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By Timothy O’Rourke, Karrie Buxton, Chris Lynagh, Daniel Dobbels, Frederick Vincent

The Doan Valley Storage Tunnel Project in Cleveland Ohio was constructed to control Combined Sewer Overflows (CSOs). It is a complex system of three tunnels ranging from 8.5 to 18 feet in diameter with a total length of about 2.3 miles that was put into operation in mid-2021. The project lies within and below the cultural, educational, and medical hub of Cleveland, which presented unique design and construction challenges. This paper provides a case history of the design and construction, with particular attention given to lessons learned in devising a large tunnel system that can carry both dry and wet weather flows constructed in rock with limited cover, within a flood plain area and vibrant urban center

Dec 1, 2022

By Verya Nasri, Agustin Rey

Once completed, the Montreal Réseau Express Métropolitain (REM) will be the fourth largest automated transportation system in the world. The REM represents construction costs of approximately 7.0 billion Canadian dollars. The project consists of 67 km of twin tracks over four branches connected to downtown Montreal. The project includes 26 stations with 3 underground stations in downtown Montreal. One of the underground stations was built using the NATM method with thin permanent shotcrete initial and final liners separated by a sprayed on waterproofing membrane. The 2 other underground stations were built with the cut and cover approach including one using permanent secant pile wall with permanent walers and struts as the support of excavation and the final perimeter wall of the station. The project also includes the rehabilitation and enlargement of the Mont Royal Tunnel. This 100-year-old double track tunnel is about 5 km long. The REM also consists of 3.6 km new TBM tunnel connecting downtown to the Montreal International Airport through saturated soft ground and karstic rock. By the time of RETC, the construction of REM underground structures will be completed. This paper presents the design and construction aspects of the underground structures of this mega project.

Jun 13, 2023

By Earle J. Klohn

"The design, construction and operation of tailings dams is rapidly becoming a major consideration for most new mining developments, as well as for many existing operations. In North America, under pressure from public opinion, various government agencies have in recent years enacted legislation covering the design, construction and operation of tailings dams. In British Columbia, comprehensive legislation has been passed during the past year (1971). All of these new regulations may be placed into two broad categories: regulations concerning the safety of the dam and appurtenant structures, and regulations concerning the prevention of pollution. Both types of regulation affect the design of the tailings dam facilities. Consequently, they must be considered jointly by the designer. A good tailings dam design must satisfy the basic requirements of safety, pollution control, storage capacity and economy. To achieve this, 'the design must be based on a thorough understanding of both the geotechnical problems involved and the requirements of the mining development. Obviously, this requires close cooperation between the designing geotechnical engineers and the mining operators. This paper outlines the major engineering factors that should be considered in the investigation, design, construct ion and operation of tailings dams. Basic methods of tailings dam construction are reviewed and the advantages and disadvantages of each briefly discussed. Comparisons are made between the design and construction of conventional water supply dams and tailings dams. Examples are presented of some of the problems that may arise during construction and operation of a tailings dam. The paper also explains the need for basic instrumentation of tailings dams and for carrying out simple field tests and measurements during construction and operation. Of prime importance is the downstream monitoring of surface and subsurface seepage flows. These observations are invaluable where contamination of surface and/or subsurface water may become a contentious issue at some future date. Each tailings dam design must be based on a study of the particular requirements of that project. To make a proper evaluation, adequate data must be available concerning a large number of items•, including such things as: topography, hydrology, geology, subsoil properties, seismicity, government regulations, fineness of mill grind, mill water balance, availability of suitable construction materials, volume of water to be stored behind starter dam, downstream development or liability, and many others. The large number of variables involved in such an evaluation often result in the designer considering two or more alternative designs. Selection of the final design, which is usually based on detailed cost analyses of the alternatives, must be made in close consultation with the owner."

Jan 1, 1972

By W. L. Chong

For a project located in Docklands Victoria, a high-rise development was proposed where the geology comprised soils of various compositions and consistencies to approximately 50m deep before being underlain by a siltstone bedrock. Due to the structural loads and spatial constraints, the majority of the foundation piles were designed to be socketed into the siltstone. Key factors in selecting the Continuous Flight Auger (CFA) technique as an effective piling solution are explained. These factors included structural and geological considerations, piling rig capabilities, pile testing regime to verify load performance and integrity, the extensive suite of construction quality controls and instrumentation records required while also achieving an appropriate piling budget and program. This paper also described how these factors underpinned the design approach of the final piling scheme. Critical aspects considered during construction and post-construction quality and pile testing records required to meet and satisfy the strict project piling specifications are also presented. The project adopted what may be considered the “best practice” in deep CFA piling. To the author’s knowledge, this project achieved the record for the deepest CFA piles in Australia where multiple piles to 53.8m deep were constructed.

Nov 1, 2022

By David Mast, Amanda Foote, Mina Shinouda

The Michigan DOT’s I‑75 Modernization Project, Segment 3, is a 30-year, $1.2 Billion design-build-finance-maintain project in Southeast Michigan. The scope includes building a nearly 4-mile long, 14.5-foot ID stormwater storage tunnel. The tunnel and pump station are being built concurrent with new roads and bridges, requiring multiple levels of design and construction coordination. Underground risks include the poten‑ tial for encountering granular soils, groundwater, and explosive gases. The new tunnel will be mined by a new open-face TBM and lined with a one-pass steel-fiber-reinforced precast concrete segmental lining. Shaft construction began in early 2020 and tunnel mining in July 2020.

Jun 13, 2021

By Patrick O. Shires, Harry W. Schnabel

With stable building sites becoming scarce in the greater San Francisco Bay Area, the new Summit Senior Care Facility is being built into the side of an unstable hillside adjacent to the San Ramon Regional Medical Center in San Ramon, California. This hillside has had a long history of instability and the site of the new Senior Care Facility required excavation into both a historic old landslide and a more recent active landslide. After a thorough geotechnical study, it was concluded that the best way to build the new facility would be to construct a tied-back retaining wall in the area of the old landslide, since it extended off-site onto two adjacent properties, and remove the active landslide and replace it with compacted fill before cutting into its toe area with an additional tied-back retaining wall. The design was further complicated by the proximity of the site to several active faults. In the area of the old landslide, the combination of an ascending slope behind the wall, landslide forces and seismic forces resulted in total design pressures between 365 to 4,575 PSF for a wall with a maximum height of 30 feet. The wall for the old landslide was constructed by first drilling and placing steel soldier piles in concrete. The tip of the soldier piles extended a minimum of 12 feet below the landslide plane that was up to 36 feet below the bottom of the wall. Permanent double corrosion protected tiebacks were then installed through the soldier beams and anchored below the slide plane. A shotcrete facing was then installed on the face of the wall. BACKGROUND The site of the Summit Senior Care Facility is located on the southwest flank of Mount Diablo adjacent to San Ramon Valley which is characterized by gently rolling hills. The San Ramon Valley Regional Medical Center, which opened in 1990, is located to the north and an existing church is located to the southwest. There are also private residences located to the southeast. The site is shown in Figure 1. Numerous faults run close to the site, the most significant of which are the Calaveras and Pleasanton faults. The site has also had a long history of slope instability and has been the subject of numerous investigations. Studies conducted in 1979 and 1984 concluded that there was a landslide in the area and recommended that a buttress shear key be constructed between the subject site and the existing church for a sewer main as well as removal and replacement of the head area of the old landslide to stabilize the hospital site. While two previous geotechnical studies in 2008 and 2016 identified slope instability, they did not recognize the genesis and limits of the old landslide on the western portion of the site or the limits of the active landslide on the eastern portion of the site.

Jan 1, 2018

By Sivilay Sayavong, David Puller, Julian Gatward, David Hard, Martin Stanley

"AbstractThe Thames Water Tideway Tunnels programme involves the upgrade of London’s combined sewer and storm water system. The first section is the Lee Tunnel between the Beckton Sewage Treatment Works (STW) and the Abbey Mills Pumping Station. This will intercept the overflows currently discharging to the River Lee and has the capacity to store and transfer 350,000m3 of storm water and sewage. The project required 4 shafts and a 6.9km 7.2m diameter tunnel. The shafts are some of the largest ever constructed in the UK, with diaphragm walls up to 98m deep and 1800mm thick. As a result of the innovative methods of diaphragm wall design and construction adopted the 4 very large and deep shafts were able to be excavated and completed safely, with minimal water ingress and with extremely high quality.MVB, a joint venture of Morgan Sindall, Vinci Construction Grands Projets and Bachy Soletanche are delivering the £635m contract with Thames Water’s Project Management Team in a collaborative manner under an NEC contract. Mott MacDonald, Morgan Sindall UnPS & Bachy Soletanche are acting as designers.Some of the important advances in diaphragm walling made included:??Diaphragm wall design to both EC2 & EC7 taking into considering the assessment of chalk stiffness, high hoop stresses, large multiple openings and non-axisymmetric loadings.??Formation of shafts as a faceted circle from a series of overlapping panels, with primary panels up to 7.2m wide demanding concrete volumes up to 1300m3 be poured in one go. Overlapping secondary single bite panels cut into the grade C50/60 concrete.??Excavation of the full geological stratigraphy of London making bentonite management complex.??Panel verticality of 1:300 required over the full depth. The results achieved this and in many cases exceeded expectations with some panels coming in at up to 1 in 800 with the majority at 1 in 400 to 1 in 500. The project is also the first in the Soletanche Bachy Group to take data from the ultrasonic drilling monitor used to check the verticalty in electronic format in order to create 3D CAD as-built drawings.??Each diaphragm wall panel was reinforced over its full depth. Up to 18 separate pieces of reinforcing cage had to be installed in primary panels. Cages underwent a full range of temporary works designs to check that lifting, splicing and placing could all be undertaken safely. Fibreglass was used in the tunnel portals in the shafts to ease breakthroughs."

Jan 1, 2014

By Ihab Allam PE, Meeok Kim. PE. Ph. D

The wet weather equalization basin (EB) planned for Pacifica, CA is a 45 feet deep rectangular shaped underground water tank containing over 2.1 million gallons of water, and located only 500 feet away from the Pacific Ocean. The location and size of the water tank, and the geotechnical characteristics of the selected site presented many engineering and construction challenges. The engineering had to consider a structural system which can fit into the limited area of the site and yet need to meet the storage volume requirement. In addition, the system construction should meet the city’s tight budget and schedule.

By Guilherme L. M. G. Carvalho, Zachary T. Fleming

In a world of 2-dimensional design documents, envisioning and understanding 3-dimensional interferences for complex foundation construction scenarios can be challenging. Videos and computer models serve as 3-dimensional spatial aids but have drawbacks related to a fixed perspective. Augmented and virtual reality (AR/VR) provide new tools to communicate design challenges and improve construction planning. This paper provides a practical look at the basics of AR/VR systems and the tools available to the foundation design and construction industry by giving a high-level example of the technologies’ use in the design and delivery phases of a complex micropile installation project for the remediation of a dam foundation. Using these technologies, GEI was able to design and deliver a complex foundation remediation solution. AR/VR benefited regulators, and the client, to help understand the design concept, construction sequencing, and approach to overcoming installation challenges. Due to its user-friendly nature and less rigorous programming and hardware requirements, AR proved to be more useful than VR for this scenario. AR/VR will likely not replace videos and computer models; however, it can be a useful 3-dimensional visualization aid that complements the project delivery process and offers benefits that traditional methods cannot. INTRODUCTION Augmented and virtual reality is a promising and rapidly developing technology within the engineering and construction world. Like any rapidly developing new technology, the language describing it can be confusing and dynamic. To eliminate the confusion some definitions must be made. AR/ VR definitions The definitions of virtual reality (VR) and augmented reality (AR) for the purposes of this paper are as follows: VR is a computer-generated immersive environment that the user experiences within a digital 3- dimensional space (Satava, 1993)AR is a composite view created by superimposing digital objects into the user’s real-world view (Azuma, 1997). Often, VR is used in an office environment and allows the user to “visit” the digital site to review site planning, construction sequences, and interference geometry. AR can be utilized in both the office and onsite environments. Like VR, the in-office application for AR is commonly site planning. AR also can be utilized in the field for applications such as seeing through the ground to locate known existing obstructions like utilities, gas tanks, etc.

Jan 1, 2019

By D Mcleod, S Brindley, S Green

The design and engineering of flotation circuits is driven by numerous inputs, including (in no particular order) testwork outcomes, site considerations, type of separation required, energy sensitivity of the flotation response, personal experience and preference for flotation machines, maintenance access requirements, operability, level of automation and capital constraints.This paper discusses these and other issues in the Australian context and covers the flotation of copper/gold ores and polymetallic (copper/lead/zinc) ores. The paper discusses aspects of the following: how should testwork be done and what are the important inputs and outcomes? how should testwork results be interpreted and how does this impact on equipment selection? what processes can have a critical impact on flotation circuit performance, eg thickening and regrind? what options are available with the typical æflatÆ Australia site? how do you minimise capital cost and what impact can this have on flotation circuit operation and maintenance? how should circuits be controlled and operated? Particular focus is placed on some practical aspects of process design and engineering and the potential impact that engineering decisions can have on flotation plant operation.

Jan 1, 2005

By V. A. Marple, K. L. Rubow, Y. Tao

"A personal diesel exhaust aerosol sampler has been designed and evaluated in both laboratory and field settings. The sampler uses size selective sampling for the determination of the respirable mass concentrations of mineral dust and diesel exhaust particulate matter found in underground coal mines. This design is based on the premise that diesel exhaust particulate matter is predominantly less than 0.8 um while mineral dust is greater than 0.8 gm. Operating at a flow rate of 2 L/min, the sampler consists of a 10 mm Dorr-Oliver respirable dust cyclone followed by an 0.8 gm cutpoint impactor and an afterfilter. Field evaluations consisted of sampling at 6 different locations in these underground coal mines. Measured aerosol concentration less than and greater than 0.8 um have been compared with a well characterized cascade impactor.Techniques must be developed for measuring the mass concentration of diesel exhaust particulate matter found in underground coal mines due to the health concerns associated with worker exposure to diesel exhaust particulate matter. Diesel exhaust particles are in the respirable size range and have been regarded as a potential occupational carcinogen by NIOSH (1988). Furthermore, a 1988 MSHA advisory committee directed MSHA to develop a sampling protocol for assessing worker exposure to diesel exhaust particles.The University of Minnesota and the Bureau of Mines, over the past 4 years have measured the size distribution of diesel exhaust particles and mineral dust, both in the laboratory and underground mines (Cantrell, 1987; Cantrell et al., 1987; Cantrell and Rubow. 1988; Marple et al, 1986; Rubow et al., 1988: and Watts et al., 1989). To date, measurements have been made in nine coal mines. Seven mines utilized diesel-powered equipment at the mine face while two used electric-powered equipment. The results of these field tests indicate that mineral dust and diesel exhaust particles can be differentiated on the basis of particle size. The measured particle size distributions have been found to be bimodal with a saddle point at 0.8 um. This has led to the hypothesis that one method for measuring worker exposure to diesel exhaust particles would be to collect size fractionated particle samples separated at 0.8 um with the diesel particles being less than 0.8 um and the mineral dust particles greater than 0.8 um.Aerosol size distribution measurements, using a micro-orifice uniform deposit impactor (MOUDI), have been conducted in the mine intake air portal, intake entry to the working section, haulageway, and section return entry. The MOUDI is a ten stage cascade impactor with particle cutpoints ranging from 0.1 to 15 um aerodynamic diameter (Marple and Rubow. 1984b; Marple et al., 1989). The sampling flow rate is 30 L/min."

Mar 1, 1992

By Kanchan Mondal, Gopi Bylapudi, Anand Bhagwat, A. J. S. (Sam) Spearing

Corrosion of steel roof support systems can cause potential premature failure of the support, thus adversely affecting the excavation stability and rock-related safety. An in-house corrosion test system was designed and developed to test full-length roof bolts for material performance based on tensile load capacity and strength under different corrosive conditions found underground. Initially, ASTM A615 grade 60 steel roof bolts, which are the most commonly used bolt material in the United States, were tested with and without stresses in a simulated underground coal-mining environment for approximately six months. This paper mainly discusses the test system, protocol and system shortcomings, and makes recommendations based on the observations and results.

By Vijaya Bhushan Rao, Ali Semercioglu, Jason Redgers

Large diameter steel water tanks with high storage capacities impart heavy loads deep into the ground, generally requiring deep foundations to adequately support them. The use of ground improvement as a sustainable and cost effective alternative is tempting but the design of the foundations for such heavily loaded, thin-shelled structures have to meet several performance requirements such as bearing capacity, limiting the specified total settlements, typically limiting the radial differential settlement to 13mm over 10m along the circumference and dishing settlement from edge to center of 1/120 as per standard API 650 Appendix B as well as the mitigation of liquefaction induced settlement risk. Any inadequacy in the soil investigation, geotechnical design, or misrepresentation of stresses of the foundations may lead to serviceability compromise or potentially catastrophic failures. Therefore, the selection of the foundation is dependent on the availability of suitable ground report and the limitations imposed by operational requirements. Two such case studies are evaluated and compared in this paper, with tank diameters ranging from 41 to 106m in the Kingdom of Saudi Arabia, (KSA) which were founded on two types of soils and supported on deep foundations i.e., stone columns and bored cast-in-situ piles.

Oct 1, 2022

By R. A. Meyr, K. A. Perry

Following three major mining accidents in 2006, the MINER Act of 2006 was enacted by the U.S.Congress. The U.S. Mining Safety and Health Administration subsequently released the Final Rule on Refuge Alternatives for Underground Coal Mines, which required every underground coal mine to install refuge alternatives to help prevent future fatalities of trapped miners in the event of a disaster. The following paper documents the research that was performed on a structural wall to be used in conjunction with a breathable air system to create a refuge alternative. A 103.4-kPa (15-psi) safe haven polycarbonate wall for use in underground coal mines was designed and modeled using finite element modeling in ANSYS Explicit Dynamics. The successful safe haven wall design was modeled for an actual underground coal mine environment using the explicit finite difference formulation program FLAC3D to determine the responses of the wall and surrounding strata within a mine. A full-scale design was fabricated and installed in an underground coal mine to determine any construction constraints and as a final step in proof of concept for the safe haven wall design. This paper is meant to introduce the reader to a new wall concept to be used in conjunction with current technology.

Jan 1, 2013

By J. Dilbeck, J. K. Ratliff, T. Petrov, Z. Brown

"In efforts to improve dust control during deep cut continuous mining a supplemental atomizing spray system, mounted on 14CM15 continuous miner, has been designed and successfully implemented in a U.S. coal mine. The mine is 2.1 m (7-ft) high and uses a blowing curtain face ventilation system with 1.1 m (3.5-ft) curtain offset from the rib. The face ventilation design parameters were set to 9.4 m3/s (20,000-cfm); 4.2 m3/s (9,000-cfm) line curtain flow rate, and 3.8 m3/s (8,000-cfm) scrubber capacity. The performed in-mine measurements, before and after the implementation of the atomizing spray system, showed a significant decrease in the respirable dust levels at the operator place as well as at the return. The paper describes the supplemental water spray system design and performance supported by three-dimensional computational fluid dynamics (CFD) simulations and in-mine test data.INTRODUCTIONThe work on this project have started in 2015 with a study of the conventionally applied face ventilation layouts. The specific behaviour of the face ventilation system have been analyzed trough in-mine measurements and computer modeling of typical cut scenarios. An computer modeling methodology have been developed for estimation the respirable dust concentration (RDC) using tracer gas to RDC contour mapping, calibrated by a single point value, provided by in-mine measurement. Utilizing the results of this study the engineering staff of the mine designed and implemented a supplemental atomizing spray system to improve the dust control during the deep cut continuous mining. Today the atomized spray system is successfully applied demonstrating steady performance and a significant decrease in respirable dust concentration on the working places of the continuous miner (CM) and coal transporters (CT) operators as well as at the return air stream. Information about the applied type of spray nozzles provided by other researchers (Cheng, 1973; Dick et al., 1996; Organiscak & Page, 1998; Pollock & Organiscak, 2007) and spray system manufacturers (Spraying System Co, 2011–2018; Steinen Mfg., 2016) have been used in this project. CFD code and simulation approach validated in a study conducted in 2000-2014 have been applied (Turner et al., 2002; Wala et al., 2004, 2007; Petrov, 2014)."

Jan 1, 2019

By Rodrigo Toro, Ivan Yutronic N

"The Copper Concentrator Plant of Compañía Minera Doña Inés de Collahuasi (CMDIC) is composed of three grinding lines, the third one being the largest. Due to the capacity feature of the third line, specially its SAG mill, it is a priority that the advanced process control team of the Company deploys a supervisory control strategy that allows this unit to operate in an optimal way, in order to achieve the maximum productivity at minimum cost. It is in this kind of tasks where advanced control applications play a key role in obtaining the best economic profit of the process.The advanced process control team, formed by people from Informatics, Automation and Operations of CMDIC have assumed the challenge of generating the transition from a manual SAG Mill 1011 operation (40 x 22 feet, the largest copper SAG mill of the world), to a fully automatic SAG Mill using a multivariable control strategy instead of a rule based on expert control system (widely used in industrial mining process control applications).Therefore, CMDIC decided to work together with Honeywell APC Team implementing an advanced automatic control strategy for the SAG Mill 1011, using for this purpose a technology called Model Based Predictive Control (MPC), based on a variety of control methods that uses dynamical models of the process, obtained from input/output data, in order to print the process knowledge into a group of mathematical relationships that links the constraints (controlled variables) with available commands (manipulated variables) and measured disturbances.The main objective of the advanced control strategy is to ensure process government, tending to throughput stability and optimization, by the execution of coordinated control actions, proactively avoiding measured disturbances effects and the SAG mill overloading.The most important benefits of using a multivariable control strategy are: the automated operation of SAG mill 1011 (that was manually operated before the implementation of this application), a safer, more coordinated and more stable process operation, achieving through this an increase of throughput and a decrease of specific energy consumption, controlling the amount of oversize material production, power consumption, mill loading, noise and torque. In addition to the operational results, this challenge has consolidated a control team, with the participation of engineers and operators, diminishing the typical implementation time and achieving a greater use of the application in a short time."

Jan 1, 2010

By C. H. Stephenson, M. Du Preez

Overland belt conveyors often use vertically guided counterweight take-ups or horizontally tensioned carriages to maintain belt tension. In the event of belt or wire rope failure, these systems can release significant stored energy, creating high-impact forces that risk structural damage and personnel injury. This paper reviews current safety arresting technologies and presents a calculation methodology for estimating impact velocity, energy absorption requirements, and stroke limitations. Worked examples illustrate the selection process for appropriate arrestor types under different design constraints. The study emphasizes early integration of safety devices to minimize structural loads, avoid costly retrofits, and enhance operational reliability. Implementing robust arrestor systems improves safety and reduces downtime in bulk material handling environments.

Feb 22, 2026

By N. J. Rarmrez, C. Perez, J. D. Calderon, L. Lopez

"Among the thermal characterization of any material, one of the variables to know is the coefficient of thermal conductivity because this value can tell how much heat passes through the material and if the material could be used as an isolator. In order to determine this parameter is required some kind of special equipment and controlled conditions which implies high costs in the development of tests. The present paper proposes a design of a low cost measurement system in order to determine this coefficient with the lower possible error. This equipment was thought for companies or labs where they do not have the economic resources or the infrastructure (environmental controlled labs, heat flux transducers, human resources with specialized knowledge) to do this kind of tests.The system is based on ASTM C 518 - 04 [l] and integrated by two plates (one that contains a thermal resistance and which temperature is controlled by a closed loop controller and the other one with a route of water flow). The thermal resistance is actuated by a relay and a supervisor system checks the total time the relay is on in order to determine the effective power applied to the system. The contact faces of the plates contain a group of temperature sensors connected to a data acquisition system that process and record the temperature in each measurement point.With the power applied to the system, the measurement of temperatures and a process of calibration is possible to determine the coefficient of thermal conductivity. IntroductionWithin the thermal characterization of a material of known variables is the coefficient of heat transfer, since this value can know the amount of heat the material is capable of transferring or isolating. To determine this ratio requires specialized equipment and controlled conditions, which implies high costs in the development of a test. This article proposes a design of a low cost machine to allow closer this coefficient with the least possible error. This equipment was done thinking about companies that do not have the infrastructure (laboratories, controlled environment, heat flux sensors, human resources expertise) and financial resources to conduct these tests."

Jan 1, 2011

By M. Nzotta, L. Teng, S. Seetharaman, A. Chychko

The objective of the present work is to optimize the EAF practice towards Mo alloying with maximum retention of the alloying element in molten steel. During Mo additions, there were significant losses to the dust (ca 7 %) and to the slag phase (ca 2 %), which had serious economic and environmental impacts. The present work was aimed at designing a suitable Mo precursor, an alternative to ferromolybdenum, as the Mo source and a process sequence for optimal retention of Mo in the steel. The design of the Mo source should be in such a way that low cost raw materials such as MoO3 concentrate have to be used, stable during the addition so that the vapour phase losses as MoO3 are kept minimum and the dissolution of the precursor in molten steel is easy without loss to the slag phase. After thermodynamic considerations, three precursor materials were chosen, viz. CaMoO4, MgMoO4 and Fe2MoO4. Synthetic mixtures of the component oxides in each case as well as pure MoO3 were investigated by TGA and high temperature XRD in order to find out the temperature range in which the compounds were formed. Experiments were also conducted separately where the evolved gases were analyzed. All the three precursors were formed easily and the loss of MoO3 to the vapour phase was found to be extremely low. Addition of the oxide mixtures to steel melts were conducted in three different scales, viz. 16 g, 500 g and 3 tons (induction furnacle). Initial experiments showed that MgMoO4 was not suitable since the Mo yield in the steel melt was not very high. Fe2MoO4 was found to perform best, the Mo yield reaching 98 %. Further trials were conducted in the 65 ton Electric Arc Furnace (EAF) at Uddeholms AB in Hagfors. Mixtures of mill scale, MoO3 and carbon in suitable proportions were added in a pre-determined addition sequence. It was found that, in the actual practice, the Mo yield reached 99 %, equaling in performance the addition of ferromolybdenum. The process offers an effective use of cheaper raw materials and very high Mo yield avoiding a pre-treatment step like the production of ferromolybdenum. This is both cost effective and environmentally advantageous. The process has been patented and is being currently implemented at Uddeholms AB, Hagfors, Sweden.

Jan 1, 2011

By Dushasan Kundu, B. N. Shivakiran Bhaktha, Khanindra Pathak, Sarbojit Mukherjee

Mine safety and quality of life of miner working in underground mines depend to a large extent on mine illumination and communication. The provisioning of reliable, safe, and cost-effective illumination is critical, particularly in underground gassy coal mines. To prevent firedamp explosion by electrical switching operation in coal mining industry requires implementing intrinsically safe illumination circuit. The luminaire design also needs to be certified and installed properly. The current illumination systems installed inside mines require a lot of energy which is obtained from nonrenewable resources. In this work, the design and implementation of solar-powered optical fiber-based illumination are studied and implemented in the Jhanjra underground coal mine, Eastern Coalfield Limited, and a Li-Fi-based communication system for underground coal mines is proposed. Silicate optical fibers of various core diameters and numerical apertures are characterized for illumination applications and their efficiencies are reported. The possibility of achieving optical fiber-based solar, laser, and hybrid illuminations in underground mines is discussed. The design and fabrication of a Fresnel lens-based solar tracker for solar illumination are also presented. The optical fiber-based illumination system is installed in an underground coal mine and the illumination of over 70 lux is achieved at the work plane. Finally, optical fiber-based illumination and simultaneous basic Li-Fi communication are demonstrated and will be beneficial to the underground coal mining industry.

Apr 14, 2023