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By Rajesh S. Ransing

An intelligent tool has been developed to analyse the quality of diecast components. The influence of both design and process parameters has been studied in great detail. The tool, based on expert systems related technologies, can identify the causes for the defective castings manufactured. Design related causes such as gate position; gate area, runner design etc. as well as process related causes such as cycle time, cavity filling time and melt temperature are suggested by analysing the data on defective castings for a manufacturing campaign. This intelligent analysis is useful for both design as well as production engineers in the decision making process. All the causes for the occurrence of defects are classified into two categories. The firs category is the 'rootcauses' i.e. the causes which are related to the actual process, material and design parameters and which can be directly monitored. The second category is more abstract in nature and is classified as `metacauses'. These capture the scientific rationale implicit in the cause and defect relationships. This knowledge on causes and defects is represented in the form of a structured graph rather than by a set of rules, which, coupled with forward reasoning and heuristic search techniques results in an elegant and efficient approach. Uncertainties and the degree of relationship among causes and defects are represented by a fuzzy probabilistic model.

Jan 1, 1994

By M S. Fenzel

Increased environmental regulations and pressures have created changing and new demands for tailings management strategies in a variety of mining applications. Critical among these items is the disposal of tailings as the pursuit of increased yields and lower costs have driven the application of different process technologies. With a number of technologies having a niche application focus, the belt filter press has been utilised for decades as a cost-effective and versatile option for dewatering different types of mineral tailings and other waste process streams. One of the critical advantages of the belt filter press is the technology’s ability to adapt and work in numerous plant designs, operating conditions and applications. As permitting and disposal options have become more stringent, plant designers, operators and equipment suppliers must develop comprehensive and site-specific economic, design and process evaluation techniques to ensure proper equipment selection and system design for belt filter presses or any other dewatering technologies. This paper will explore these techniques in relation to belt filter presses (with reference to other technologies) in a variety of different applications, along with other considerations to ensure a successful tailings dewatering system and disposal design. Summaries of equipment performance characteristics, operating and maintenance strategies and optimisation techniques will also be addressed in conjunction with the belt filter press’s adaptability to different plant designs and the resulting tailings characteristics.CITATION:Fenzel, M S, 2015. Analysis and adaptability of belt filter presses and other technologies for tailings dewatering over a range of mineral processes, plant designs, conditions, regions and operating philosophies, in Proceedings Tailings and Mine Waste Management for the 21st Century , pp 35–44 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 27, 2015

By E. Tulcanaza

The practical significance of the in situ grade variability is usually neglected. Although recognized, often times it is either ignored or just considered as a vague guideline in many of the decisions dealing with exploration, reserve estimation, and mine planning. This paper stresses the significance of grade variability for exploration and mining, and illustrates its liaison to the structural features of the ore deposits, as well as to the mining parameters used for mine extraction. Some geostatistical results obtained from a silver mine, tungsten mine, and copper mine in South America are discussed.

Jan 1, 1985

By Edmundo Tulcanaza

Increasing exploration costs and the need to reduce the time-frame from exploration to production presently demand formalized procedures to assist exploration planning and reserve analysis. Exploration planning is basically required to select the most cost-effective drilling/sampling program, and to flag the needs for data of greater relevance and reliability. Reserve analysis is necessary to determine the sensitivity of grade-tonnage relations, and to clarify the economic implications of mining when alternative technical choices are to be considered.

Jan 1, 1982

By Kamil Nuzha, Jianchao Li, Bashar S. Qubain

"The Philadelphia Water Department is rehabilitating Belmont Raw Water Basin. As part of this work, a 500-ft long, temporary cofferdam was designed to retain 35 ft of combined water and soil at the western half during the reconstruction of the eastern half. A cofferdam that comprises two integral rows of sheet piles was selected to take advantage of the soil’s weight between the sheet piles for increased stability. To fine tune the design, a geotechnical investigation was carried out to verify the subsurface conditions and, in particular, the top of rock variations along the centerline of the cofferdam. A detailed finite element analysis was performed based on the subsurface findings and incorporating the construction sequence to evaluate the behavior of the cofferdam at the following stages: installation of tie rods to connect to the two rows of sheet piles; partial excavation and installation of tiebacks; complete excavation of the east basin, and demolition of the cofferdam. Inclinometers and survey markers were installed every 100 ft along the cofferdam and were monitored throughout construction. The deformation measurements were in good agreement with the finite element results.INTRODUCTIONThe Philadelphia Water Department (PWD) Belmont Raw Water Basin is located at the intersection of City Line and Belmont Avenues in Philadelphia, PA. The facility actually contains two raw water basins, east and west, separated by an earthen dividing dike. Water leakage at the bottom of the basins and through the dividing dike together with increasing demand for a larger storage capacity dictated the replacement of the wide earthen dike with new narrower concrete structure. The temporary cofferdam was designed for a two-year period to facilitate excavation support, water cutoff, removal of the existing earthen dike and replacing it with a new concrete dike. During this construction sequence, the water level in the west basin had to be maintained at or near its full capacity.Various excavation support systems were considered for this project prior to the selection of a double wall sheet pile cofferdam. Fig. 1 shows a plan view of the cofferdam and the new dividing dike. A typical cross section of the two structures is shown in Fig. 2. Double row sheet pile walls are commonly used as both temporary and permanent retaining systems in open water applications such as construction works, quaywalls, breakwaters and revetments for storing industrial waste as indicated by Ohori, et al. (1984), Ohori et al. (1988), and Khan, et al. (2001). There are many advantages to double row sheet pile systems as recognized by Ohori, et al. (1984; 1988): (1) It can be installed and removed in the presence of water easily and quickly; (2) it provides stability with small width to height ratio, utilizing the existing soils between the installed sheet pile rows; and (3) it serves well as a means for water cutoff. These advantages meet the specific project requirements."

Jan 1, 2016

By Yu Chuang, Zai Jinmin, Liu Songyu

"The piled raft foundation is a geotechnical composite construction method, consisting of three elements, piles, raft and soils, which is applied for the foundation in an increasing number. Differential settlements have numerous negative effects on a superstructure in piled raft foundations. Through the analysis of the production mechanism of differential settlements and differential settlements control measures, a method of adjusting pile configurations is presented to control differential settlements. By comparing the measured data and finite element method analysis of one oil storage piled raft foundation, the new method is verified that the differential settlements can be reduced effectively and the inner forces of foundations are more reasonable with varying length pile configurations. The differential settlements can be minimized or even reduced to zero with right pile length.INTRODUCTIONPiled raft foundations are widely adopted for the prominent advantage of limited settlements and adequate bearing capacities. However, there always exits differential settlements in conventional piled raft foundations. The differential settlement is the main cause that produces additional stresses in the structure. Differential settlements have numerous negative effects on a superstructure as well as on a foundation, and should be restricted to allowable limits. How to control the differential settlement is the key interest.An increasing number of structures are founded on piled rafts. For this reason, design strategies that enable an optimized design have a major importance for safety and economy. An optimized design may be defined as a design achieving maximum economy of the solution, that is minimum cost for the installation of the foundation."

Jan 1, 2005

By Inoka E. Perera, Michael J. Sapko, Marcia L. Harris

Experiments conducted with limestone dusts and dolomitic marble dusts have indicated that when rock dust is wetted and subsequently dried, it becomes a solid, non-dispersible cake. However, in order to be effectively inert a coal dust explosion, rock dust must be able to disperse as individual particles to air. To counteract this, rock dust manufacturers created treated rock dusts that will resist caking after moisture exposure. National Institute for Occupational Safety and Health (NIOSH) researchers conducted a series of laboratory-scale experiments on four base rock dusts and their treated counterparts to assess the effectiveness of various anticaking additives after being exposed tomoisture and then dried. The dusts were exposed tomoisture using humidity cabinets having a high relative humidity (99% RH) and by also exposing the rock dust bed to water through bottom wicking. The dusts were then evaluated for dispersibility after drying using the NIOSH-designed dust dispersion chamber. The anti-caking additives were different concentrations of stearic acid, oleic acid, and xylene-based surfactants. All results were compared to a reference rock dust used to conduct large-scale experiments in the Lake Lynn Experimental Mine (LLEM), Fairchance, PA. When the untreated dusts were dried after exposure to moisture for 1 day, no dispersion was measured. However, rock dusts treated with anti-caking agents were readily dispersible even after exposure to moisture for 6 months. This report details the analysis and characterization of anticaking additives using the NIOSH-designed dispersion chamber and the 20-L explosion test chamber.

Apr 12, 2021

By M. L. Harris, I. Zlochower, M. J. Sapko, I. E. Perera

Experiments conducted with limestone dusts and dolomitic marble dusts have indicated that when rock dust is wetted and subsequently dried, it becomes a solid, non-dispersible cake. However, in order to be effective, rock dust must be able to disperse as individual particles to inert. To counteract this, rock dust manufacturers created treated rock dusts that will resist caking after moisture exposure. National Institute for Occupational Safety and Health (NIOSH) researchers conducted a series of laboratory-scale experiments on four base rock dusts and their treated counterparts to assess the effectiveness of various anti-caking additives after being exposed to moisture and then dried. The dusts were exposed to moisture using humidity cabinets having a high relative humidity (99% RH) and by also exposing the rock dust bed to water through bottom wicking. The dusts were then evaluated for dispersibility after drying using the NIOSH-designed dust dispersion chamber. The anticaking additives were different concentrations of stearic acid, oleic acid, and xylene-based surfactants. All results were compared to a reference rock dust used to conduct large-scale experiments in the Lake Lynn Laboratory (LLL), Fairchance, PA. When the untreated dusts were dried after exposure to moisture for one day, no dispersion was measured. However, rock dusts treated with anti-caking agents were readily dispersible even after exposure to moisture for six months. This report details the analysis and characterization of anti-caking additives using the NIOSH-designed dispersion chamber and the 20-L explosion test chamber. INTRODUCTION In order for a coal dust explosion to propagate, five elements are required. In addition to the fire triangle in which three elements are necessary to sustain a fire—fuel (coal dust), heat (ignition source), and an oxidizer (oxygen in air)—a combustible dust explosion requires dispersion of a dust cloud (pressure wave) and confinement of a dust cloud (underground mine entry) (1). Coal dust explosions can originate anywhere in a mine. For example, when a small volume of a flammable methane and air mixture is ignited in a closed end, the high-temperature gases rapidly expand to create a pressure wave, sometimes referred to as a “pioneer wave,” that may steepen into a shock wave as it propagates away from the ignition source. The shock wave produces a wind that disperses the dust preferentially from any elevated and exposed surfaces (roof, ribs, belt structure, cribbing, etc.). Factors that are known to affect the intensity of an explosion are the dust particle size, the location of the dust within the entry, the dust dispersibility, and the volatility of the coal dust (1). Particles less than 75 μm (< 200 mesh) in size are most reactive (2). Dusts that are located on the roof, ribs, and elevated surfaces are more readily dispersed than dusts on the floor. Therefore, application of quality rock dust in sufficient quantities is essential to inert coal dust and to prevent continued flame propagation. 30 CFR 75.402 and 75.403 require 80% total incombustible content be maintained within 40 ft of the face, and 30 CFR 75.2 defines rock dust acceptable for use in underground coal mines. It also defined that “when rock dust is wetted and dried, will not form a cake”.

Jan 1, 2019

By Felicia F. Peng

Using a fuzzy logic controller, a signal applied on the processes may be generated through a linguistic protocol expressing an operator&apos;s intuitive control strategies. In this work, fuzzy logic controller and PID controller imposed upon the feedback liquid level control systems for a stirred tank are studied and compared. The construction factors including the shape of membership functions, number of fuzzy variables, number of inputs, number of rules, and different defuzzification methods are considered in design and formulating the fuzzy logic control strategies and algorithms. From the analysis of the strategies and control performances, an optimum controller may be generated by making use of the best combination of these fuzzy construction factors.

Jan 1, 1997

By D. Bogunovic

The U.S. coal mining industry consumes a significant amount of energy, primarily diesel fuel and electricity. The continuous global increase in energy demand, high energy prices, and environmental issues related to carbon dioxide emission represent a substantial challenge for the mining industry. This paper presents a result of research work on development of an integrated data environment system for analysis and control of energy consumption in a surface coal mine. A case study on an operating surface coal mine is carried out to demonstrate the practical application of the developed system. The research work presented here may be used by mining professionals to help provide the answers to the crucial questions of when, where, and how much energy is being used. This developed system represents a framework for efficient management of energy consumption. Key words: surface mining, coal, energy consumption, Information System.

Jan 1, 2009

By Jorge A. S. Tenorio, Chuanwei Zhuo, Joner O. Alves, Yiannis A. Levendis

"The disposal of wastes is a serious environmental problem, since available landfill space is dwindling. Their treatment by pyrolysis or combustion has merit, and the corresponding fuel or power production is of technological interest. However, such processes need a rigid control of emissions. This work addresses the gaseous light hydrocarbons (LHCs) generated during sequential pyrolysis and partial oxidation of unserviceable tires, PET bottles, com wastes (DDGS) and sugarcane bagasse in a two-stage laminar-flow horizontal furnace, kept at 1000 °C. Gas chromatography was used to identify and quantify the components of the emitted gaseous light hydrocarbons. The results showed that the biomass residues generated the highest emissions of aliphatic hydrocarbons, whereas PET generated the most aromatic hydrocarbons. When stainless steel meshes were inserted in the exhaust flow, it was found that hydrocarbon emissions were curtailed; as such meshes catalyzed partial conversion of these carbon-bearing gases to carbonaceous nanomaterials.IntroductionLight hydrocarbons (LHCs) are volatile organic compounds, consisting of hydrogen and carbon with low molecular weight; the most common species are methane, ethane, propane, butane, etc. LHCs are valuable since they are a very important energy resource. However, uncontrolled release of light hydrocarbon gases to the atmosphere should be avoided [l, 2]. In this work, a development is presented for the evaluation of LHCs generated during the controlled pyrolysis/combustion of several wastes in a two-stage laminar-flow horizontal furnace. Samples of unserviceable tires, post-consumer PET bottles and waste residues from the bioethanol industry (DDGS and sugarcane bagasse) were burned. A catalyst system, consisting of stainless steel screens, was tested for its effects on the gaseous emissions."

Jan 1, 2011

By I. K. Ozaydin

Analysis of piles groups loaded with large bending moments and both vertical and batter piles can be best performed by matrix analysis. In this paper, a case history about a tall marine control tower is presented. The soil conditions at the site and the results of the computer analysis of the piled foundation are summarized. It is shown that the pile loads are indeed less than the allowable load for a single pile. Pile head loads and moments are used in the analysis of the raft foundation.

Jan 1, 2010

By Dale Preece, Steven Sobolik, Richard Jensen

Recent events demonstrate that civil and government facilities and structures face an ever-increasing need to be designed for protection against malevolent explosions. Modification of existing public structures and especially design of new ones increasingly includes provisions for explosive protection. ISEE members endorse and promote responsible application of explosives to benefit mankind and deplore any other use. However, our knowledge of explosive behavior and our ability to predict the results of explosive events puts us in a unique position to give guidance to designers of civil and public structures. Recent advances in computational methods have resulted in new computer codes with ALE (arbitrary lagrangian eulerian) simulation capabilities. Historically, lagrangian computational methods have been used for modeling solids because the mesh or discretization moves with the material. Rock breakage resulting from explosively induced shock-waves has been successfully modeled with lagrangian codes. Explosive detonation has traditionally been modeled with eulerian techniques. Eulerian methods have been used to model gases and fluids, tracking the material as it moves through the computational grid. ALE computational technology couples the two methods together in a manner never before possible. An ALE simulation can accurately treat the explosive detonation, interaction of explosive gases with air, and the impact of explosive event on nearby solid structures. ALEGRA (Budge et al. 1997 a & b) is an ALE code developed at Sandia National Laboratories. ALEGRA simulations accurately predict the explosively induced impulse on the structure to be protected. It has been applied to the analysis and design of blastwalls to protect structures and people from explosive events. The impulse calculated can be used by structural engineers to design a blastwall. ALEGRA has also been applied to predict the effect of a blastwall on explosion overpressure some distance behind the blastwall to assess the effect on people present during the event.

Jan 1, 2000

By Mark Colwell

This paper summarizes the results of a research project whose goal was to provide the Australian coal industry with a longwall installation roadway (faceroad) design methodology that could be utilized by suitably qualified colliery personnel. This goal was achieved in 2012 and the design methodology (and software package) is referred to as Analysis and Design of Faceroad Roof Support (ADFRS). The intended benefits to underground operations, in the provision of this information and resource, are a safer and more productive workplace.

By Mark Colwell, Christopher Mark

This paper summarises the results of a research project whose goal was to provide the Australian coal industry with a rib support design methodology and software tool that could be utilised by suitably qualified colliery staff. The project was primarily funded by Australian Coal Association Research Program (ACARP) and further supported by several Australian longwall operations. The outcome of the project is a design methodology and software tool called, Analysis and Design of Rib Support (ADRS). ADRS is an empirical technique, which recognises that several geotechnical and design factors affect ribline performance and in addition that operational and safety issues essentially dictate the level of performance required. Therefore, the design recommendations associated with ADRS are specific to the Australian coal industry; however the procedure(s) for data collection and analysis could be applied to other countries&apos; &apos;underground coal industries. Case history data were compiled from 34 longwall and two bord and pillar operations resulting in 204 case histories with each case history data set being defined by approximately 130 individual data fields. In addition monitoring (incorporating stress cells and extensometers) was undertaken at 10 collieries to assess and quantify the effectiveness of different rib support patterns and hardware on rib performance. The monitoring sites allowed for an improved understanding of the mechanisms of rib failure and degradation in terms of its interaction with the installed support and at the various stages of the mining cycle. The design methodology deals with both mains development and gateroad development specific to Australian longwall mines. This paper focuses on longwall gateroads subjected to abutment loading and in particular the travel road which becomes the tailgate of the subsequent panel. The statistical analyses associated with these cases suggested that the level of rib support should be based primarily on the development height and the pillar stress level. The ADRS software guides users through the design process, allowing them to develop rib support plans based on sound science and a broad base of in-mine experience To the best of the authors’ knowledge ADRS is the first systematic rib support design technique to be developed for any country’s underground coal industry. The development and use of empirical models in mining have substantially contributed to improving safety and productivity. ADRS further demonstrates that empirical techniques are particularly relevant and beneficial in dealing with the complexities of geotechnical design associated with underground coal mining.

Jan 6, 2008

By Theodore Feldsher, Seung Han Kim, Mourad Attalla, John Roadifer, Chu-Chieh Jay Lin

Lifelines in seismic regions of the world seldom can escape crossing active faults. Cities in California have been mitigating this risk by constructing improved fault crossings. This paper discusses the analyses and design of the lining for a tunnel carrying a water conveyance pipeline through a fault that can potentially displace during a major earthquake event. The paper presents expected fault displacement, fault width and orientation respective to the tunnel, characterization of the ground surrounding the tunnel and its interaction with the lining, and performance required of the lining. Several other fault crossings will also be presented and discussed

Dec 1, 2022

Thermal barrier coating (TBC) systems provide thermal insulation to high temperature for aero¬propulsion. A fracture mechanical model developed earlier for multilayer systems is applied on TBC to realize superior performance by enhancement of fracture resistance. Functionally gradient materials (FGM) solution concept is the basis of approach followed here. A few realistic FGM TBCs are considered in the analysis in addition to a conventional TBC as the base case and a hypothetical worst case with YSZ-YSZ interface. Parameters like number, composition and thickness of graded layers and elastic modulus are considered for the analysis and quantitative improvement of fracture resistance of TBCs. The analysis is confined to deep crack with crack size to width ratio as 0.5.

Jan 1, 2010

By A. J. Meir, Paul G. Schmidt

"We present a novel approach to the mathematical analysis and computational simulation of fully three-dimensional, nonlinear, viscous, incompressible MHD flow in complex configurations involving several liquid and solid conductors. Such configurations arise in numerous metallurgical processes. Employing the current density rather than the magnetic field as the primary electromagnetic variable, it is possible to avoid artificial or highly idealized boundary conditions for electric and magnetic fields and to account exactly for the electromagnetic interaction of the flow region with the surrounding space. In addition, the approach lends itself naturally to finite-element based discretization techniques. As an application, we simulate the stationary flow of an electrically conducting fluid around a solid spherical particle of arbitrary conductivity, in the presence of crossed uniform electric and magnetic fields, and compute the Lorentz, pressure, and viscous forces exerted on the particle. This problem arises in connection with the electromagnetic filtration (purification) of molten metals before the casting stage.IntroductionNumerous metallurgical processes are governed by MHD effects resulting from the macroscopic interaction of liquid metals with applied or induced currents, electric and magnetic fields. Frequently these effects are technologically exploited in order to drive or to control the flow of metallic melts. Typical examples include the electromagnetic stirring of molten metals before the casting stage [1]; electromagnetic turbulence control in induction furnaces [2]; electromagnetic damping of buoyancy-driven flow during solidification [3]; and the electromagnetic shaping of ingots in continuous casting [4]."

Jan 1, 1999

By M Fahey, A B. Fourie

Over the past ten years, the mining industry has witnessed the introduction of a new and innovative mine filling technique known as paste fill, which consists of placing full stream tailings with small amounts of binder and water into underground stopes. Paste fill has benefits over traditional backfill methods, such as higher solids contents than hydraulic fill and easier transportation than rock fill. From a geotechnical perspective, the behaviour of very fine material in a fully saturated state can be complex, particularly when binder is added. Previously, there has been no rigorous solution to understanding the paste fill deposition process, resulting in uncertainty regarding critical aspects such as barricade load calculations. This uncertainty has the obvious consequences of potential barricade failures (including at least 12 over the past four years), and for many operations attempts to deal with this uncertainty has led to excessively conservative filling schedules, restricting production. This paper presents an application of Minefill-2D, the first rigorous model capable of representing the paste fill deposition process. The model couples the processes of material accretion, consolidation and cement hydration to calculate the distribution of stress around a stope (including the total stress applied to barricade structures) during filling. Minefill-2D is a finite element numerical program, which has been verified using laboratory element tests, centrifuge tests and in situ measurements (Helinski, 2008). The authors present a sensitivity analysis, carried out using the model, to demonstrate some of the critical and less critical aspects relating to paste backfill deposition. The results of this sensitivity analysis are used to devise a fill management strategy that can be utilised to minimise the risk of barricade failures and maximise fill rates where appropriate.

Jan 1, 2008

By R. Venugopal

Hydrocyclones have been used extensively for more than 100 years to classify mineral slurries for recirculation in grinding circuits. Sometimes hydrocyclone classification is carried out in more than one stage to improve the efficiency of classification. Factors affecting separation efficiency include fluid velocity, density, and viscosity as well as the mass, size, and density of the particles. The geometric configuration also affects its efficiency; it includes parameters like cyclone diameter, underflow and overflow diameter, position of vortex finder, height of the cyclone, feed inlet geometry, and diameter etc. Besides changes in the basic parameters some modifications in cyclone has also been introduced from time to time which have affected its efficiency, some of these are :-(i).Introduction of magnetic force along with the centrifugal and drag force to control the flow of the magnetic particles inside the chamber.(ii). Introduction of sparger, air is introduced in the chamber in the form of bubbles, to control the flow of fine particles and hydrophobic particles. (iii). Introduction of dilution technologies for the dilution of thickened underflow. (iv).Introduction of new model. In spite of wide use and simple geometry, the real working principle of hydrocyclone chamber is extremely complex because of the swirling turbulent flow inside the device. In order to get more knowledge about hydrocyclones and to increase its efficiency, past 10-15 years simulation techniques are being developed. The simulation models also enabled a deeper insight into the static and dynamic behavior of hydrocyclones. Therefore, more emphasis on simulations by methods like Computational Fluid Dynamics (CFD), Finite Element method (FEM) is given. Overall, a status review of the work carried out on the analysis of hydrocyclone performance, modeling approaches and its contribution in the efficiency of mineral processing operation is highlighted.

Sep 1, 2012