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Performance of Dry Separation Processes in Cenospheres Recovery from Coal Fly Ash

Sep 13, 2010

By Graham JW, Cullen GV

edicted increase in, Aluminium production and the possibility of a diminishing supply of petroleum coke for anode electrodes in alumina reduction cells makes it desirable to find alternative electrode materials. Brown coal char, with a lower ash content and with an elemental purity similar to petroleum coke, has been produced by leaching in hydrochloric acid, washing with water and charring at 115000. The cost of processing is estimated to be competitive with petroleum coke. Without further processing the bulk density and real density were undesirably low, but. by briquetting the coal before charring and crushing, the bulk density was improved to 92 per cent of the petroleum coke value and the Particle density was improved to 92 per cent of the density of petroleum coke by water-displacement or 75 per cent by mercury displacement. Pre-baked electrodes were prepared from the char alone, mixtures of petroleum coke and char and from petroleum coke alone, all bonded with coal tar pitch. The electrodes were tested for the usual physical properties and were, evaluated for performance in a laboratory size alumina reduction cell. Electrodes based on brown coal char alone were found to be inferior in physical properties, and performance, but mixtures of the char and petroleum coke, despite poorer density, electrical resistivity and carbon consumption on a theoretical basis, in performance tests gave up to 17 per cent better carbon consumption per weight of aluminium produced and 21 percent better electrical current efficiency than the electrodes based on petroleum coke alone. It is suggested that larger scale tests are warranted.

Jan 1, 1970

A predicted increase in aluminium production and the possibility of a diminishing supply of petroleum coke for anode electrodes in alumina reduction cells makes it desirable to find alternative electrode materials. Browncoal char, with a lower ash content and with an elemental purity similar to petroleum coke, was produced by leaching in hydrochloric acid, washing with water, and charring at 1,150°C. The cost of processing is estimated tobe competitive with petroleum coke.Without further processing the bulk density and real density were undesirably low, but by briquetting the coal before charring and crushing, the bulk density was improved to 92 per cent of the petroleum coke value andthe particle density was improved to 92 per cent of the density of petroleum coke by water displacement or 75 per cent by mercury displacement.Pre-baked electrodes were prepared from the char alone, mixtures of petroleum coke and char, and from petroleum coke alone, all bonded with coal tar pitch.The electrodes were tested for the usual physical properties and were evaluated for performance in a laboratory size alumina reduction cell.Electrodes based on brown coal char alone were found to be inferior in physical properties and performance, but mixtures of the char and petroleum coke, despite poorer density, electrical resistivity, and carbon consumptionon a theoretical basis, in performance tests gave up to 17 per cent better carbon consumption per weight of aluminium produced and 21 per cent better electrical current efficiency than the electrodes based on petroleum,coke alone.It is suggested that larger scale tests are warranted.

Jan 1, 1971

By B. L. Seegmiller

Regular entry trusses are used in headgates, tailgates, roadways and intensely-faulted areas. These trusses have proven to give the required support and maintain roof stability even under major abutment loading conditions for both the re-treating and advancing longwalls. Areas previously requiring steel arches have been eliminated. A special Continuous Entry Truss? provides permanent support to adjacent tunnel/crosscut zone for more than 300 feet in each tunnel. The continuous nature of the tensioned truss allows sup-port forces to be placed on the roof in not just the two-dimensions of regular trusses, but in a full three-dimensions. A newly developed Roktruss? provides support in an arched 30-foot high rock zone. The Roktruss? allows truss support concepts to be used in an opening with a curved roof.

Jan 1, 1989

By Mary Ann Harrington Baker, John Trudnowski, Marietta Canty, Marek Zaluski

Three Sulfate-Reducing Bacteria (SRB) passive field-bioreactors were constructed at an abandoned mine site near Butte, Montana, to mitigate AMD emanating from a waste rock pile. Each SRB field-bioreactor contains chambers of an organic source, limestone, and cobbles. The field-bioreactors are configured differently to test the effect of different environmental conditions on the SRB. Preliminary observations indicate that, during start up and the first eight months of operation, the quantity of organic carbon supply significantly impacts the SRB activity. To date, the dissolved metals have been reduced significantly and the pH has increased.

Jan 1, 2000

By C. M. Haberfield

"1 INTRODUCTION Around the world, there is a demand for larger structures, tall buildings and large bridges. While good footing design is important for all structures, it is even more important in the case of large structures. Recent experience with footing design for tall buildings (e.g. Burj Al Alam development and Nakheel Tower in Dubai, the Gate of Kuwait in Kuwait, the City Centre Project in Bahrain and Eureka Tower and Freshwater Place in Melbourne) has shown the benefits of investing in footing planning, design and construction (Haberfield, 2011, Poulos and Bunce, 2007). The footing systems for most of these projects include the use of deep bored piles or barrettes (piles of rectangular cross-section). Many use piled rafts where the piles, while acting to support the load, are primarily used to reduce settlements. A clear understanding of the factors controlling the behaviour of the footing system is needed to enable a good engineering design to be achieved. This starts with a sound understanding of the ground characteristics and individual pile performance, including adequate collection of data and testing. The best footing solution can then be found using recent improvements in data collection and analytical techniques, complex and highly capable computer-based models and the availability of high speed computers. This paper focuses on the axial performance of deep bored piles socketed into rock – both their individual performance and their performance as part of a larger footing system. Recent research and construction practice is discussed. In practically all cases, serviceability conditions control the behaviour of the footings. Methods of establishing the parameters for input into sophisticated computer programs are described. Application of the methods to case studies is included and it is shown that the behaviour of individual piles can be closely predicted. These developments lead to lower construction costs, better constructability and shortened construction time because of the better understanding of footing behaviour. 2 FACTORS AFFECTING PERFORMANCE OF FOOTINGS ON ROCK For a typical pile-supported footing, it is necessary to consider both individual pile, pile group and raft performance. These require consideration of the behaviour of the ground immediately beneath the surface raft or footing, along the pile shaft, and at and beneath the pile toe (Figure 1). Immediately beneath the surface raft or footing, the important factors are strength for bearing capacity and stiffness for settlement and interaction effects. Along the pile shaft, of most interest are strength for bearing, excavatability and stability; stiffness for settlement and interaction effects; geology and permeability for pile stability and, most importantly, pile shaft resistance. At the pile toe all the above factors for the pile shaft are present and in addition the pile end bearing is of interest. Below the toe, stiffness for pile settlement is important to at least a depth of twice the building width."

Jan 1, 1900

By William (Bill) H. Walton

"I arrived in Chicago in 1993 with Dr. Ralph Peck’s University of Illinois bulletin titled Engineering Properties of Chicago Subsoils (Bulletin 429), which he published in 1954 with William Reed. Being an outsider, I wanted to learn from Chicago geotechnical practice leaders that included Clyde Baker, Jr., John Gnaedinger, Charles Pfingsten, Dr. Safdar Gill, Robert Lukas and Dr. Jorj Osterberg, who have influenced foundation designs for the structures that make up the contemporary Chicago skyline. One of my immediate goals was to get the Illinois Structural Engineering license to be on par with the likes of Eli Cohen, Mike Tylk, Stan Korista, Bob Halverson, Joe Burns, Ron Johnson, Bill Baker, Bob Sinn, Chuck Anderson and Dave Eckmann, who have led their structural firms in the design of the skeletal core and frames of many of Chicago’s iconic buildings (and for many other buildings around the world). From my time with GEI Consultants (GEI), then on with STS Consultants (STS, and now AECOM), and now back with GEI, I have had the opportunity to analyze and design foundations and, with the help of many skilled foundations and building constructors, to verify that predicted foundation performance matches actual movement data. The theme of Chicago’s foundation design practice is to assume and verify. In 1948, Peck published the History of Building Foundations in Chicago (Bulletin 373) that was updated in 1998 by Baker, Pfingsten and Gnaedinger, who meticulously documented hundreds of Chicago’s foundations, and have shown the value of advanced analyses and testing to advance the deep foundation design practice that includes a variety of high-capacity driven and drilled deep foundations. Mehmet Uyanik, Peck and Baker have made Chicago’s subsurface into a full-scale foundation test laboratory. They confirmed soil mechanics principles like Terzaghi’s 1-D consolidation theory when early foundations bearing on sand-clay crust over soft to medium silty clays (e.g., Auditorium, Masonic Temple, Monadnock Block and Old Board of Trade buildings) took 40 to 60 years to consolidate clay 1 to 2 ft (0.3 to 0.6 m). They also confirmed proven increases in bearing pressures based on measured performance of deep foundations bearing on the glacially derived hardpan clay till and in solid dolomite that underlies Chicago."

Jan 1, 2017

By Jörg Holzhäuser, Matthew Crow

An 18.5 km (12 mile) long tunnel is being driven by four Earth Pressure Balance Tunnel Boring Machines (EPB-TBMs) of 4.7 m (15.5 ft.) diameter through alluvial sand, gravel, silt and clay above and below the groundwater table in Los Angeles beneath buildings, railroads, freeways and the L.A. River. Continuous automatic data recording of TBM operation and field inspectors' records, accompanied by monitoring of 5,000 surface reference points and 268 borehole extensometers were used to obtain information. The paper explains the reason for selecting the method of EPB-tunneling to ensure stability of the tunnel and meeting of environmental requirements, and presents data collected to monitor and demonstrate the performance of the TBM sin the different ground conditions encountered.

Jan 1, 2003

By P Jere

Mechanically coupled rock bolts encapsulated in cementitious or polyester cartridge resin grouts have been widely adopted for various underground rock reinforcement applications. Resin grouts are considered a superior product, however, both systems have their advantages and limitations, with the relative performance, quality installation cost and cycle time as the most notable parameters. Both applications have optimal rock bolt combinations and preferred ground conditions. Cementitious grouts are favourable for use with secondary deep embedment anchors. These are installed using various equipment with a series of autonomous tasks required to complete the installation cycle. The cartridge resin system can be utilised by a bolting or face boring rock drill to complete the full support installation cycle. This reduction in equipment changeouts mid-cycle generally deems it the more practical application and popular choice for primary support. Self-drilling anchors (SDAs) and hollow bolts have been a viable alternative to traditional rock reinforcement in variable and challenging ground conditions. Using a pumpable post installation grouting system, SDAs have proven to aid the quality of installation, but due to the additional equipment and cycle steps associated with application, the cycle time is increased. In recent years, fully mechanised bolting equipment designed to utilise a combination of self-drilling anchors and a thixotropic pumpable resin installed in a single pass has entered the market. This innovation is anticipated to deliver the advantages described above, with fewer limitations, and significantly improved development and rehabilitation rates. St Barbara Mining and Byrnecut Australia, supported by Master Builders Solutions, were first to conduct extensive trials and implement this rock bolting approach in an Australian hard rock underground mine and record the actual performance.

Mar 29, 2023

By David R. Crouthamel, Francis L. Fong, Troy L. Page

This paper focuses on the results and the performance of the grouting program as a means to control groundwater infiltration during the excavation of the 7.7 km (25,160 lf.), 3.5m (11 ft. - 7 in.) diameter Inter-Island Tunnel beneath Boston Harbor in Massachusetts. Two major operations of grouting were performed - water cutoff grouting behind the tunnel heading after excavation and face grouting ahead of the Tunnel Boring Machine (TBM) operation. An array of products from cementitious to chemical grouts and various grouting procedures and equipment were employed to evaluate their effectiveness in controlling the water in-flows. Evaluation of the overall performance of each of the grouting rations, overall costs and comparison of face grouting versus post excavation grouting is made.

Jan 1, 1997

By N. J. Contini, R. W. Knopp

"In March 1988, old Denver flotation cells were removed from Dickenson's Arthur w. White Mill, and a new flotation circuit, consisting of four Prochem rougher cells and a Hydrochem agitated cleaner column, was commissioned. The refractory portion of the gold in the ore is associated with arsenopyrite, therefore the flotation circuit is set up to produce a saleable sulphide concentrate. Tailings from the leach circuit are conditioned prior to being pumped as feed to the flotation circuit. The prototype Hydrochem agitated column has been in operation as a single cleaner stage for rougher concentrate. The effect of flotation circuit changes on gold recovery data, as well as cleaner concentrate production, and development work to achieve the target results, have been investigated. Flowsheet modifications and the resulting circuit performance data, along with test results to date, will be presented.INTRODUCTIONThe mill is capable of treating 1000 stpd of ore averaging approximately 0.30 oz/ton Au. The ore is crushed and ground to 75% - 200 mesh. Gravity concentration, cyanidation, and Merrill - Crowe precipitation yields 84% gold recovery. Detailed descriptions of the comminution, gravity separation, and leaching circuits, as well as background information have been presented elsewhere (Suttill, Van Weert et al). The target cleaner concentrate grade is 1.0 oz/ton Au for custom smelting and refining. Historical gold recovery values of the old circuit was approximately 20% of the gold present in the float feed at the target grade. The recovery value objective set for the new circuit during the planning stages was 50% of the gold present in the flotation feed at 1.0 oz/ton Au in cleaner concentrate."

Jan 1, 1989

By Crasta Jeason, T. Sreenivas, M. Narasimha

The subtle nature of the flow inside the hydrocyclone has encouraged development of mathematical models for predicting its performance, which are widely used in simulation of comminution circuits. But most of the models available are based on single average feed density. But the feed to hydrocyclone classifier is generally mixture of particles of different densities. This effect of varying density of feed particles on performance of hydrocyclone has been reported in literature. Further investigation of the effect of multi component feed on the performance of hydrocyclone is the objective of this work. This work involves experimental work to study multicomponent behaviour in various size cyclones. The performance of hydrocyclone for feed mixture of magnetite and quartz has been studied. The effect of presence of magnetite, a high density material on efficiency of separation of quartz has been analysed. It was observed that the effect of component interaction increases with feed solids concentration leading to an increased cut-size for a given optimum cyclone conditions. Based on the multi-component exiperiments available in literature, a concept for modeling the performance of hydrocyclones is proposed. A set of semi-empirical model equations for cut-size, sharpness of separation are presented. An attempt to validate the new hydrocyclone model on multi-component behaviour is made.

Jan 1, 2014

By Guillermo A. Vidal

With the introduction of monitoring technologies, process computers and Web services on Industrial Facilities the need for electrolytic processes automation has been set. Recently designed facilities have substantially improved plant layouts, automated cathode processing and copper harvesting. Despite these advancements only limited progress has been accomplished on the electric current distribution of the process. Lately a number of proposals focused on preventing short circuits and balancing cathode currents have emerged. Among these are the AZSA intercell, the Outokumpu double contact, and the Optibar InterCell Plus. Although these intercell bars are clearly superior to the conventional bar, little or conflicting data is available about their merits relative to each other. Consequently, selection of the best intercell bar for most applications is accompanied by uncertainty, which can lead to less than optimum results. A critical evaluation of the performance of the aforementioned bars on the basis of the application is provided, thereby giving the framework and guidelines for the selection of the best bar for each application.

Jan 1, 2003

By Erik Q. Dahl

The strength of green and sintered pellets during reduction under various conditions in a laboratory kiln has been investigated. Equipment and test methods are described, together with the results obtained. The strength of sintered pellets drops sharply when the reduction starts, and goes through a minimum at the 70 per cent oxidation level. At more advanced reduction, the strength increases with increasing metallization. Successful use of green pellets as kiln feed requires that more attention be paid to the pellet preparation than is necessary when producing pellets for separate sintering. In particular, the ores have to be ground to a greater fineness. The initial strength of green pellets is low. Below the 70 per cent oxidation level, however, the strength of these pellets is about the same as the strength of sintered ones. Additions of such materials as silica, limestone and anthracite coal; within reasonable limits, affect the strength only slightly.

Jan 1, 1966

By John J. Childress, Russell L. Cook

Stringent environmental regulations, which have limited the use of sludge ponds, coupled with the economic incentive to clean more coal or to add fine coal cleaning additions to existing preparation plants have increased the use of static thickeners in preparation plants. The Lamella Gravity Settler, sometimes designated Lamella Thickener, is a shallow depth sedimentation device which has been applied in a variety of industrial process and wastewater control projects in place of the conventional raked thickeners. This paper presents the theory and design of the Lamella Thickener, as well as describing the operating results from several full scale installations in a variety of Appalachian preparation plants.

Jan 5, 1978

By Russell L. Cook

Stringent environmental regulations, which have limited the use of sludge ponds, coupled with the economic incentive to clean more 'coal or to add fine coal cleaning additions to existing preparation plants have increased the use of static thickeners in preparation plants. The Lamella Gravity Settler, sometimes de signated Lamella Thickener, is a shallow depth sedimentation device which has been applied in a variety of industrial process and wastewater control projects in place of the conventional raked thickeners. This paper presents the theory and design of the La-mella Thickener, as well as describing the operating results from several full scale installations in a variety of Appalachian preparation plants.

Jan 1, 1977

By John J. Childress, Russell L. Cook

Stringent environmental regulations, which have limited the use of sludge ponds, coupled with the economic incentive to clean more coal or to add fine coal cleaning additions to existing preparation plants have increased the use of static thickeners in preparation plants. The Lamella Gravity Settler, sometimes designated Lamella Thickener, is a shallow depth sedimentation device which has been applied in a variety of industrial process and wastewater control projects in place of the conventional raked thickeners. This paper presents the theory and design of the Lamella Thickener, as well as describing the operating results from several full scale installations in a variety of Appalachian preparation plants.

Jan 1, 1979

By Michael I. Brittan, Craig M. Sams

"Economies of scale and the variable characteristics of many large ore deposits have resulted in grinding installations using very large SAG mills fitted with variable speed drives. Low-aspectratio single-stage SAG mills were introduced in South Africa to process the consistent gold bearing Witwatersrand quartzites. Elsewhere, circuits were patterned after the more conventional North American circuits with high-aspect-ratio SAG mills followed by ball mills. This paper provides information on two recent Gold Fields group installations covering both types of SAG mill in large, single-stage applications. While these operations process similar tonnages, the mills represent opposite ends of the aspect-ratio spectrum. The Tarkwa mine in Ghana employs a low-aspect 27’ x 42’ 14MW SAG mill. The St Ives mine in Australia operates a conventional 36’ x 18’ 13.4MW SAG mill.INTRODUCTIONGold Fields is one of the world’s largest gold producers with annual production of approximately 4.2 million ounces. The Gold Fields group has operations in South Africa, Ghana and Australia, along with numerous exploration sites and advanced projects in several other countries. This paper discusses new milling operations in Ghana and Australia.TarkwaThe Tarkwa Gold Mine is located in Ghana, West Africa, approximately 350 kilometers west of the capital city of Accra (Figures 1 and 2). The site conditions are tropical with an average annual rainfall of 1,930 mm and a maximum temperature of around 35°C."

Jan 1, 2006

By Zaw Zaw Aye, Sereyroath Chea, Nutthapon Thasnanipan, Thayanan Boonyarak

"As there are only limited numbers of bored pile constructed in sandstone and siltstone in Thailand, load transfer and settlement behavior of a pile in these rocks are still not fully understood. Major factors which influence the performance of the pile in the sedimentary rock should be systematically investigated. The objective of this paper is to analyze load distribution and load-settlement behavior of bored pile in sedimentary rock. Interpreted data was obtained from instrumented load testing results of large-diameter bored piles. These piles were drilled in aeolian soil and socketed in sandstone or siltstone, having socketed length varying from 1 to 3 times the pile diameter. Factors that influenced pile settlement behavior, consisting of rock type at the pile base, socket length, at-rest earth pressure and rock conditions, were analyzed. For interpretation of results, analytical solutions were used to estimate load bearing capacity and calculate settlement of each pile. According to test results of mobilized unit skin friction in siltstone, relationship of 0.1 – 0.3 square root of the unconfined compressive strength of rock appears to reasonably capture the measured shaft friction. Note that shaft movement in siltstone layer was not fully mobilized as maximum pile head settlement was still less that 1% of the pile diameter.INTRODUCTIONExtensive research of bored pile construction in soft soil in Thailand and Myanmar (Boonyarak et al., 2016; Aye et al., 2015) has been carried out. However, behavior of bored pile in weak rocks such as sandstone and siltstone is still not fully understood. Unit skin friction and unit end bearing of piles in these weak rock were reported by Horvath et al. (1983) and Pells and Turner (1980), respectively. Further research is still required to minimize variation in data presented in their study.This paper presents interpretation of load testing results of instrumented piles. These piles were excavated in aeolian deposit in the Northeast Thailand. Some piles were socketed in sandstone or siltstone. Analysis results of load-settlement, shaft shortening, pile settlement estimation, factor for calculating shaft friction and end bearing are reported. Discussion and explanation of pile behavior in sandstone and siltstone is provided.BRIEF INFORMATION OF THE PROJECTProject locationsThe construction sites are located in Khon Kaen and Nakhorn Ratchasima Provinces in the Northeast Thailand. Bored piles in this project were designed for supporting elevated structures for railways, overpasses and U-turn bridges for vehicles. These overpasses and U-turn bridges are distributed along the existing railways with the distance of about 180 km."

Jan 1, 1900

By Ralf Winterberg, Axel G. Nitschke

"Macro synthetic fiber reinforced concrete or shotcrete is seen by many design engineers as offering a viable alternative to steel reinforcement in tunnel linings. The technology is now commonplace for primary and permanent ground support in both mining and civil tunnel applications. It has for instance become the standard form of reinforcement in the Australian mining industry, and has been used for a majority of permanent tunnel linings in recent tunnel construction in Norway. Similarly, macro synthetic fibers are becoming a standard solution for the initial lining in the USA.The use of macro synthetic fiber offers innovative solutions, yielding robust and sustainable tunnel lining designs. Citing recent research and actual projects, this paper presents state-of-the-art design considerations for fiber reinforced tunnel linings relating to structural and long-term performance. Topics include seismic resistance, crack width control, corrosion and durability, as well as sustainment of performance with age.INTRODUCTIONMacro synthetic fiber reinforced concrete (MSFRC) and shotcrete (MSFRS) has reached maturity as an engineered material and is widely used in all forms of tunnel linings, for temporary as well as permanent ground support in both, mining and civil tunnel applications. In the Australian underground mining industry, it became the standard form of reinforcement, where 2014 literally marked the end of steel fiber use in shotcrete [1], and has been used for over 80 percent of permanent tunnel linings in recent tunnel construction in Norway. Similarly, macro synthetic fibers are becoming a standard solution for tunnel initial linings in the USA. Recent examples in civil tunneling are the Devil’s Slide Tunnel and Caldecott Fourth Bore Tunnel in California or the Anacostia River Tunnel Intershaft Connector Tunnel in Washington D.C. In addition, an increasing number of tunnels are adopting shotcrete permanent linings using macro synthetic fibers. Examples include the A3 Hindhead tunnel near Guildford in the UK and the North Strathfield Rail Underpass in Sydney, Australia [2, 3]."

Jan 1, 2016