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By Eurípides do Amaral Vargas Jr., J. A. de Mello Franco

"It is frequently necessary to excavate a tunnel for Civil Engineering purposes, or wells for petroleum exploitation, in laminated rock mass like schists or phyllites or in highly foliated gneisses. The determination of the pre-existing in situ stresses is essential, in order to assure the stability of these excavations. In most cases, the pre-existing triaxial stress field is arbitrary in relation to the tunnel or well axis. For these rock masses the concept of Generalised Plane Strain can be correctly utilized.There are closed form solutions for the calculation of stresses in anisotropic rock masses under Generalised Plane Strain conditions (Lehknitskii, 1981 and Hong , 1994). Based on these analytical solutions, established for the cases of Generalised Plane Strain, a synthetic problem will be formulated: the theoretical in situ stress tensor acting on this rock mass will be determined, with the aid of Bayesian Inverse Problem Techniques, as developed by de Mello Franco (2009). Additionally, the reliability of results obtained will be evaluated, in accordance with the research performed by this author. INTRODUCTIONThe Inverse Problem Technique, as developed in the paper, is based on the definitions and concepts obtained from the current literature and used for the solution of Inverse Problems, but the innovation to be presented is the utilisation of Bayesian Techniques and the determination of the reliability of the results obtained. This will be shown in a synthetic example where the determination of the in situ stress tensor, from strain measurements in a drill hole is supposedly performed. It is assumed that this drill has its axis arbitrarily placed in relation to the rock mass. Generalised Plane Strain conditions will hold for use with problem. The equations of Beltrami – Mitchel, in agreement to Lekhnitskii (1981) and Ong (1994), will be used in this synthetic case, for calculating strains, hypothetically measured in the hole before the final excavations. Finally a synthetic example for the determination of the in situ stress in a fully anisotropic rock mass, based on Bayesian Techniques and its reliability, developed in de Mello Franco (2009) is presented."

Jan 1, 2015

By Q. B. Li, B. Gonçalves da Silva, J. T. Germaine, H. H. Einstein, Z. Moradian

"Shale gas and oil production has grown rapidly in recent years, and consequently there are increasing demands to understand the mechanical and microseismic properties of shale. Acoustic emission (AE) monitoring provides useful information on the fracture mechanisms of shale rocks, and provides a basis for interpreting field seismic observations. While there have been attempts for microseismic monitoring of conventional hydrocarbon reservoirs, shale presents a large number of issues that require further investigation. For this purpose, experiments were conducted to understand the characteristics of the AE waveforms propagated through Opalinus shale rock in the time and frequency domains. Frequency range, arrival time, first arrival amplitude and other parameters such as counts, duration and energy of the waves generated from artificial and natural sources in the shale specimens were detected and compared with AE characteristics of granite, a brittle rock that has been extensively investigated. The experimental tests showed that there are some important factors that influence the analyses and interpretations of seismic surveys and microseismic monitoring of shale compared to granite. One of these factors is the anisotropic behavior of shale that causes the wave to propagate with different velocities in different directions. Also bedding planes and micro-discontinuities in the shale cause attenuation of the waves. Thus the AE waveforms that arrive at the sensor are a distorted and attenuated versions of the source waveform.INTRODUCTIONMonitoring microseismic activity from hydraulic fracturing of shale provides vital information for mapping injection paths and fluid migration in order to check the effectiveness of the hydraulic fracture stimulation. Analysis of microseismic source locations can be used to identify fracture networks induced or mobilized during the hydraulic fracturing operation (Rotherd and Shapiro, 2003). On the other hand, by monitoring and assessing detected signals from hydraulic fracturing one can evaluate the induced seismic impact of the stimulation operation.While there have been attempts to monitor microseismic events in conventional hydrocarbon reservoirs, shale presents a large number of issues that require further investigation. For this purpose, experiments were conducted on Opalinus shale to understand its acoustic emission (AE) characteristics in the time and frequency domains."

Jan 1, 2015

By Hongyan Qu, Lihui Zheng

"Horizontal wells in coal seams, Qinshui basin, China are prone to wellbore instability problems induced by drilling, completion and production operations due to the presence of natural cleat network, anisotropy with regard to permeability, brittleness and mechanically weak property of the coal rock. The mechanism of wellbore instability in coal seams is very different from that in conventional formations, the traditional wellbore stability study methods therefore, are not proper for wellbore stability analysis in coal.In this study, the mechanism and controlling of wellbore stability of coal seams in the Qinshui basin was investigated through theoretical modeling, laboratory experiment and field operation. Firstly, a new physical model of wellbore stability for highly-cleated coalbed was proposed, considering the combined effect of mechanical mechanism and reservoir characteristics, specifically, taking the effect of reservoir pore pressure in the vicinity of the wellbore on the wellbore stability into account. Then experiments on the triaxial stress evaluation were conducted at laboratory where rock mechanical parameters such as Poisson's ratio, Young's modulus, compressive strength, tensile strength, angle of internal friction and cohesion ability were measured respectively. The in situ stress at different depths in four wells of Zheng 1-303, Zheng 1-308, Zheng 1-309, and Zheng 1-310 in the Zhengzhuang were calculated, and the collapse pressure and formation breakdown pressure were predicted through the theoretical model we developed. Finally, by comparing the maximum collapse pressure and minimum breakdown pressure of the four wells in the coal as well as in the roof and floor of the coal seams, the fluid weight window for safe drilling in each coal seams was determined, and appropriate approaches against anti-sloughing in coal seams, Qinshui basin were applied in the field operation.The wellbore stability was found not only related to the wellbore pressure, but also affected by the pressure in the reservoir through the theoretical model. The fluid weight window for safe drilling in each coal seams varies with the coefficient of wellbore stability in the model. The laboratory experiment results indicate that the roof and floor of 3 # coal in Qinshui basin has high breaking strength, high heterogeneity, and are easy to collapse and breakdown. In addition, the whole rock mineral analysis shows that 3 # coal in the Duanshi block has high clay content, resulting in the phenomenon of hydration swelling as clay encountered water, and leading to unstable coal and extreme large drilling uncertainties. Due to the effect of the unstable rock mechanical properties of the roof and floor formation on the wellbore stabilizing, drilling parameters, drilling fluid performance and BHA were optimized during the drilling process according to the formation properties, rock mechanical properties and drilling techniques in the field operation."

Jan 1, 2015

By R. Holmestad, M. Gazizov, S. Wenner, R. Kaibyshev, J. K. Sunde

"Mechanical properties and microstructure of an Al-4.7Cu-0.74Mg-0.51Si-0.48Mn-0.10Cr-0.09Ti-0.02Fe (wt. %) alloy subjected to various thermomechanical processing (TMP) have been investigated and compared to conventional ageing at 170°C (designated T6). Three TMP routes involving cold deformation of solution treated samples were tested. These were (i) 3%-stretching (T8-3%), (ii) equal-channel angular pressing (ECAP) to true strain (e) of ~1 (T8-1) and (iii) ECAP to e~2 (T8-2), all with subsequent ageing at 170°C for 0-96 h. At peak age conditions, both yield stress, ultimate tensile strength and elongation-to-fracture decreased for the T8-3% state as compared to the T6 condition. Intermediate ECAP (T8-1 and T8-2) lead to significant increase in maximum yield stress, ultimate tensile strength and elongation-to-fracture. The changes in mechanical properties were related to microstructure evolution, encompassing changes in grain sizes, dislocation densities, precipitate morphology and phase fractions, which were characterised using transmission electron microscopy. Relations between TMP, precipitation behavior and contributions to different strengthening mechanisms are evaluated.INTRODUCTION Al-Cu-Mg-Si alloys are widely used as structural materials in aerospace industry due to their attractive combination of high specific strength, good fracture toughness and enhanced creep resistance. These properties are largely due to the formation of a large number of nano-sized metastable precipitates during artificial ageing (Polmear, 2006; Eskin, 2003; Gazizov, Dubina, Zhemchuzhnikova, & Kaibyshev, 2015). The precipitation behaviour in these alloys is complicated and depends among other things on Cu concentration and the Mg:Si ratio (Wolverton, 2001; Chakrabarti, & Laughlin, 2004). In general, the precipitation sequence has been presented in a prior study (Eskin, 2003) as follows:"

Jan 1, 2018

By Mark Holdsworth

In 2002, Kennecott Utah Copper Copperton Concentrator installed an Expert Control system for optimization of their SAG and Ball milling circuits. The advanced process control has been well received and is utilized well over 95% of the time. In the years since, many lessons have been learned and many advances have been made. Improvements have produced millions of dollars of benefits and have included directly controlling feedrate with complex logic as opposed to using a bearing pressure controller, modifications to how sound is used for control, modifying logic for maximizing asset utilization and using advanced control for automating equipment restart.

Jan 1, 2012

By J. E. Dutrizac, R. J. C. MacDonald, J. B. O'Reilly

"Sometime around 3000 B.C., primitive metallurgists working in the mountainous regions of Asia Minor bordering on the Black Sea (Pontus) produced a soft, easily fused metal today known as lead. It appears certain that the first metal was made by reductive smelting of galena, but whether this recovery arose by the accidental inclusion of galena in the stones of a fire hearth or whether it occurred as a consequence of simple pyrometallurgical experiments on a series of interesting ""stones"" will likely never be known with certainty. The properties of galena, high metallic lustre, great density and facile cleavage, must have excited the ancients, and such ""stones"" would have been the object of primitive testing111 - Shortly after the discovery of lead, the ancients found that the controlled oxidation of this metal at elevated temperatures yielded smaller amounts of a more interesting material, silver. Again, it is uncertain if the production of silver by primitive cupellation techniques was the result of a fireside accident or the consequence of a deliberate experiment, but the important fact is that silver was produced shortly after the discovery of lead. The techniques for making lead and silver spread gradually throughout the entire civilized world, likely as a result of both technology diffusion and independent rediscovery. The physical properties of lead could not have been overly attractive to the ancients, but silver was a different matter altogether. The gleaming white lustre and relative immunity to oxidation quickly assigned silver to the precious materials category, a status it still enjoys. In early times, argentiferous galena was inevitably processed only for its silver values; lead was generally an unwanted byproduct and was frequently discarded as litharge (PbO) during the cupellation process. The silver was eagerly sought, however, and resulted in considerable mining activity culminating in the famous Athenian silver mines at Laurium at the southern end of the Athenian peninsula."

Jan 1, 1999

By Meifeng Zhi, Yuqing Niu, Xixin Chang, Fengqi Zhao, Weimin Qiu, Hao Wang, Zhenqian Wen, Zujun Shu

An applicable Eluex process was developed for acid in-situ leaching (ISL) uranium mine in Bayanwula. In this process, uranium was adsorbed with strong base anion resin from the pregnant solution, then the loaded resin was eluted by sulfuric acid. After D2EHPA extraction, the concentrated eluate was enriched, and the loaded organic phase was stripped by sodium carbonate. The yellow cake was obtained by sodium hydroxide precipitation at last. The uranium concentration in the loaded strip solution was 52.8 g/L. Parameters of the process were determined, and the impact of the Eluex process in underground leaching was also investigated. In industrial design, 95% of raffinate went back to elution and 5% back to in-situ leaching. No significant effect on uranium leaching or resin adsorption was found.

Jan 1, 2020

By J. A. Brown, F. P. Kerr, M. A. Archer

Extensive testwork on Global Atomic’s Dasa Project in Niger has been conducted at SGS Minerals laboratory in Lakefield, Ontario. Much of this testwork has focused on a two-stage counter-current leach as a means of improving leach efficiency and decreasing reagent consumption. The ore contains uranium mineralization requiring relatively high sulphuric acid concentrations during leaching to achieve acceptably high extractions. Excess free acidity in the leach solution may be utilized by recycling the high acid solution and contacting it with fresh ground ore. The resulting pregnant leach solution (PLS), now higher in uranium concentration and depleted in free acid, is forwarded on to uranium recovery by solvent extraction. The first stage residue proceeds to the second stage leach where fresh acid and oxidant are provided to leach the remaining uranium. This paper presents the results of the testwork conducted on both a Master Composite and Variability samples.

Jan 1, 2020

By A. Kobzhanov, S. Saparova, S. Brochot, D. A. Mango

KATCO (an ORANO Mining and Kazatomprom joint venture) is the largest in-situ leach uranium mining operation in the world, exploiting the Muyunkum and Tortkuduk uranium deposits in southern Kazakhstan. After extraction from the deposits, uranium is then transported via a hydraulic network to be purified in three processing plants located near these deposits. Within KATCO, with the support of ORANO Mining and CASPEO, in 2018 and 2019, a large project that had as its main objective to improve the uranium accounting system was implemented. The objective of this paper is to describe this project and all the changes that it entailed. At KATCO plants, a black-box approach was previously used for uranium accounting. However, it is recommended to use all the available measurements and to deploy a data reconciliation model (between well-fields and plant) as the reconciliation uncertainty is overall lower and it provides a more accurate uranium balance. During the deployment of this project, the rules and algorithms to generate the uranium accounting report, the associated flow diagrams (for uranium accounting), the streams, units of operation, stocks, reporting and Key Performance Indicators calculation rules were re-defined.

Jan 1, 2020

By J. Lapointe, S. Leger, D. Proulx

"Une méthode non-électrolytique est utilisée pour plaquer au cuivre la fibre d'amiante chrysotite. En variant les paramètres de placage du bain, on détermine les conditions optimales du taux de deposition du cuivre . Une analyse par diffraction aux rayons-X permet une comp araison relative des résultats de placage et de précipitation d'oxyde cuivreux dans Ie bain. Le traitement de placage a pour but d'assurer une adhésion suffisante de la fibre dans une matrice métallique Iors de la fabrication éventuelle de materiaux composites.IntroductionCette communication se veut un compte-rendu de nos travaux sur Ie placage au cuivre de la fibre d'amiante chrysotile, en vue de I'incorporer éventuellernent dans une matrice métallique. La fibre d'amiante est constituée de fib rilles élementaires d'un diamètre d'environ 0.02 um qui ont une résistance en tension de I'ordre de celie de la fibre de verre ou de carbone(1). Pour être efficace, la fibre de renf'ort d'un matériau composite doit d'une part, avo ir des propriétés mécaniques intrinsèques élevées, et d'autre part, adhérer solidement â la matrice pour que Ie transfert de charge s'effectue sans qu'il y ait décohésion entre les composantes du matériau.La fibre d'amiante étant naturellement soyeuse, il faut la traiter superficiellement pour que l'adhésion avec la matrice soit suffisante. Ainsi, on recouvre la fibre de phénol-formaldéhyde(2) ou de silane(3) lorsqu'elle est employée avec une matrice polymere. Dans Ie cas d'une matrice métallique, ces dépôts organiques ne peuvent resister aux températures de mise en oeuvre, d'où l'intérêt de plaquer les fibres par un dépôt métallique.Dans cette étude, nous rapportons les résultats relatifs à la methode utilisée pour plaquer au cuivre la fibre d'amiante chrysotile. Une analyse par diffraction aux rayons-X permet de comparer les différentes conditions de placage non-électrolytique."

Jan 1, 1985

By H. R. Butler, R. N. Browne

"The International Nickel Company of Canada Limited consumes some 33 ½ millions of gallons of fresh water and reuses more than 100 millions of gallons of water daily. The continuing search for suitable recycle methodology has enabled the Company to put one 25,000 TPD mill on line utilizing recycled water entirely and a second 35,000 TPD mill is under construction which will likewise employ the concept of recycled water. Future milling plans are aimed at the replacement of all fresh water with recycled water, including sewage effluent and mine waste water.WATER REUSE AT INCO’s SUDBURY MILLSAs man searches unexplored horizons for new and economic industry, he must be constantly and acutely aware of the presence or absence of that precious commodity without which Industry, indeed Man himself, could not survive -- W A T E R. The water requirements of the world today are magnanimous, considering that in 1960 the estimated consumption in the United States was over 300 billion GPD (l) or more than 1,700 GPD per person(5) The magnitude of the problem can be visualized as one considers that three times this quantity of water will be required in the United States by the year 2000, when the dependable supplies of water are estimated to be only two-thirds of that required(2). How, then can we continue to wreak such havoc on that life-sustaining substance - WATER?"

Jan 1, 1970

By C. E. St. Denis

"Training Program at Sherritt Gordon's Ruttar:. ConcentratorA formal training program for mill operators is being developed and employed at Sherritt Gordon's Ruttan Concentrator. The program was set up to fulfil the needs created by a shortage of skilled reliable labour, a 200% turnover of personnel within the first six months of operation and the rapid advances in mineral processing technology. All new employees are introduced into the Mill Department through an orientation program designed to familiarize them with the operation of the plant. All training and orientation of new employees is the responsibility of a. small training section consisting of two training foremen and one assistant. Using a combination of classroom and supervised on the job training, the training times have been cut by at least one half. High operating standards have been set and are maintained through the use of detailed manuals for each work area and competent instruction at all operating levels. The major portion of training costs arise from the salaries of the training staff but are negligible when compared to the improved recoveries, smaller turnover and less downtime. Government assistance is available to all industrial employers to offset the costs of training employees."

Jan 1, 1974

By Ian M. F. Arnold

"Occupational health programs and their role in improving the quality of working life in the mining industry are discussed. Attention is directed to some problems peculiar to the Canadian mining industry. Factors affecting program development are reviewed, as well as parameters affecting cost-benefit analyses.IntroductionThe quality of working life in the mining industry is a more important consideration than in many other industrial environments because of the very nature of the undertaking. It was a strange paradox of the 1960s that preventive maintenance programs for machinery and equipment were well accepted, whereas the concept of ""preventive people medicine"" was basically ignored. Fortunately, there seems to be a swing toward the development of occupational health programs in many sectors of the business community; however, there is a noticeable lack of consistency and uniformity for thought among the members of the mining industry. The blame for this lack o f progress in the occupational field cannot be entirely attributed to the industry, but must also rest with (for the most part) apathetic and inadequately trained physicians. This latter problem is slowly improving with the growing recognition that a well-planned and executed occupational health program may improve the quality of working life for mining employees and their families.There are a number of factors which relate to occupational health in mining, and its effect on working life quality. Included among these are:1. Community isolation.2. High accident risks.3. Occupational disease risks.4. Production demands and the state of the economy.5. Government regulatory requirements.6. Travel demands.These, and others, reflect on all levels of the mining industry. To examine how these factors can be moderated by an occupational health program, it is necessary to first review the rationale for such a program and some of the costs related to it."

Jan 1, 1983

By Georges Houlachi, Akram Alfantazi, Maysam Mohammadi

Manganese ions in zinc electrowinning electrolytes form a protective MnO2 layer that ultimately decreases Pb contamination in the zinc product. In this study, the effect of dissolved Mn2+ on the electrochemical performance of Pb, Pb-Ca and composite Pb-MnO2 anodes was investigated. The properties of the MnO2 layer formed on these anodes were studied and compared. Potentiodynamic polarization and cyclic voltammetry experiments were performed in 180 g L-1 sulphuric acid to study the electrochemical reactions occurring on the anodes. The anodes were subjected to galvanostatic polarization at 50 mA cm-2. The morphology and uniformity of the MnO2 layer on the anodes were examined using scanning electron microscopy (SEM). Experimental results revealed that the MnO2 layer formed on the composite anode was more compact and uniform compared to that formed on the Pb and Pb-Ca anode. It was also observed that the cell mud formation rate, and consequently manganese ions consumption, depended on the anode type. Although initial formation of the MnO2 layer decreased the oxygen evolution overpotential, its growth might negatively affect electrocatalytic activity of the anodes.

Jan 1, 2014

By I. Lackey

In 2004, Zinifex Budel Zink commenced testing with the objective to increase the precipitation of aluminium in the iron purification stage of its hydrometallurgical zinc circuit, without the use of expensive reagents. Findings from the literature applied to the leach circuit at Zinifex Budel Zink demonstrated that aluminium removal from the leach circuit could be increased by lowering the ferric concentration and acidity in the vessels where jarosite precipitation occurs. An associated increase in copper precipitation was mitigated by limiting the extent to which the ferric concentration was lowered in the vessels where jarosite forms and lowering the ratio of copper to aluminium in the solutions entering these vessels.

Jan 1, 2006

By Z. Ren, M. Tomlinson, E. Asselin

"Organic carbon blinding is a common, yet often partial, solution to the reduction of preg-robbing. A quantitative method to assess the extent of adsorption of a given blinding agent is presented herein. The adsorption of several blinding reagents on various carbon samples is quantified using electrochemical impedance spectroscopy (EIS). EIS results showed that kerosene is more strongly adsorbed on carbon than sodium lauryl sulphate (SLS), while SLS can hinder the charge transfer process of the oxygen reduction reaction on the carbon surface more effectively. The effectiveness of SLS is pronounced when its concentration is higher than 100 ppm. Raman spectra are presented for selected carbon samples: as the area ratio of the disordered peak to the graphitic peak increases, blinding agent adsorption increases.INTRODUCTION The presence of naturally occurring constituents in gold ores may adversely affect the extraction of gold in cyanide leaching since the gold cyanide complex, Au(CN)2–, can be adsorbed by these constituents (M. Adams & Fleming, 1989; Afenya, 1991; Miller, Wan, & Díaz, 2005). Such ores are known as “preg-robbing”. Preg-robbing behavior may arise from natural carbonaceous materials in the ore (M. Adams & Burger, 1998). In the past decades, a number of pre-treating methods have been developed for refractory carbonaceous ores (Arriagada & Osseo-Asare, 1984; Beer, 1994; Dunne et al., 2007; Jiang, Liu, Xiao, & Yang, 2012; Kohr, 1997; Kulpa & Brierley, 1993; Menne, 1992; Menne & Revy, 1994; Moyes & Houllis, 2010; Petrie, Craw, & Ryan, 2005; Simmons, 1996). The method known as blinding is one of the most effective and economical pre-treatment methods (M. D. Adams & Burger, 1998; Albert, 1923; Darrow, 1924; McQuiston & Shoemaker, 1975; Van den Berg, 2000). Blinding, also referred to as blanking or passivation, uses a chemical reagent to passivate the preg-robbing carbon by selective absorption or wetting (Bas, Altinkaya, Yazici, & Deveci, 2012; Brierley & Kulpa Jr, 1993; Dunne et al., 2012; Van den Berg, 2000; Yang, Qian, Song, & Dong, 2013; Yen, Amankwah, & Choi, 2008; Zhou, Jiang, & Choi, 2014). Organic reagents, which selectively adsorb on the surfaces of activated carbon and “smother” the surface, have been used for blinding carbonaceous matter in gold ores prior to cyanidation. Two comprehensive studies by Abotsi and Osseo-Asare and Adams and Burger have been published on this topic (Abotsi & Osseo-Asare, 1986; M. D. Adams & Burger, 1998)."

Jan 1, 2017

By N. Sauret-Szczepanski, G. Patry, S. Gauthier, G. Potvin, C. Munger

Adsorption/thermal desorption with sorbent cartridges and analytical method using gas chromatography coupled to mass spectrometry (GC/MS) was developed for the determination of tetrafluoromethane (CF4) and hexafluoroethane (C2F6) emitted from primary aluminum smelters. A customized cartridge was built like a packed column with a stainless steel tube filled with a specific resin. The optimization of adsorption and desorption parameters was carried out to support the PFC sampling for all aluminum production technologies. The proposed method showed good linearity for concentrations ranging from 10 to 500 ppbv for CF4 and from 5 to 500 ppbv for C2F6 with correlation coefficients above 0.999. In certain conditions, the detection limits of the analytical method reached 0.3 ppbv for CF4 and 0.15 ppbv for C2F6- Using this methodology, a field campaign was carried out using a sequential sampler allowing the simultaneous sampling of PFC with cartridges and sampling bags. The results showed no significant difference (t-test) between the two sampling technologies and no breakthrough was observed from the cartridges .

Jan 1, 2006

By W. A. Gow, J. A. Vezina

"A new process for treating scheelite for the production of tungstic tri-oxide is described. The novelty of the process resides in that an ion-ex-changer is used to convert sodium tungstate to either ammonium tung-state or tungstic acid.The process consists of a conventional hydrochloric acid leach of the scheelite concentrate, and the dissolution of the impure tungstic acid thus produced with sodium hydroxide at pH 8. The sodium tungstate solution is clarified and passed through a column of Dowex 50Wx8 ion-ex-change resin to exchange the sodium ions for either hydrogen or ammonium ions, both being suitable. The tungsten-bearing column effluent is evaporated to crystallize the tungsten as ammonium tungstate; the crystals are washed with nitric acid and water and decomposed by heat to pro-duce tungstic trioxide of high purity.Ninety-six per cent of the tungsten in the concentrate may be re-covered as tungs tic trioxide (W03), and the reagents consumed are 0.7 g HCl, 0.41 g NaOH and either 1.73 g NH.Cl or 225 g HCl per gram of tungsten."

Jan 1, 1966

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

By D. Stone, N. J. Aslin, W. Webb

In today's modem copper electro-refineries, increasingly higher average current densities are being employed. With these increases many refineries are approaching their limiting current density. The nearness of the average operating current density to the limiting current density has placed increasing emphasis on the need to maintain an even current distribution. This paper explores the importance of maintaining even current density and discusses the factors, processes and practices that are necessary to achieve and maintain high quality production at high operational intensity.

Jan 1, 2005