Search Documents

By Khosrow Nikkhah

Increasingly ion exchange systems are being included in design of hydrometallurgical plants for metal extraction or impurity removal. Because such systems operate sequentially and are based on resins that exchange one ion for another, store it temporarily and release it to a regenerating solution, the usual steady state heat and mass balancing tools and spreadsheets cannot be used to design them successfully. This paper outlines the role of dynamic simulation in design of ion exchange systems. Examples are given for use of dynamic simulation in design and investigation of equipment based on consideration of the effect of input criteria such as expected ion loading and elution profiles. The methodology for dynamic modeling using IDEAS in design of multi column ion exchange trains operating in parallel is presented. Results shown include the non-steady state distribution of extracted metal and limitations imposed on operating conditions. These conditions include proposed sequencing of columns for loading and elution cycles, loading, elution and recycle flow rates as well as size and choice of related ion exchange plant equipment.

Jan 1, 2003

By J. W. Matousek

Copper losses in smelter slags are :typically normalized with some form of the distribution coefficient, written as the ratio of the weight percent assays of metal in slag to the metal in matte or its inverse: L(s/m) = %(Cu)/%[Cu] or L(m/s) = %[Cu]/%(Cu) However, this simple approach ignores the dynamics of the smelting process. It overlooks the effect of the chemical work done in producing a given matte grade from concentrates of different grades -- or from a single concentrate blended with varying quantities of copper bearing precipitates or reverts. This paper examines the combined influences of matte grade and the work done in smelting on the copper content of smelting furnace slags. A simple model for the relationship is proposed.

Jan 1, 1999

By A. Chaisantikulwat

Most solid-oxide fuel cell (SOFC) modeling emphasizes steady state cell operation. However, understanding the dynamic behavior is essential to predict the performance and limitations of SOFC power systems. In this work, we demonstrate a dynamic model of a SOFC, and we simulate a feedback control scheme that can maintain output voltage despite load changes. Dynamic response is determined as the solution of coupled partial differential equations derived from conservation laws for energy, mass and electric charge. From such a model, the step responses to system input variables can be determined. Low order dynamic models that are sufficient for feedback control design can be derived from the step responses. The development of the partial differential equation model is outlined, and the limitations of the control system are discussed.

Jan 1, 2005

By C. Steyn, J. D. le Roux

A dynamic model is used to represent the single-stage closed grinding mill circuit at Mogalakwena North Concentrator. The circuit consists of a ball mill closed by a hydrocyclone. The circuit is modelled according to a semi-mechanistic non-linear dynamic model available in literature. An algebraic routine is used to fit model parameters to steady-state process data. Preliminary validation results against dynamic data indicate that the model is capable of capturing the main dynamic trends of the plant. Since classical system identification techniques proved insufficient to produce accurate models; the non-linear model can be used as a reliable source for model-predictive controller design. Keywords: Grinding, modelling, process control, parameter estimation

Jan 1, 2020

By Helen Shang, Jianjun He

In nickel and copper production, sulfur dioxide (SO2) is generated during mineral smelting. Emission of sulfur dioxide into the atmosphere causes serious health and environment issues. Sulfuric acid plants, which convert the harmful SO2 gas to commercially useful sulfuric acid product, ensures safe and environmentally sound smelter operations. The sulfuric acid plant is mainly composed of a SO2 to SO3 converter, a series of heat exchangers and SO3 absorption towers. The SO2 converter is crucial for minimizing SO2 emission in a smelter. In this paper, steady state and dynamic modelling are carried out for the converter using mole and energy conservations. Simulations are performed to investigate the effect of feed conditions on SO2 conversion. The developed model represents an important component for modelling the acid plant in a smelter and is expected to provide a fundamental tool for the future optimization and control development.

Jan 1, 2014

By Wood CJ, Davis JJ, Askew H

A dynamic model of a dense medium circuit has been developed and tested against plant data. The model shows the response of the circuit to both controlled (changes in specific gravity set point or changes in circuit coal feed rate) and uncontrolled changes (changes in raw coal moisture, loss of raw coal feed) in operating conditions. The model is built up from dynamic models of the individual sumps, pumps, pipes, splitters, magnetic separators and automatic controllers in the circuit. The model can be used for design of automatic control loops and for investigation of possible process modifications such as changes in water addition points. This paper describes the model construction, the testing of the model against actual plant data and gives some examples of its use in investigating plant response to changes in operating conditions.

Jan 1, 1978

By R. Q. Honaker

Although the fundamental principles of hindered bed classifiers are relatively simple, the complex interactions between the operating parameters provide a degree of difficulty that hinders the ability for on-line plant optimization. Thus, a dynamic population balance model was developed for determining the hindered settling velocity of particles varying in density and size. The steady-state results of the model include partition curves as a function of particle size and density as well as metallurgical data. A statistical comparison of the simulation results with those obtained from industrial units reveal a high level of accuracy with adjusted R2 values greater than 0.95.

Jan 1, 1999

By Ali Nadir Khan

Depleting copper resources and advancing technologies have challenged industries to develop more viable, adaptable and cost efficient processes using also secondary raw materials in copper production. This study is targeting to that goal by dynamic modelling of flow and heat transfer coupled with chemical kinetics in an industrial scale flash smelting furnace settler using commercial CFD software ANSYS Fluent. First, different physical phenomena occurring inside the settler, for example, settling and separation of the matte/slag phases, and heat transfer between slag/matte phases and settler walls are studied. Secondly, reaction kinetics between matte and slag, and between slag/matte and settler walls, and impurity element distribution will be studied. This would also include phase changes phenomena due to these reactions and the flow of the reaction gases inside the settler. Settling of polydispersed droplets, their coagulation, breakage, and WEEE particle behavior are further targets of the modelling work.

By M. Karamoozian

Modelling and optimisation of the power draw of large SAG mills are important due to the large power draw which modern mills require (5~10 MW). The cost of grinding is the single biggest cost within the entire process of mineral processing. Traditionally, modelling of the mill power draw has been done using empirical models. Although these models are reliable, they cannot model mills and operating conditions, which are not within the model database boundaries. Also, due to their static nature, the impact of the changing conditions on the power draw, within the mill, cannot be deter-mined using such models. Despite advances in computing power, on-line modelling of large plant scale mills could be a time consuming task. On the other hand, using on-line parameters for model-ling, result in more reliable control of SAG mill without performing any more costly tests. In this paper, SAG mill power draw is modelled using neural network approach. Six inputs, namely: solid percent, two bearing pressures, noise, recycle and feed rate were used to model the power draw. The produced model shows an acceptable correlation coefficient, R2 =0.9623.

Jan 1, 2014

By Markus A. Reuter, Antoinette van Schaik

"INTRODUCTIONGoods and products, such as passenger vehicles, are manufactured by using a wide spectrum of different raw materials to meet highest consumer requirements during use. Due to the time-varying composition and complexity of multi-component products such as cars, recycling is complicated. It involves a network of interconnected processes and material and energy flows. Improving the efficiency of the material cycle of the car to comply with the recycling targets as imposed by EU legislation, requires insight into all aspects influencing the closing of the material cycle (dynamics, technology, economy, legislation, etc.) and their mutual relation. In order to define the link between recycling end-of-life products, their changing composition and design a dynamic model was developed for the resource cycle of cars. The model integrates the optimisation of the material cycle with the dynamic behaviour of recycling systems."

Jan 1, 2003

By K. Nikkhah, N. Dhadli, G. Freeman

Ammoniacal pressure leaching operations have been in commercial use at the Fort Saskatchewan refinery of Sherritt International Corporation since 1954. Recent improvements have significantly increased the capacity of this circuit. The computer modeling of this process has proved to be a valuable tool in facilitating the evaluation of different operating scenarios in an effective manner. Reagent response in the ammonia leach of nickel and cobalt sulphides is examined using the dynamic process simulation capabilities of IDEAS(TM) software. The dynamic simulation enables accurate measurement of the sensitivity of the process to variables such as temperature, feed rate and ammonia concentration as well as compartmental analysis of metals concentration, pulp density, vent gas composition, and the formation of specific complexes. The complexity of the ammonia leach process makes it a logical choice for evaluation by computational analysis. The methodology for dynamic modeling of a pressure leach process is presented.

Jan 1, 2005

By H. W. Smith, D. Guerin

"This paper describes the development of a dynamic model for a full- scale (64 tonnes/hr) grinding circuit consisting of an open-circuit rod mill feeding a ball mill operating in closed circuit. The object of constructing such a model is to investigate the static and dynamic behaviour of potential control schemes. Model selection, data processing and parameter estimation are discussed, and static and dynamic results of simulations are presented. Conclusions are drawn with regard to the adequacy of the model for such studies, and likely limitations on control of such circuits.IntroductionThe model developed here is intended to represent the grinding behaviour of the grinding circuit at the Lake Dufault division of Falconbridge Copper Mines Ltd. This circuit has been fully described elsewhere. At the time of the work described, the ball mill discharge was fed to a four-cell flotation bank , the tailings of which are combined with the rod mill discharge in the cyclone feed pump sump. As the emphasis in this study is on grinding behaviour, and as only I per cent of cyclone feed material is removed in these cells, no attempt has been made to include flotation behaviour in the simulation. One effect of the presence of flotation cells in the grinding circuit is, however, to necessitate somewhat finer grinding than might otherwise be needed: this will have effects on mill parameters.The paper is organized as follows. First the selection of models is discussed, paying particular attention to the problem of selecting simple, yet adequate, flow models for the mills. Then data gathering is described. The method of deriving mill model parameters is explained, and the results presented. Mass balancing of cyclone data and the determination of cyclone model parameters are described. The linking of the models into a full simulation is outlined, and sta tic and dynamic results presented. Finally, the results are discussed and conclusions drawn ."

Jan 1, 1980

By D. Bahrami, W. K. Asante, G. L. Danko

It is prudent to interpret atmospheric monitoring signals in real time for checking the safe limits of the air conditions in underground mines. In gassy mines, real-time evaluation increases the safety of operations. In all mines, continuous monitoring and evaluation contributes to maintaining air conditions within healthy and safe limits. Signal interpretation for safety conditions in mines is difficult for many reasons. An increase in hazardous contaminant concentrations can be predicted by signal pattern recognition, root cause analysis of rapid changes toward deterioration, and forward prediction in time using algorithms and numerical models. The paper describes an early warning system for analyzing monitored signal patterns continuously in real time as well as forward predicting the various environmental and working conditions to recognize dangerous trends that may affect safety and health in underground mines. A dynamic, numerical ventilation model with heat and gas contaminant simulation components is used for the analysis of atmospheric data. Methods and test results are discussed with numerical examples for signal propagation prediction. Several mine examples are studied using controlled, synthetic data for malfunction simulations to evaluate time delays between the detection time of suspicious signal trends and the time of dangerous threshold crossing marking an accident scenario. Delay time is found in the order of 20 min in the examples, signifying the useful time period for preventive intervention between EWS warning and the likely breakout of a following accident.

By D. Bahrami, W. K. Asante, G. L. Danko

It is prudent to interpret atmospheric monitoring signals in real time for checking the safe limits of the air conditions in underground mines. In gassy mines, real-time evaluation increases the safety of operations. In all mines, continuous monitoring and evaluation contributes to maintaining air conditions within healthy and safe limits. Signal interpretation for safety conditions in mines is difficult for many reasons. An increase in hazardous contaminant concentrations can be predicted by signal pattern recognition, root cause analysis of rapid changes toward deterioration, and forward prediction in time using algorithms and numerical models. The paper describes an early warning system for analyzing monitored signal patterns continuously in real time as well as forward predicting the various environmental and working conditions to recognize dangerous trends that may affect safety and health in underground mines. A dynamic, numerical ventilation model with heat and gas contaminant simulation components is used for the analysis of atmospheric data. Methods and test results are discussed with numerical examples for signal propagation prediction. Several mine examples are studied using controlled, synthetic data for malfunction simulations to evaluate time delays between the detection time of suspicious signal trends and the time of dangerous threshold crossing marking an accident scenario. Delay time is found in the order of 20 min in the examples, signifying the useful time period for preventive intervention between EWS warning and the likely breakout of a following accident.

By Patrick J. Hannigan

The pile foundation designer typically performs a subsurface exploration program and static pile capacity calculations before selecting a pile foundation type, length, and capacity. During construction, a pile installation criterion must be established to meet these design requirements. This installation criterion usually consists of a minimum penetration resistance or blow count to confirm pile capacity and may also include a minimum embedment requirement. This text will focus on use of wave equation analysis and dynamic measurements to meet design requirements. BEFORE THE WAVE EQUATION Since the mid-1800s, over 450 dynamic formulas for pile driving control have proliferated. In their simplest form, these formulas relate hammer energy to the work of soil resistance, or simply: W ? h = R ? s (1) Where W = ram weight h = ram drop height or stroke R = pile capacity s = pile penetration per blow

Jan 1, 1990

By D. Michael Holloway

The realignment of Interstate 880 replaces the double-decked (Cypress) viaduct collapsed in Oakland, California during the 1989 Loma Prieta Earthquake. The California Department of Transportation (CALTRANS) evaluated several pile foundation schemes for supporting the proposed structures. Structural support demands led to the selection of steel pipe piles (16-, 24-, and 42-inch-(406-, 610- and 1067-mm-)diameter), filled with concrete and steel reinforcement. Deep penetrations required through layers of very dense/cemented sands in some locations, caused serious drivability and pile integrity concerns. The need for large pile driving hammers and large diameter steel pipe piles pushed the engineers and prospective contractors well beyond the limits of local experience. Such questions as the feasibility of driving the pipes closed-ended through dense upper strata, and quantifying the effects of installation on the long-term capacities of the piles, led CALTRANS to develop a comprehensive pile test program to address the design and construction issues effectively. The results were furnished to prospective bidders on the production stages of the ensuing contracts.

Jan 1, 1996

By Garfiansyah Rayes

In 2023, an Indonesian coal mine experienced significant contamination of an emulsion blend explosive by dynamic mud and water flow, triggered by flooding due to exceptionally high rainfall. This intrusion into explosive columns compromised the stability and efficiency of blasting operations, thereby impacting overall mining productivity. The extent and impact of these contaminants on the stability and performance of the emulsion blend explosive were rigorously analyzed through a robust assessment methodology that included comprehensive field measurements and controlled laboratory experiments designed to replicate the challenging site conditions. Utilizing a combination of theoretical calculations and Computational Fluid Dynamics (CFD) simulations, this study evaluates the kinetic interactions between dynamic mud flows and emulsion explosives within drill holes. The methodology integrates Torricelli’s theorem for velocity assessments and Darcy’s Law for understanding the penetration mechanics of mud into the emulsion blend. CFD simulations are further correlated with actual blast data to assess discrepancies between theoretical predictions and real-world outcomes. Results demonstrate a significant reduction in the velocity of detonation (VOD) of the explo-sives, traced directly to mud contamination levels, which align with the quantified penetration rates in the study. Practical measures for mitigating such contamination are proposed, including the reinforcement of water-ways, culverts, and bund walls at drilling locations based on validated simulation data. Additionally, rec-ommendations for operational adjustments during high rainfall events are discussed, aiming to enhance blasting safety and efficiency. The paper concludes by suggesting future research directions towards the development of more resilient emulsion formulations and enhanced predictive modeling techniques to better forecast the impacts of en-vironmental variables on explosive performance in mining operations

Jan 21, 2025

By Yuji: Wada Ogata, Kunihisa Katsuyama

It is well known that a compressed stress wave reflects at the free face, it propagates to the backward as a tensile stress wave, and cracks grow when the tensile stress becomes the dynamic tensile strength. The behavior of these cracks has been discussed through the observation of the dynamic photoelastic high speed photography.

Jan 1, 1993

By H. W. Reinhardt, J. W. Dally

A dynamic photoelastic analysis of stress waves interacting with a free surface is described. The free surface is that of a bench with a fixed bottom so common in quarry applications. The stress waves are generated by line charges of lead azide (Pb N,). Four models of identical geometry are investigated with the direction of detonation of the line charge varied between the four models. Dynamic photoelastic patterns are recorded and analyzed to indicate which method of detonating the line charge produced the largest magnitude of tension at the free surface. The mechanics of rock breakage by means of explosives has received considerable treatment by many investigators including Duvall, Obert, Broberg, Rinehart, and Langefors1-11 over the past two decades. Indeed in more recent years several texts12-15 have been written on the topic, treating a wide variety of subjects which are logically related to the modern technique of rock blasting. In rock blasting the chemical energy of a concentrated explosive contained in a relatively small diameter borehole is utilized to fragment the rock. The explosive is transformed into a gas with enormous pressures which exceed 10-5 bars18 This high pressure shatters the rock in the area adjacent to the borehole and produces dilatational and distortional stress waves which propagate radially away from the borehole. The state of stress associated with these outgoing waves produces a system of cracks which extend for a few feet from the borehole. The breakage produced in this manner is limited as the dynamic stress in the pulse attenuates markedly with distance. In the absence of a free surface, the stress wave propagates away from the source without further fracture. With a free face of rock near the drill hole, another mode of breakage occurs which is due to scabbing failure of the layer of rock adjacent to the free face. These scabbing failures are produced by the reflection of the incident waves and the conversion of compressive stresses into tensile stresses sufficiently large to fracture the rock. The detailed nature of the interaction of the stress waves with the free surface is complex and difficult to treat analytically. However, dynamic photoelasticity offers an experimental approach which gives a fullfield visual display of propagating stress waves and the reflection process. Applications of static photoelasticity to solution of problems related to mining technology have become relatively common (see, for instance, Refs. 17 and 18) with a plastic model loaded to produce a state of stress representative of that occurring in the workings of a mine. The application of dynamic photoelasticity is ex tremely limited. Tandanand and Hartman19 have used a multiple spark camera to study fracture in glass and plastic plates impacted by a chisel-shaped tool. This paper describes a dynamic photoelastic analysis of stress waves interacting with a free surface. The free surface is that of a bench with a fixed bottom so common in quarry applications. The stress waves are generated by line charges of lead azide (Pb-N6). Four models of identical geometry are investigated with the direction of detonation of the line charge varied between the four models. Dynamic photoelastic patterns are recorded and analyzed to indicate which method of detonating the line charge produced the largest magnitude of tension at the free surface. Experimental Procedure The model illustrated in [Fig. 1] was fabricated from a sheet of Columbia Resin CR-39 to represent a bench with a fixed bottom. Properties of the CR-39 pertaining to these dynamic experiments are listed in [Table 1]. Scribe lines on 1-in. centers are used to identify locations along the bench face. The bench height was 8 in., the burden was 3 in., and the overall dimensions of the sheet, 16 and 18 in., were large enough to eliminate reflections from nonessential boundaries during the period of observation of the dynamic event. To simulate a charge in a borehole, a groove 0.062 in. wide and 0.080 in. deep groove was cut into the sheet from one side. The lower end of the groove was 1 in. or 1/3 the burden distance below the bottom of the bench. The upper end of the groove was 3 in. or one times the burden distance below the upper level of the bench. The groove was packed with 60 mg of Pb No per in. of length, and ignited with a bridge wire detonator. Four different ignition procedures were used to examine the effects of detonation direction on the stress wave interaction with the free face of the bench. In Test 1 the line charge was ignited at the top and the line charge detonated downward. In Test 2 the line charge was ignited at the bottom and the charge burned upward. In Test 3 the charge was ignited in the center with the top half burning upward and the bottom half burning downward. Finally in Test 4 the line charge was ignited at both ends simultaneously. Sixteen high-speed photographs of the photoelastic fringe patterns representing the stress wave propagation were recorded for each of the tests. A Cranz-Schardin multiple spark gap camera 20,21 was operated at framing rates which were systematically varied from 110,000 to 250,000 frames per sec during each test.

Jan 1, 1972

By Scott Webster

Dynamic pile Monitoring Services (DMS) have been used for testing of offshore piles for several decades. However, most of this testing was to measure hammer performance and pile stresses rather than pile capacity or soil resistance. As the need for more economical solutions for foundation support increases, the use of DMS has provided a better means of evaluating in-place pile capacity for offshore structures, and therefore a method of determining pile acceptance. The authors have been involved in several offshore projects where DMS has been the primary source of data for acceptance of the driven pile foundations. The use of DMS for evaluation of offshore foundations requires considerations quite different from land applications and these considerations are often necessary for the careful and thorough analysis of the collected data in nearly real time for determination of pile acceptance. Case Method capacity estimates are often of little use due to the non-uniform cross sections of the foundation piles and their deep penetrations. Therefore, capacity assessments should be made using CAPWAP which is a signal matching program whose utility and reliability has been proven on thousands of projects every year, both on land and offshore. Depending upon the soil conditions at a given location, capacity assessment after soil setup effects may be necessary. In addition, tension capacity is often critical when pile refusal occurs significantly before the design pile penetration depth. Evaluation of uplift capacity can be accomplished by a CAPWAP analysis, which results in a total capacity prediction and its shaft resistance component. The use of hydraulic hammers for driving of these piles also adds the requirement of controlling hammer energy such that over-stressing of the pile is avoided. The calculation of non-axial stresses such as bending or eccentric stresses may also be involved in order to prevent pile damage.

Jan 1, 2010