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By F. J. Guevara

A two-dimensional mathematical model for fluid flow and heat transfer in a sixin- line electric smelting furnace was developed to study the effects of temperature on slag viscosity in both the liquid and mushy zones. The model focused on the fluid dynamics of the molten slag and the effects on the formation of a slag freeze layer on the hot face of the furnace wall. Previous experimental and mathematical work, carried out under Ra number of 109 and using a fluid with Pr number of 65, showed that it is possible to mathematically describe the freeze layer formation over a vertical wall using a fixed-grid model. The chemical composition of the slag was taken into account through its effect on the viscous activation energy as well the solidus and liquidus temperatures. The results show that the flow pattern is strongly modified in areas of high viscosity, in front of the cooling system and at the slag-matte and slag-calcine interfaces. The results are discussed in terms of heat flux over the refractories and their effects on cooling system design.

Jan 1, 2007

By Y. Wang

In this study, homogeneous (unseeded) precipitation of nesquehonite (MgCO3.3H20) by the reaction of MgC12 with (NH4)2CO3 in supersaturated solutions at 30 °C was investigated. Factors which influence the precipitation of MgCO3.3H20, such as initial concentration, temperature, stirring speed, titration speed, equilibration time, have been studied. SEM images show that the initial concentration and titration speed have significant effect on nesquehonite's crystal morphology and particle size. In addition, stirring speed and equilibration time also have some influence on its properties. With the optimization of operating conditions, the crystals can grow up to a length of about 40µm and a width of 5µm, indicating good filtration properties. High purity nesquehonite obtained in this study was calcined to produce highly pure MgO at 800 °C as shown by XRD results. The novel process may be used to separate Mg and Li from high Mg/Li ratio brines in Qinghai, China.

Jan 1, 2007

This work illustrates the potential of two welding processes for joining AA1100-16 vol.% B4C metal matrix composite: laser welding process using a 4 kW Nd:YAG laser and Friction Stir Welding. A comparison is made between these two welding techniques in terms of microstructure and mechanical properties of welded joints. A large amount of brittle needle-like phases, together with some residues of B4C particles were observed in the fusion zone of laser welded joints. The use of Ti filler can improve the microstructure and increase the joint efficiency from 63% to 75%. On the other hand, the friction stir welding process being a solid state welding technique is interesting as it avoids the formation of brittle intermetallic phases. In addition, the breakage of B4C particles and the grain refinement of the matrix were observed in the weld zone. Consequently, FSW joints show much better mechanical properties than laser welded joints. Up to 100% joint efficiency can be achieved by FSW for annealed AA1100-16 vol.% B4C materials.

Jan 1, 2011

By S. Amira

The corrosion behavior of high pressure die-cast and thixocast AXJ530 magnesium alloys has been investigated in 0.05M NaC1 solution at pH 6.0 using potentiodynamic polarization tests, electrochemical noise (EN) technique, electro-chemical impedance spectroscopy (EIS) and scanning reference electrode technique (SRET). The behavior of die-cast and thixocast specimens were compared using each of these techniques and the results discussed. Further tests have been carried out with die-cast AZ91D alloy to better compare and interpret the results. Experiments indicate that the thixocast specimens of AXJ530 alloy have a better corrosion resistance than those of die cast alloy in neutral solution.

Jan 1, 2006

By Olivia Gamache

When working in remote and extreme environments, projects are faced with new challenges for engineering and project execution. This is heightened when also working in countries with a developing environmental regulatory framework, small skilled workforce available for recruitment, and minimal infrastructure such as power, roads, and water. There is an increasing realization that social and environmental aspects need to be built into project execution. Giving proper attention to these issues during project development and execution, and maximizing opportunities is an ongoing challenge.

May 1, 2013

By Reinis Sipols

AGENDA ? Introduction ? Definitions and Key features ? PEA - Preliminary Economic Assessments ? PFS ? Preliminary Fesibility Studies ? FS ? Feasibility Studies ? Costs and Risks ? Cash Flow, Economic Analysis and Reporting ? Recommendations for Improved FS accuracy INTRODUCTION ? The reporting of material information on mineral deposits has been governed by NI 43-101 legislation for almost a decade. ? The investment sector depends on the independent, professional QP to provide objective observations, comments and recommendations through all levels of geological, engineering and financial evaluation until a mine construction decision has been made.

May 1, 2013

By J. Q. Chen

The elastic-plastic behavior and the fracture mechanisms of two 2198 Al-Cu-Li thin sheets are investigated. The first material (2 mm thick) is in a recrystallized state after cold rolling. The second material (6 mm thick) is hot rolled and has a fibrous grain structure. The two materials are studied in both T351 and T851 conditions. Tensile tests are carried out along different sheet directions using flat and notched specimens. Fracture resistance was characterized using Kahn tear specimens and M(T) panels. Macroscopic fracture surface of smooth tensile specimens depends not only on testing material but also on the loading direction. For Kahn tear specimens, fracture is initiated in a small flat triangle whereas slant fracture is observed during crack propagation. Fracture mechanisms were investigated using scanning electron microscopy (SEM) and X-ray 3D tomography.

Jan 1, 2011

By P. Su

Friction stir spot welding of a range of Mg-alloys is investigated (AZ91, AZ31, AM50 and AM60). The peak temperatures during friction stir spot welding of all Mg-alloys are close to their solidus temperatures. Also, the apparent material viscosity of Mg-alloy sheet is lower than that when Al-alloy sheet material is spot welded. This is important since it means that the widths of the stir zones forming during spot welding of Mg-alloy sheet are smaller than those when Al-alloy sheet is welded (when identical welding parameter settings are applied). These lower apparent viscosity values must be taken into account during numerical modeling of the Mg-alloy spot welding process. The efficiency of energy utilization is very low when Mg-alloy sheet is spot welded and is of the same order as that when fabricating Al-alloy sheet. The energy generation contributions of the rotating pin and the tool shoulder are investigated. When the spot welding operation is carried out without the application of a dwell period, the contribution made by the rotating pin vis-à-vis energy generation is around 66%. The contribution made by the tool shoulder increases to about 65% when a dwell period of four seconds is incorporated during the spot welding operation. This increase results from a longer contact time between the tool shoulder and material within the stir zone, The failure load during overlap shear testing increases when the bonded area and the energy input increase during spot welding. Sample failure initiates from unbonded regions and from discontinuities at the edge of the stir zone. The formation tendency of discontinuities is increased when Mg-Alloy sheet is spot welded because of the limited deformation characteristics of the base material at lower temperatures.

Jan 1, 2006

By A. Longval, Q. Jiao, T. Shannon

In 2000, Xstrata Zinc (former Falconbridge Ltd.) Brunswick Smelter commissioned a modified lead blast furnace. Since then, efforts have been made to improve its operation in order to achieve optimal operation in terms of coke consumption, lead loss to slag, and improved environmental and hygiene conditions. This paper will review the important step changes in operational philosophy, undertaken since 2004, for the control of the blast rate, oxygen enrichment in blast, slag chemistry and charge level. Furthermore, a review of the improvements made in secondary materials consumed at the blast furnace will be made. This paper will also discuss the significant reduction of the frequency of accretion removal as a result of improved furnace operation.

Jan 1, 2008

By H Zorychta

Based on underground measurements made at the Nova Scotia coal mines of the Dominion Coal Company, Limited, this paper presents a comparison between the physical properties of hardwood packs and steel friction props when used for longwall support. The probable loads sup-ported by steel friction props on a longwall face at both the Dominion No. 20 Colliery and the Princess Colliery are delineated, and the results of the tests are presented in graphical form. It is concluded that the steel friction props are more efficient than the hardwood packs that they replaced as roof supports. Introduction AN evolution in the methods of longwall face support is taking place in the Sydney coalfield. Longwall face support had consisted primarily of timber props and hardwood packs. In 1957, however, at the Princess Colliery, Sydney Mines, Nova Scotia, the first longwall was equipped with steel friction props. At the present time, eleven longwall faces are supported on wood and sixteen faces are carried on steel friction props.

Jan 1, 1965

By B. Chareyre, H. Pourpak, L. Scholtès, E. Papachristos

"Numerical methods used to study hydraulic fracturing in low permeability rock masses need to take into account the interaction between the progressive failure mechanism of the intact rock matrix and the pre-existing natural fractures. A fully coupled hydro-mechanical 3D discrete elements model dealing with such interaction is presented here. The ultimate objective is to grasp the role of the rock-matrix failure on the propagation of the main fluid driven fracture under different stress fields and pre-existing fracture orientations. The proposed method provides the spatiotemporal distribution of the induced crack events which can be tracked during the simulations, making possible the identification of the local mechanisms leading to macro-failure in the rock matrix or reactivation of the discontinuity planes. Fluid flow inside a fracture, pressurized crack and hydro-fracking experimental tests were simulated as part of the validation process of the model and, are presented in this paper.INTRODUCTIONWith the expansion of shale gas and geothermal reservoirs exploitation, the technique of Hydraulic Fracturing (HF) has been widely used over the past years (McClure, 2012; Britt, 2012). Despite recent advances in micro-seismicity analysis or numerical modeling (Nagel et al., 2013), the way progressive failure of rocks affects the fluid flow depending on the in situ stress conditions or the rock heterogeneities is not fully controlled yet (Zoback, 2010).In this work we focused on setting up a three-dimensional discrete elements model to study fluid driven fractures propagation. The intact rock is modeled by a discrete element method (DEM) able to reproduce fracture initiation and propagation (Scholtès and Donzé, 2013, Garcia et al., 2013). The pre-existing fractures are explicitly modeled and can be individually defined or be part of a discrete fracture network (DFN) (Harthong et al., 2012). Their mechanical response is fully coupled with the fluid within a HM-DEM framework. The fluid flow and it’s interaction with the intact matrix and the pre-existing discontinuities is modeled through a Pore-scale Finite Volume (PFV) scheme specially enhanced for fractured rock modeling (Chareyre et al., 2012, Catalano et al., 2014) ."

Jan 1, 2015

By M. Uszko

The climatic area in which Poland is located requires heating the ventilation air at intake shafts during the winter season. Air heating of the intake shaft should ensure safe operation of hoisting devices; while at the same time it also affects the conditions of the mine environment. The paper presents the issues of shaft heating in coal mines in terms of the mining law, the effect on the conditions of the mine environment and heating technology solutions used in the mines of Kompania Weglowa S.A. (KWSA).

Aug 1, 2013

By Guoxiang Chi

This paper consists of two parts: the first part describes the principles and functionality of the BsnMod program, and the second part presents preliminary application of this program to paleo-fluid flow modeling in the Anticosti Basin. The BsnMod program simulates fluid flow and heat transfer during the evolution of sedimentary basins through numerical solution (finite difference method) of three partial differential equations, which describe sediment compaction, fluid continuity, and heat conservation. It can be used to estimate the evolution of fluid overpressure, flow rate, and temperature during the basin history. The program was written in C++, works under Windows environments, and has a user interface allowing inputs in dialogues and outputs in both tabular and graphic forms. The program was applied to the Lower Paleozoic Anticosti Basin in eastern Canada. The basin history consists of a passive margin stage and a foreland basin stage. Preliminary simulation results indicate that no significant fluid overpressures were developed in the passive margin stage and during the early period of the foreland basin stage, but strong overpressures were developed within the foreland basin succession during the middle and late periods of the foreland basin stage. Fluid flow rates were generally slow, and thermal profiles were not significantly disturbed by fluid movement throughout the basin history. Potential source rocks of hydrocarbons were found in the foreland basin succession. The strong overpressures in the foreland basin succession could have been a major driving force for hydrocarbon migration from the source rocks to the underlying potential reservoir rocks.

May 1, 2001

By Hongpu Kang

The fully mechanized top coal caving mining method has been the main mining approach for thick coal seams with high output and efficiency in Chinese coal mines. The gateroads for the top coal caving mining faces should be driven along the floor of the thick coal seam with a part of the seam as roof. The support of the gateroads is commonly difficult because of the low strength and broken structures of the coal seams, and the increasingly large section of gateroads meeting the need of greater and greater face coal output. Based on the analyses on the geomechanics properties and production conditions of the top coal caving mining, the influences of the top coal caving mining parameters on the stability of gateroads, including mining thickness and face length, are studied. The deformation and damage features of the rock mass surrounding the gateroads with the top coal seam as roof are investigated, the interaction of the support with the surrounding rock mass, the support theory are studied. The bolting design method and criteria, bolting forms and parameters for the gateroads with the top coal as roof are put forward. The rock bolting components, including bolt bars, face plates, cable tendons, meshes, and steel straps, are introduced. Finally, the gateroad bolting effects are evaluated through a typical case study on the basis of field monitoring data, such as the displacement of surrounding rock mass and the forces along bolts and cables.

Aug 1, 2013

By Jian Deng

Rockbursts are sudden and violent failure of rocks in deep and/or high stress mines, which may destroy the excavation space and cause an accident or even the death of mining workers. This study is motivated by the pervasiveness of rockbursts all round the world. It has been found that rockbursts are often stimulated by dynamic fluctuation which is generated by mining operations or other sources of vibrations, such as blasting in adjacent stopes. This paper attempts to investigate the dynamically stimulating mechanism of pillar rockbursts in hard rock mines from an innovative point of view. Rockbursts are classified into triggered rockbursts and induced rockbursts in accordance with the magnitude of the stimulation force. Triggered rockbursts occur only when a small fraction of stress changes associated with rockbursts is accounted for by the causative excavation, whereas induced rockbursts happen where the causative factor is responsible for most of the stress changes required to produce the rockburst. By considering rockbursts as a dynamic instability problem of structures, rigorous mathematical models are set up for triggered rockbursts and induced rockbursts, respectively. By using the method of averaging and the method of eigenvalue problems, the boundaries of rockburst occurrence of a pillar are obtained for these two rockbursts. A new explanation of the failure mode of fretting or necking of pillars is given, the perturbation effect for pillar rockbursts is found, and the parametric resonance mechanism of pillar rockbursts is revealed. The quantitative relation between blasting parameters and pillar rockbursts obtained can be directly used to control the rockbursts. Contrary to conventional methods where only rock materials or rock specimen were used to study rockbursts, this investigation attaches more attention on the structural effect on rockbursts, which have strong potential applications in deep mining.

Jan 1, 2015

By M. H. ElMaghraby

This paper describes the development and validation of a strategy for vibration-based online detection of faults in a particular class of machinery commonly found in industry. This machinery is defined by two basic characteristics that preclude it from the application of standard online condition monitoring approaches. The first characteristic is that the machine is in a constant state of transient operation, thus making it difficult to differentiate between changes in transducer measurements that are due to variable duty and those that are due to machine malfunction or fault. The second characteristic is the fact that the machinery involves multiple sub systems that are subject to identical and simultaneous loading, operating environments and duty cycles. An example of such machinery is a system of multiple hydraulic pumps driving a common load. The monitoring strategy presented here employs an anomaly detection scheme together with methods of signal processing and feature extraction that exploit the parallel duty arrangements of this equipment. Preliminary data is collected from a pair or motor-gearbox assemblies used in a material haulage system in the mining industry. Testing and validation was performed on a mechatronic test bench with both healthy and faulted components. Experiments were carried out to investigate how various configurations of the system were able to detect different types of faults. The results indicate that this approach is effective and merits further investigation.

May 1, 2013

By A. K. Alzo?ubi

Block toppling in natural rock slopes has been under investigation since the 1970?s. De Freitas and Watters (1973) introduced the term ?toppling? to describe the movements of rock slopes by rotation in steeply dipping beds. The Lornex pit case history from British Columbia (Canada) was chosen to study the effect of mining on the stability of toppling rock slopes. A discrete element approach that allows fracturing of intact material was applied successfully to model the composite rock slide-rock topple movement. Three main movement modes were observed in the field and the numerical model; the sliding of the top of the slope exposed normal scarps, the toppling at the middle part of the slope exposed obsequent scarps facing opposite to the slope face, and dilation of the rock caused by fracturing at the toe formed loose material. The development of the rupture surface at the toe of the slope was traced and did not evolve into a continuous rupture surface throughout the slope both in the field and the numerical simulation. Good agreement was achieved between the deformations recorded in the field and the numerical simulation.

Jun 1, 2012

By Roger J. Goodman

"Major industrial restructuring, which started to manifest itself in the mature economies of the Western World and Japan in the 1970s, will accelerate in the 1980s and 1990s. Conventional heavy manufacturing industries will continue to lose ground to lighter processing/assembly operations and the new wave of high technology, information and service sectors. The decline in heavy manufacturing has severely impacted on the steel industries of Western Europe, the U.S.A . and Japan.World trade in metallurgical coal has shifted correspondingly, with declining demand in the mature developed countries being only partially offset by large increases in the steel intensity of the newly-industrialized countries (NICs) of the Far East, Latin America and, to a more limited extent, the Middle East and Africa. These trends will be accentuated in future years with direct implications for the distribution of metallurgical coal trade. This paper discusses, in quantitative terms, such changes in the 1980s and 1990s, and examines the implications for, and impacts on, Canadian metallurgical coal exporters.IntroductionThe twenty-year period from the early 1950 s to the early 1970s was characterized by inexorable growth in consumer demand and industrial expansion in most of the advanced countries of the western world. Long- term forecasting during this period typically used linear extrapolation techniques which , despite their simplicity, invariably ended up predicting future demand and production level s with uncanny accuracy. Times have changed!The last decade has been characterized by a n abysmal failure of our economies to respond to simple long-term, linear growth patterns. We appear to have entered a new world in transition, where we can observe a wave of dying or sunset industries reluctantly being submerged by a wave of emerging or sunrise industries.This paper is aimed a t examining the evidence for long-term industrial restructuring trend s. For want of a better word, these so -called, megatrends are then used to predict future demand level s and spatial distribution of steel development and , hence, metallurgical coal trade. It is tempting to correlate the decline in economic activity in the western world with the first Organization of Petroleum Exporting Countries' (OPEC) crisis of 1973. This crisis was probably no more than the straw that broke the camel's back, as the megatrends and embryo s of major industrial restructuring were already evident. Today these megatrends are merely more apparent and transparent than they were ten years ago.While the concept of industrial restructuring is the new economic buzz word, the process was at work, to a lesser degree even throughout the period of strong economic growth of the post-Second World War boom. Many people still remain convinced that our present-day sluggish economy is just part o f the typical , though rather more prolonged, recessionary cycle. Yet, we have always been part of a dynamic economic system and industry throughout history has been the subject of a continuous process of evolution, restructuring and reconstitution . Now the time is ripe to examine the evidence for such restructuring in order to develop coherent policies of adjustment in this transition from one industrial regime to another."

Jan 1, 1985

By K. Scholey, S. Marcuson

As high grade nickel sulphide ores are being depleted and with the continuing challenges experienced in economically processing nickel laterite ores, it is important to investigate technologies that can extract nickel from low grade ultramafic ores which are present in large quantities worldwide. In the Thompson Nickel Belt, there are some hundred million tonnes of mineralization that are potentially amenable to surface mining. Since the original discovery of the Thompson orebody, recovery of nickel from these ultramafic deposits has been an elusive goal. Research and development projects as well as commercial processing have been attempted. In the 2000's as other resources became scarcer, a major drilling, mine evaluation and research project was initiated at Vale. In 2007, Vale Base Metals Technology Development invited Cytec and potential academic partners to participate in an industry-university research consortium with the goal of developing new technologies and methods of processing the ultramafic deposits. Three university professors, J. Finch of McGill, P. Somasundaran of Columbia and R. Pelton of McMaster accepted, each group attacking the problem with a different approach. This paper describes the management of the research consortium and the significance of the results from Vale's perspective. The next four papers in this session will summarize the project and results from the partners' point of view. Vale is pleased to share the experience of the collaborative research and development with the mining industry.

Jan 1, 2011

By Stanislaw Trenczek

Natural hazards such as rock bumps, methane, coal dust explosions, airborne respirable dust, outbursts of gas and rocks, water, radiation caused by natural radioactive materials, spontaneous fires, and climatic hazards, occurring in the Polish hard coal mines, should be controlled. These hazards are characterized by different scale levels numbered from 2?5. To recognize the amount and levels of hazards, research works were carried out in 109 mining districts of mines belonging to Jastrzebska Spólka Weglowa, Katowicki Holding Weglowy and Kompania Weglowa. These are 86 % of all mines and could be regarded as representative of the majority of Polish mining. The hazards have been classified as regards the frequency of their occurrence as: commonly occurring ? with a frequency of 100 % (like airborne respirable dust and fire hazards), high occurrence frequency ? frequency from 60 to below 100 % (methane hazard ? 83.5 %, coal dust explosion hazard ? 92.0 %, and water hazard ? 99.1 %), medium occurrence frequency ? from 30 to below 60 % (rock-bump hazard ? 52.3 % and climatic hazards ? 51.4 %), and episodic occurrence frequency ? below 30 % (outburst of gas and rocks and radioactive hazards). The dynamics of effects of growth in hazard levels to their intolerable values is diverse. Some of them are passive in nature, which allows for longer observation of changes and appropriate early response (as for climatic and spontaneous fire hazards). However the majority of them take on the character of disasters, like methane or coal dust explosions and damage of the excavation structure ? as occurs after a rock-bump or rock outburst; and creation of an atmosphere unfit for breathing ? during open or spontaneous fires, or after gas outbursts containing methane. There are also latent hazards whose effects do not influence indeed a process of production; however they are detrimental to health when a worker is exposed for a long time to airborne respirable dust and radiation. For other types of hazards a level of danger may be only estimated. Since the systems monitoring allows a wider range of control, therefore, aside from rock-bump and methane hazards, there are monitored also fire hazards including measurements of other air parameters (velocity, pressure, humidity, temperature, O2, CO2 concentration). A few types of monitoring systems are used in Polish mines, like the monitoring systems for environmental parameters such as SMP-NT, SMP-NT/A, the telemetric systems CST-40, CST/A, including the computer-aided system for methanometry control officer SWµP, the computer-aided measuring systems KSP-1, KSP-2, KSP-2C, or the production and safety control system VENTURON. The underground part of the systems monitoring of natural hazards contains measuring devices and equipment for automatic control (power-off) of machines and electric devices in case of increased methane hazard. The surface part of the monitoring system allows the measuring data to be visualized and pre-alarm (warning) and alarm states to be displayed. Furthermore it makes it possible to archive and report the data and to control the underground supply and signalling devices. The EMAG Institute developed monitoring methods to extend a measuring range of monitored parameters (such as methane and fire hazards) as well as to monitor so far unmonitored hazards like dust hazards (by continuous monitoring of dust levels in mine air) and climatic hazards (by online monitoring climatic parameters of mine air).

Aug 1, 2013