof support dust; however, some of these controls are limited. More research and development is needed to improve dust control technology for longwall roof supports.

Jan 1, 1985

By Yongsik Jeong, Kwangmin Kim

Conventional tailings slurry contains a significant amount of water, and water management is key to ensuring the stability of a tailings storage facility (TSF). Simply reducing the water content in the slurry before discharging it from the mill could be an effective way to improve TSF water management. This study investigated the potential for using an environmentally friendly polymer as a new drag reduction agent (DRA) to reduce frictional pressure loss and also conserve water. It entailed conducting pipe loop tests to assess the polymer’s effect on pressure loss in tailings flow and then applying the test results to validate a numerical model using computational fluid dynamics (CFD). The model was also used to determine the polymer’s optimal concentrations at given solid concentrations and flow rates, its effect on energy efficiency for tailings transportation, and its potential for saving water. A case study for a mid-sized, hard-rock mine with a throughput of 50,000 t/day found that the solid concentration could be increased from 30 to 45% with no pressure loss by applying 1996 m3 of the polymer per day. Adding the polymer also resulted in water savings of 57,552 m3/day. The results of this study demonstrated the potential for using the new DRA not only to improve TSF stability but also to save water.

Jun 29, 2020

By E. R. Hoskins

Results of a primary stress measurement investigation conducted on the 1100 copper ore body of the Mt. Isa mine, Mt. Isa, Queens., Australia, are presented in this chapter. The investigation started in September 1965, after discussion with the engineering staff at Mt. Isa, and consisted of both underground or in-situ tests at Mt. Isa and laboratory tests on Mt. Isa rocks and stress measurement techniques at the Australian National University in Canberra. Underground stress measurements were made in and adjacent to the 1100 copper ore body. The primary stress measurement site was in J 32 west crosscut on 14 Level. Approximate coordinates on the mine grid are 3000 north, 1650 east. The vertical depth below ground surface at this point is approximately 2180 ft. Some preliminary measurements were made in M 30 west crosscut on 13 Level, coordinates 3000 north, 2000 east, depth beneath the surface approximately 1990 ft. Additional flatjacks were installed on 11 Level in L 30 west crosscut, coordinates 3000 north, 2200 east, and depth beneath the surface approximately 1580 ft. All of the sites were in rock that from a mining engineering viewpoint must be considered extremely sound. The 13 and 14 Level crosscuts were approximately 14 ft on a side and nearly square and the 11 Level crosscut was approximately 10 ft on a side. All of the crosscuts had been standing open for several years and no artificial support of any type was necessary. Extraction openings hundreds of feet on a side have been made in this mine in similar rock and these have remained open also without additional support (see Davies 1 for a recent summary of mining techniques and conditions). The geology of the Mt. Isa mine has been most recently described by Bennett.2 Briefly, Mt. Isa is a silver-lead-zinc and copper mine in a series of Precambrian siltstones, shales, and bedded carbonates that strike north-

Jan 1, 1972

By C. A. Rowland

When studying the feasibility of using autogenous or semi-autogenous grinding, operating and engineering companies frequently request assistance from the mill manufacturers in three areas - 1. Recommendations for studying the suitability of autogenous or semi-autogenous grinding for the specific ore. 2. Mill sizing, to accomplish required grind. 3. Recommendations on mill design and operation. Rod mills and ball mills are selected by the use of bench scale standard grindability tests and established calculation procedures, of which the most frequently used are the Bond Grindability tests and the Bond Work Index equation(1). The accuracy of these have been reviewed by C. A. Rowland in his papers, showing the correlation of work indices calculated from plant operating data and laboratory grindability tests(2)(3). The selection of autogenous and semi-autogenous primary mills has not reached the stage where mill size selection can be made from bench scale tests. Considerably more extensive testing will be necessary than required for selecting rod mills and ball mills.

Jan 1, 1974

By Adam Turcotte

Mining operations consume a considerable amount of energy, and while reduced energy consumption is desirable, it is not always clear how to achieve this goal. Understanding the opportunities to optimize energy consumption is crucial, and the key to understanding is visualization. One option is the Sankey diagram, which has been used for over 100 years to visualize the flow of energy, materials, or cost through various processes. However, there are drawbacks to this approach that must be addressed. In a Sankey diagram, each flow is represented by an arrow possessing a width proportional to the magnitude of the flow it represents. The diagrams show input flows, how energy is converted and into what form, and also output flows. As per the first law of thermodynamics, the total energy output is equivalent to the total energy input, so any energy that is not transferred to another process is considered to be wasted. These waste flows are depicted in Sankey diagrams and make it straightforward to associate energy sources, sinks and waste flows. Unfortunately, Sankey diagrams do not convey all information required to support practical decision making for redirecting individual energy flows. Based only on a Sankey diagram, it may become evident that a significant flow of waste heat is of the appropriate grade (temperature) and volume to meet an on-site heat demand currently being met with paid-for, possibly carbon intensive fuel. However without augmenting the Sankey diagram with 3D spatial, true geometric analysis, the practicalities of the concept or idea may not be fully appreciated. Another issue with a Sankey diagram is that the magnitude of the energy flowing between processes may have temporal fluctuation or variability on different timescales (diurnal, seasonal, interannual). Currently, Sankey diagrams only provide a static picture of energy conversion and consumption, so that, for example, 4 separate diagrams could have to be prepared for each season. A new energy flow visualization technique which we have called Sankey Trees has been developed. Process locations are defined within a 3D model of the site being studied, and the magnitude of the flow between each pair of processes considered is replaced with a time series. Branches of sustained and diminishing flows are represented through variation of the geometric properties of the branches of the trees. These branches are animated to indicate the direction of flow, and branch joints are used to indicate that a process is transporting one form of energy to multiple processes.

Aug 1, 2013

By A. Vasenev

The quality and durability of asphalted roads strongly depends on the final step in the road construction process; the profiling and compaction of the fresh spread asphalt. During compaction machine operators continuously make decisions on how to proceed with the compaction accounting for project specific aspects as: ambient conditions, road geometry, roller type, asphalt mixture characteristics and behavior of other machines. In discussions over quality improvement in road construction it is often suggested to robotize rollers. To operate such robots would of course require operational strategies and routines. The reality of this moment is that these operational strategies and routines are not documented. To identify the existing best working practices and, ultimately, to proceed with developing automated robotized compactors, the knowledge of machine operators should at first be explored and described in a formalized way. Unfortunately operators have difficulty verbalizing their expertise. Observation of behavior, as machine movement patterns, could be helpful to extract the operational strategies, but such observations are time and labor consuming. To overcome this burden we developed a Virtual Reality (VR) environment. In this VR environment operators perform compaction virtually, and their operational choices are traced and analysed. This paper describes this VR development and explains how it helps in following machine operators and extracting their (tacit) professional knowledge. The road geometry and the working conditions are visually represented; the operators show - rather than explain - how they would proceed with the compaction process in the given conditions. Movements of virtual machines are documented, analysed, visualised and discussed. This VR approach is expected to contribute to learning, to more formal description of operational strategies; stepping stones towards compaction algorithms for roller robotisation.

Aug 1, 2013