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By G. Girard, A. Larouche, J. Colbert, G. Doyer

"The Direct Chill (DC) casting process uses water to extract heat from molten aluminium and helps to control the solidification process. Many factors such as the water flowrate, water distribution around the mould and water impingement angle have significant impacts on the solidification process. It has been noted that the chemistry variation of the cooling water is also an important factor that has a major impact on the presence of defects on the ingot. A significant change in the water quality can produce defects on the ingots such as cracks, bleedouts, or runouts. Understanding the impact of water quality variation on ingots is therefore essential to ensure good ingot production and reduce defects. This paper aims at describing a new approach to follow the variations of process water quality over time. It is an original and innovative method, which is still under progress. A water quality and stability index (WQSI) is under development to evaluate changes in the water composition based on water physico-chemical parameters. The index is calculated by comparing each of the actual parameters with historical values previously modeled by a statistical law. It is a dimensionless number having an adjustable weight factor for each parameter. The positive or negative contribution of each parameter, with respect to the water cooling capacity, is taken into account to calculate the WQSI. The current selection of parameters is based on knowledge from the literature as well as on empirical experience. When the developed tool will be mature, it could be used to track water variations upon time and anticipate problems, enabling proactive actions to ensure good ingot production.INTRODUCTIONFor many years, the impact of water chemistry on heat transfer, during DC casting, has been of great interest in the aluminum industry. Several papers have been published to demonstrate the correlation between water chemistry and heat transfer (Yu, 1985), (Gildemeister, 2014). Although numerous studies do present the effects of water parameters (i. e. hardness, conductivity, oil, and grease…) on cooling capacity under controlled experimental conditions, they do not reflect the strong interactions between the parameters and variations present in a casting center. Wells and Cockcroft also demonstrated that laboratory based studies are not fully representative of real heat transfer in an industrial casthouse, there are too many factors involved (Wells, Li, & Cockcroft, 2001). In this context, it becomes very difficult to obtain a quantifiable relationship between the capacity of water to cool the ingot and ultimately the performance of the cast."

Jan 1, 2016

By Robert B. Parsons

"Effective January 1, 1990, mines in British Columbia are subject to a new provincial mining tax statute, the Mineral Tax Act. Under this Act, mines are subject to a two-tier tax system, with a minimum tax payable on ""net current proceeds"" and a higher tax paid on net income. For many mines, the present value of tax paid under the new rules should be comparable to the amount paid under the old rules. Earlier cash payments could pose difficulties, particularly for smaller mines, but existing producing mines could benefit in the short-term.IntroductionEffective January 1, 1990, British Columbia has replaced the provincial mining tax regime under the Mineral Resources Tax Act with a new system under the Mineral Tax Act. The new rules borrow some ideas from other provinces (New Brunswick's two-tier concept, and Saskatchewan's indexed costs) with a view to levying a tax that is fairer to both the producer and the province."

Jan 1, 1990

By R. Prioul, J. Kear, D. Chuprakov, A. P. Bunger

"Hydraulic fracture (HF) growth through naturally fractured rocks challenges the development of accurate predictive HF models. The authors present laboratory experiments differentiating behaviours associated with orthogonal and oblique intersections between HFs and natural fractures (NFs). HFs were created in sandstone and crystalline (gabbro) rock specimens, impinging orthogonally or obliquely on an unbonded machined frictional interface. Ultrasound monitoring was used to observe the rate of propagation through the interface. A contrast was observed between direct and offset crossing for orthogonal and oblique intersection, respectively. The stresses required to promote crossing depended on the intersection angle between HFs and NFs.RÉSUMÉ La propagation des fractures hydrauliques (FH) dans les roches naturellement fracturées pose un défi pour le développement de modèles prédictifs. Nous présentons des essais en laboratoire qui différencient les comportements associés aux intersections orthogonales et obliques entre les FH et les fractures naturelles. Des FH ont été créées dans des spécimens de grès et de roches cristallines (gabbro), heurtés de manière orthogonale ou oblique sur une interface machinée, non liée, de frottement. Un suivi par ultrasons a servi à observer le taux de propagation à travers l’interface. Un contraste a été observé entre un croisement direct et un croisement indirect des intersections respectivement orthogonales et obliques. Les contraintes requises pour promouvoir le croisement variaient selon l’angle d’intersection entre les FH et les fractures naturelles."

Jan 1, 2016

By Osamu Inoue, Takashi Yamashita, Takashi Ikemoto

The expansion project in Naoshima smelter and refinery to meet enhancing recycling business of E-scrap was successfully completed in 2016 to have a capacity of 110,000 tpa of E-scrap treatment. Increasing treatment of E-scrap has raised the Ni content of copper anode to 4000 ppm on average, which is double the level of 10 years ago, and to 6000 ppm or more occasionally. The tank house has refined such copper anode to copper cathode with starter sheets. Since most Ni in Copper anode dissolves in copper electrolyte, the Ni content of the electrolyte has increased to 27 g/L and more. Ni accumulated in the electrolyte has increased power consumption during the electrolytic refining of copper, although cathode quality has been controlled satisfactory so far. In order to ensure sustainable operation while growing E- scrap business, the NiSO4 process has been expanded recently so as to recover Ni in the electrolyte more and the pressurized-leaching technology will be introduced to the slime leaching process so as to enhance the capacity of slime treatment and to improve Ni recovery in the near future. INTRODUCTION In recent years, the treatment amount of E-scrap at Naoshima smelter and refinery has increased according to the growth of its recycling business as shown in Figure 1, while impurities from E-scrap have concentrated in copper anode as well. Especially, Ni content in anode has been increasing remarkably since 2012, causing to raise Ni content in the electrolyte as shown in Figure 2. The increment of Ni content in copper anode and electrolyte has adversely affected the electrorefining process, slime leaching process, and NiSO4 crystallization process at the tank house. Such severe conditions provided opportunities to redesign the tank house to establish a robust process to which more Ni is acceptable.

Jan 1, 2019

Agenda ?Introduction ?Geology ?Mining ?Metallurgy ?Process, Layout ?Environmental Background ?Kinross Gold Corporation owns the Lobo-Marte gold property, located in Region III of northern Chile. ?The property is close to two other Kinross mines, Maricunga 50kmto the south and La Coipa 60km to the north, plus a regional office in Copiapo and district level operating synergies are expected. ?Lobo and Marte were discovered in the early 1980s and are intrusion-hosted, porphyry-type precious metal deposits, typical of the Maricunga District. ?The Marte open pit heap leach mine was in commercial production in late 1988, but was suspended in February 1992 as it did not meet forecasted production levels and recoveries. ?Kinross plans to recover ore from the Lobo and Marte deposits through an open-pit, heap leach47,000tonne per day operation.

May 1, 2010

By David R. Winfield

I would like to thank you for spending the time with me today to review the FLIR PathFindIR thermal imaging camera system: It is truly an innovative safety system that has the added benefit of offering increased efficiency Our company the Winsted Group, specializes in mobile video systems that are fully customizable to address standard and unique operational requirements in a variety of industries from heavy equipment cameras to police and military digital recording systems, high end video camera systems are a hallmark of Winsted?s product line. The use of thermal imaging camera systems to enhance mobile safety is a relatively new concept as it relates to their use in both transportation and heavy equipment operation. This technology, like so many before it, has been adopted for civilian use from its military roots. The identification of enemy combatants through their heat signature has given our troops a decisive edge in military operations in total darkness Likewise, the ability to discern people and objects that give off heat is a significant step forward in collision and accident avoidance. The PathFindIR camera system that I am demonstrating today is so advanced that it cannot be exported outside of continental North America without a US government approved export license I would like to commence my presentation with a short video clip that discusses the technology associated with the FLIR PathFindIR Thermal Imaging camera systems. The video demonstrates the operational effectiveness of thermal imaging camera systems installed on a vehicle operating on the roadway at night, of course there are definite parallels to use in a mining environment, primarily the fact that lighting is limited and the chance for vision limiting dust is ever present. We are, of course more concerned with personnel safety in our mines than encountering wildlife on the roadside. From the same perspective, the transport driver is just as concerned with encountering a stalled vehicle as our mine truck operators are with other mine traffic.

Feb 1, 2008

By T. Holmes, S. Davison

"The Special Standard Surge bin at Agrium’s Vanscoy Potash Operations (VPO) has been plagued with flow problems and wear, and corrosion issues for it’s entire working life. Investigation showed that the carbon steel construction, bin geometry, and resultant funnel-flow pattern were directly responsible for production losses and disproportionate maintenance and capital costs. Potash enters this bin at between 140°C and 165°C, but the stagnant potash outside the active flow channel was much cooler, allowing moisture to migrate toward the outer regions, which caused corrosion of the walls and reduced live capacity as the potash in this area hardened and built up on the walls over time.A 2013 inspection revealed holes and paper-thin areas in the lower cylinder wall sections and in the conical hopper. The only thing preventing major leaks and even a potentially catastrophic failure was the buildup of stagnant hardened product on the cone walls. It was concluded that the cone had reached the end of its life and required replacement. VPO’s original plan was to replace the cone in kind and repair the cylinder as necessary; however, a failure-mode and bin-performance investigation combined with a lifecycle- cost analysis indicated it would be better to redesign the hopper.For success in retrofit projects, it is essential at the design stage to consider the bulk solid flow properties and the operating environment involved. Because education in this area is not offered at a university level, engineers often do not fully appreciate the effects of the flow properties of bulk solids on bulk material handling equipment.Jenike & Johanson conducted flow properties tests on samples of potash and using the data, redesigned the bin and the feeder. After the modifications, VPO’s surge bin provides safer, more reliable operation with a much longer predicted working life. Using this retrofit as an example, we aim to provide a general understanding of bulk solids flow theory and highlight the importance of customizing the design to the appropriate flow properties in the cost effectiveness, reliability, and safety of a bulk material handling system."

Jan 1, 2016

By Dirige. A. P. E.

A study was conducted for an operating mine to determine the appropriateness of its tailings material to be used for the preparation of a low modulus, high density backfill. The research was initiated due to issues arising from increased observations of compressive failure of backfill placed in stopes and inconsistent backfill behaviour (i.e. increased backfill brittleness and modulus). Backfill materials investigated were classified tailings and de-slimed tailings. Characterization of the physical properties of the classified and de-slimed tailings materials was conducted to assess the effect that these material properties would have on the strength and deformation behaviour of high density backfill products made using them. Such behaviour was investigated to determine whether differences in tailings physical properties would influence the strength and modulus character of the backfill materials. Uniaxial (UCS) and consolidated-undrained triaxial compression strength tests were conducted to determine strength performance and deformation behaviour of backfill. This paper presents the results of the backfill material characterization study and how different particle size distributions affected the strength performance and deformation behaviour of the different backfill mixes. It also demonstrates how stress-strain curves generated from material strength tests were used to evaluate variation in high density backfill mix response when such materials were subjected to unconfined and confined (triaxial) compression loading.

Aug 1, 2013

By T. S. Golosinski

"This paper reviews the types of selective continuous miners (SCMs) available at present, and compares their main features. Furthermore, operating practices and mine planning aspects of the SCMs applications are reviewed and conditions for efficient application of this equipment are defined. Finally, the potential applications of the SCMs in surf ace mining of oil sands are discussed INTRODUCTIONIn the 1970s the United States Bureau of Mines (USBM) conducted a program of investigations, design and demonstration of various continuous surface mining concepts, This included continuous mining equipment which was an adaptation of several civil engineering and/or underground mining machinery concepts to surface mining. Upon termination of this program, the related development was continued by a number of equipment manufacturers, leading to development of several types of SCMs. This new type of surface mining equipment is able to mine selectively hard and thin multi-layered formations at high, sustained, and economically viable production rates.While used mostly in coal mining at present, the characteristic features of this equipment permit conclusion that it may prove to be an efficient tool for surface mining of oil sand, and/or related overburden stripping. Of particular interest here may be the ability to mine thin layers of hard material, without a need for its earlier fragmentation, and the ability of the SCMs to load a variety of haulage equipment, including belt conveyors."

Jan 1, 1989

By Farzad Khodabakhshi, Adrian P. Gerlich

"Multi-pass friction stir processing (FSP) was performed to fabricate a new Al-Mg-Graphene nanocomposite. Microstructural developments and distribution of graphene were studied by using electron backscattering diffraction (EBSD) and transmission electron microscopy (TEM) analysis. In the stirred zone (SZ), grain structure was refined down to about 2 µm attributing to the operative dynamic restoration mechanisms and the locking effect of graphene phase. As a result, the yield strength of Al-Mg alloy was improved more than two times due to incorporation of graphene nano-sheets. Also, the indentation hardness resistance of nanocomposite was increased up to ~60%.INTRODUCTION Aluminum-matrix nanocomposites have garnered significant in recent years due to their superior performance and potential advantages for several industrial applications including the automotive and aerospace sectors. Among various reinforcing nano-materials, carbon-based structures featuring sp2 or sp3 hybridization bonds have been found to offer considerably improved physical and mechanical properties. Such carbon allotropes form at micro- and nano-scales including; graphite, carbon nano-tube (CNT), nano-fiber, and graphene. The potential of two-dimensional (2D) carbon materials was introduced in 2004, with the development of graphene as an alternate 2D allotropic form of the carbon structure with a honey-comb lattice at the atomic-scale. It has been shown that it is currently among the strongest materials ever tested with an intrinsic tensile strength of 130 GPa and Young’s modulus of 1000 GPa, and also offers unique thermal and electrical properties.To fabricate metal-matrix nanocomposites reinforced by graphene nano-sheets with typical metallurgical processing techniques, some attempts have been reported in the literature for various solid-state techniques including; hot rolling, mechanical alloying, and friction stir processing (FSP) of pre-cast plates or surface dispersed graphene oxides. The main challenge in those methods was to facilitate the considerable high temperature and pressure for attaining a uniform dispersion of the nano-sheets during the consolidation process. In most cases, significant difficulties have been reported in obtaining a uniform dispersion of graphene within the metal matrix. Among various techniques for production of metal-matrix nanocomposites, FSP has attracted significant attention as a method of surface modification since it was first reported by Mishra et al. In this process, a non-consumable rotating tool is plunged into the surface of material for the aim of microstructure modification. Extreme material plasticity is induced without melting as a result of friction between the tool and workpiece. Frictional heating and severe plastic deformation induced by the FSP process enables metal matrix nanocomposite fabrication by softening the base material and mechanical stirring to disperse the reinforcing nano-materials into the matrix."

Jan 1, 2017

By Robert B. Parsons

"In all likelihood, Canada's mining industry would be adversely affected by corporate tax reform proposals actively being considered by the Department of Finance in Ottawa. When the next set of proposals for lax reform is released later this year as promised by Finance, the mining industry had better be prepared 10 take a hard look.IntroductionTwo federal budgets ago, in May 1985, Finance Minister Wilson tabled budget papers that were more massive in terms of volume than most federal budgets. Buried in this mass of documentation is a discussion paper entitled ""The Corporate Income Tax System-A Direction For Change"". When the discussion paper was tabled over one year ago, reaction from the business sector was almost nonexistent. By and large, the paper was regarded as nothing more than one more federal publication of mild academic interest.But, recent events suggest that this discussion paper for corporate tax reform could be the cornerstone for a series of changes to the tax laws which would have more profound and widespread effects for all sectors of the economy than any reform since 1971 . No industry in Canada can afford to ignore the movement afoot in Ottawa for corporate tax reform."

Jan 1, 1986

By Dale Scott

"The Aggregate Resources Inventory Program was initiated 10 produce reports which assess the aggregate resources of municipalities designated under the Pits and Quarries Control ACI, 1971.Each report consists of three copies accompanied by a text. The text describes the local mineral aggregate resources, extractive activity and characteristics of the ""Selected Deposits"". The first map shows the known sand and gravel resources and their quality. The second map indicates selected sand and gravel resources of primary, secondary and tertiary significance. The third map indicates both bedrock resources and bedrock areas suitable f or extraction. These maps and the text are prepared in a formal suited for use by planning personnel.Recently, the Aggregate Resources Inventory Program has undergone evolutionary changes. New sources of data are being utilized in the inventory reports; in particular, detailed field assessment by inspecting, sampling, drilling and backhoe pitting. Liaison and joint assessment with district and regional Mineral Resources staff of the Ministry of Natural Resources, and personnel of the Ministry of Transportation and Communications, are key components of the Program.Twenty-two reports were available to the public as of December 1980, with a further thirty-six awaiting publication. Our present production rate is 3.5 reports per month. The reports appear to be well accepted by the municipalities and have proven effective in conserving prime aggregate resource areas.IntroductionThe urbanization of Southern Ontario has resulted in a major increase in the production of industrial minerals, such as sand, gravel, clay, shale, gypsum and stone, for use as cru shed aggregate, building stone, lime and cement.Although mineral aggregate deposits are plentiful in Southern Ontario, they are fixed-location, non-renewable resources. The potential for extractive development is usually greatest in urban fringe areas where land-use competition is extreme. Comprehensive planning and resource management strategies are required to make the best use of available resources, especially in those areas experiencing rapid development. Such strategies must be based on a sound knowledge of the total mineral aggregate resource base at both local and regional levels."

Jan 1, 1982

By Dale Scott

"The Aggregate Resources Inventory Program was initiated 10 produce reports which assess the aggregate resources of municipalities designated under the Pits and Quarries Control ACI, 1971.Each report consists of three copies accompanied by a text. The text describes the local mineral aggregate resources, extractive activity and characteristics of the ""Selected Deposits"". The first map shows the known sand and gravel resources and their quality. The second map indicates selected sand and gravel resources of primary, secondary and tertiary significance. The third map indicates both bedrock resources and bedrock areas suitable f or extraction. These maps and the text are prepared in a formal suited for use by planning personnel.Recently, the Aggregate Resources Inventory Program has undergone evolutionary changes. New sources of data are being utilized in the inventory reports; in particular, detailed field assessment by inspecting, sampling, drilling and backhoe pitting. Liaison and joint assessment with district and regional Mineral Resources staff of the Ministry of Natural Resources, and personnel of the Ministry of Transportation and Communications, are key components of the Program.Twenty-two reports were available to the public as of December 1980, with a further thirty-six awaiting publication. Our present production rate is 3.5 reports per month. The reports appear to be well accepted by the municipalities and have proven effective in conserving prime aggregate resource areas.IntroductionThe urbanization of Southern Ontario has resulted in a major increase in the production of industrial minerals, such as sand, gravel, clay, shale, gypsum and stone, for use as cru shed aggregate, building stone, lime and cement.Although mineral aggregate deposits are plentiful in Southern Ontario, they are fixed-location, non-renewable resources. The potential for extractive development is usually greatest in urban fringe areas where land-use competition is extreme. Comprehensive planning and resource management strategies are required to make the best use of available resources, especially in those areas experiencing rapid development. Such strategies must be based on a sound knowledge of the total mineral aggregate resource base at both local and regional levels."

Jan 1, 1982

By M. U. Savich

In Canadian mines, ear muffs are now an essential part of safety equipment. Because of this, a research study was conducted to investigate their efficiency. The main characteristics of eleven commercially available ear muffs were investigated in the laboratory and analyzed by: (I) a psychophysical method; and (2) a physical method. These investigations showed the following effects: head size has a significant influence on the attenuation because of a different clamping force; the amount of hair trapped between the ear muff cushion and the head decreased ear muff attenuation; attenuation and comfort are not in a causal relationship; with the use of glasses and their adapters, attenuation decreases-the adapters are not effective sound barriers; there are no great differences in attenuation with neck movement; the efficiencies of various brands of ear muffs are not equal; ear muffs with a small cushion area start serving their purpose more quickly because the force per unit area is larger; a clamping force larger than 900 g wt, in most ear muffs, does not cause an increase in attenuation; attenuation characteristics (ANSI 224.22 - 1957) of ear muffs show some correlation with physical tests. Nine ear muffs out of the eleven were tested under uniform conditions in mines. Three ear muffs were found to be the best. All three ear muff s have bands passing behind the head. The ear muff with a support strap, which improves comfort and maintains a good fit during wear, showed the best attenuation. Causes of poor attenuation are numerous: bad mounting of ear muffs on helmets, improper fitting, interferency by hair and glasses, improper wearing by miners, unsatisfactory enforcement by supervisory personnel, incomplete training of miners, etc. Results of this research have indicated that none of the ear muff s tested in this study contain all of the characteristics desirable in an ideal unit. Because of unsatisfactory ear muff attenuation in working conditions (/5 dBA), it should be a mandatory requirement that workers wear both ear muff s and ear plugs if the noise level is higher than 105 dBA (various literature recommends t io dBA). The key to the solution lies in the following: the foreman must be capable of helping and controlling miners in their task of wearing ear muffs properly; the program must be introduced to miners; and constant contact must be maintained with manufacturers.

Jan 1, 1979

By Lanny Pasternak

"This article is directed at plant production, engineering and maintenance personnel. Seldom does any industrial operation take the time to study the costs involved in the generation of what is probably their most expensive plant utility energy source.IntroductionIn the typical industrial plant in Canada, a 200 hp, 900 cfm, air compressor costs about $60,000* per year to operate (Fig. 1). In 1989 when BC Hydro embarked on their industrial energy management program Airflow Energy Ltd. were asked to spearhead the “Efficiency Compressed Air” portion of that program with a mandate to perform onsite overview surveys and physical hands-on testing of some 300 selected industrial plants throughout British Columbia for compressor efficiencies and wasteful air leaks (Fig. 2). The program duration lasted until 1995, during which time a tremendous amount of data were amassed relating to equipment types, clients’ operating habits, end-use applications and operating costs.During the past six years, Airflow Energy also performed somewhat similar surveys but on a smaller scale in Alberta, Ontario, the United States and the Republic of China. It was no surprise to find some inherent equipment concerns related to efficiency as well as neglected energy wasteful air leaks, so British Columbia was not alone and the problems appear somewhat universal."

Jan 1, 1996

By David L. Anderson

This paper explores the financial impact of the initial version of the Saskatchewan Potash Reserve Tax; first, a one; and second, in conjunction with the other taxes affecting the industry's profitability. A though the introduction of the Reserve Tax is shown to lead to a substantia increase in a hypothetical firm's effective tax burden, the more unusual outcomes frequently attributed to this levy on y occur after the imposition of other non-provincial tax rulings. Despite this qualification, the results obtained suggest that the Reserve Tax undoubted y acted as a catalyst in the polarization of attitudes during the ear y period of industry/government confrontation

Jan 1, 1979

By A. B. Parsons, P. G. Howes

"This article discusses how recent changes in the federal and Quebec .income tax laws have contributed to an improved investment climate for mineral exploration in the Province of Quebec. Individual investors who are resident in Quebec and who are in the highest tax bracket (1984-60.4% marginal rate) may obtain tax benefits that result in only nine cents of each invested dollar being at risk.IntroductionIn a recent submission by the Mining Association of Canada to the Royal Commission on the Economic Union, it was stated that the mining industry ""is no longer discovering and opening new mines at rates sufficient to offset the depletion of existing orebodies and to maintain pre sent output"". With world metal prices still in a depressed state following the prolonged 1981-82 recession, moreover, the continuing success of Canadian mining in world markets will depend on this country's ability to compete in a new environment characterized by subsidized Third World production . For the most part, this new competitive environment will encourage the development of cost-efficient mines that are better equipped to withstand the troughs and valleys of international metals prices."

Jan 1, 1984

By C. A. Born

This paper describes the rejuvenation of a molybdenum mine mill complex at the head of Alice Arm, 500 miles north of Vancouver and 85 miles north of Prince Rupert, British Columbia. It includes a description of the property history of the deposits and of the previous operations, together with details of the project for re-opening the mine.

Jan 1, 1979

By Tom Shumka

INTRODUCTION ?The Electro-Magnetic Crack Detection (EMCD) technique is an electromagnetic inspection method used for detecting and sizing surface breaking flaws. ?It works well on structural material or welds, ferrous or non-ferrous metals. ?EMCD?s rapid scanning is achieved using a hand-held probe. ?EMCD provides reliable crack detection and sizing (length and depth). Cracks can be sized accurately. ?EMCD dramatically reduces most cleaning requirements as there is no need to clean to bare metal. ?EMCD is capable of inspection through thin metallic coatings, or through non-conducting coatings up to 10mm thick. ?EMCD allows full data storage for back-up, off-line view and audit purposes.

Oct 1, 2010

By T. Plikas, T. Porretta, M. Al-Dojayli, B. Pretorius, J. Woloshyn, H. Ghorbani

"Water-cooled ducts represent an integral part of high temperature off-gas systems in metallurgical processes. Typically, off-gas enters these ducts at significantly elevated temperatures; therefore, water cooling may be required to maintain the duct skin temperature within allowable design limits. These off-gases are typically of high mineral content that could lead to dust buildup, and there is a possibility of slag buildup / molten metal splashing. Therefore, dust cleaning provisions may be necessary in order to remove or minimize accretion on the duct wall, which could otherwise impact the water cooling and the system process efficiency. These ducts may have complex geometry and experience a wide range of loading, including gravity loads, water and gas pressures, cyclic thermal loading and dynamic impact forces. Consequently, the thermo-mechanical assessment of such water-cooled ducts is critical and requires consideration phenomena such as high temperature gradients, potential nucleate boiling, thermal ratcheting and fatigue failures. Such assessment is not comprehensively covered by design-by-rule design codes and guidelines due to its complexity. This paper presents a successful implementation example of design-by-analysis methodology to improve the design and extend the life of a water-cooled furnace transition duct using Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA).INTRODUCTION Water-cooling represents an important part of high temperature off-gas systems in metallurgical processes. Typical temperatures of the off-gas in the furnace uptake are in excess of 1400°C, and thus there is a need to maintain the water-cooled duct and jacket skin temperatures within their material allowable design limits. Water-cooled channels have been used effectively in arc furnace roof design (Sosonkin et al., 1972; Smolyarenko and Khainson, 1988) and other furnaces as well as in furnace fuming jackets (Scholey et al., 1994). The design of these systems was based on one-dimensional analysis to ensure sufficient cooling is available under extreme furnace conditions (Smolyarenko and Khainson, 1988; Scholey et al., 1994). With advancement in furnace and fuming system designs, water-cooled duct designs have become more complicated in geometry. Numerical techniques, such as three-dimensional fluid flow and heat transfer modeling, are therefore needed to more accurately calculate water velocity, temperature and convective heat transfer coefficients in the water-cooled channels (Haywood et al., 2002; Henning et al., 2010). This is of particular importance around geometric corners where stagnant water flow may lead to local nucleate boiling at the critical heat flux, causing hot spots (Bergman et al., 2011). High wall skin temperatures increase the risk of failures due to thermal stresses as well as increasing corrosion rates (Gelfi et al., 2012), leading to costly equipment downtime and potential safety risks."

Jan 1, 2017