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By Baoliang Xiao, Hui Pan, Yajun Hui, Kun Liu

The microstructure, properties, strengthening mechanism and work hardening mechanism of 600MPa grade high ductility hot-rolled sheet steel for automotive square tube were investigated by utilizing optical microscopy, scanning electron microscopy and transmission electron microscopy. The results show that the microstructures of low C-low Mn-Nb and Ti microalloyed steel (Steel A) and high C-high Mn-Nb microalloyed steel (Steel B) are composed of ferrite and a small amount of pearlite. Compared with steel B, the size of ferrite and pearlite of steel A is finer, while the size of the second phase precipitates is larger. The mechanical properties of the two tested steels are similar before tube forming, except that the yield ratio of steel A is higher. Steel A has/exhibits significant work hardening after tube forming; the yield strength and tensile strength increase by 45 MPa and 26 MPa, respectively, while the elongation decrease by 6.0 percent. The yield strength and tensile strength of steel B increase by 22 MPa and 10 MPa, respectively, and the elongation decrease by 4.0 percent. The grain refinement strengthening is the dominant strengthening mechanism, accounting for 52.9 to 61.8 percent of the total yield strength; the solid solution strengthening is the second strengthening mechanism, accounting for 17.2 to 25.3 percent, while the precipitation strengthening and dislocation strengthening contribute little to the yield strength. The dislocation strengthening increase by 82 MPa of steel A after tube forming, which is higher than that of steel B. Therefore, steel B has a low work hardening rate that is more suitable for manufacturing automotive square tube for secondary tube forming.

Oct 1, 2019

By H. Vuthaluru, O. Kavianipour, C. -Z. Li, N. Suresh, D. Sahu

The paper describes a CFD model developed for 76mm Dense Medium Cyclone (DMC) using Ansys Fluent Software to gain insights into the separation of particles according to their size and density. The simulation used in this paper includes the Reynolds stress model to predict the turbulence inside the cyclone body. An Eulerian-Eulerian multiphase CFD model was applied to model a number of physical aspects such as the separation of coal particles and the segregation of magnetite media solids. The experimental results generated in a laboratory scale DMC were used for the validation purpose and the predicted results of CFD have been validated for the flow splits of water, magnetite and coal. The simulation results obtained from the Eulerian-Eulerian multiphase model revealed that the prediction agreed with experimental results, and matched reasonably well in terms of the mass flow rates of water, magnetite and coal. Furthermore, the partition curve of the DMC when mapped for the separation of - 3.0+0.50 mm size also showed to be in agreement with the experimentally obtained curves. The gravity of cut (SG50), also predicted by the Eulerian-Eulerain multiphase CFD model, was found to be in the vicinity of observed experimental value of SG50. Keywords: Dense medium cyclone, Eulerian-Eulerain multi-phase modelling, computational fluid dynamics, cut gravity (SG50)

Jan 1, 2020

By L. Petzold

The demand for stainless steel is ever-increasing. As an essential element in stainless steel-making process, so is the demand of chromite concentrate. At the same time, the industry proven technologies for beneficiation of chromite are limited. Chromite is only crushed, screened and jigged to produce a concentrate. However, for ultrafine and low-grade material, no satisfactory beneficiation methods for the enrichment of chromite fines exist in industrial operation. This poses a clear challenge for the industry, which Primetals Technologies has addressed with the development of a new beneficiation process. The aim of this process was to enrich low grade chromite tailings to a quality suitable for the smelting process. Required concentrate grades are different over the world, concentrate grades of Cr2O3=40% and lower are found at the Bushveld Complex, South Africa. The target for the present study was a Cr2O3-grade in the area of 49%. Three different chromite tailings with Cr2O3 grades between 16 % and 29 % were part of a study, executed by Primetals Technologies. All three tailing materials were characterised by Mineral Liberation Analysis (MLA). Based on the physical, chemical and mineralogical findings, process flowsheets were developed. The process flowsheets included grinding to ensure a full liberation of the chromite. The liberated material was classified at a cut size of 63 μm to a coarse and fine fraction. Gravity separation and flotation processes were tested with the coarse particle fraction. Due to the limitations of gravity separation with fine particles, only the flotation process is suitable and was tested with the fine fraction < 63 μm. A Design of Experiment (DoE) with six factors, each three levels, was conducted to identify optimal parameters for the fine chromite flotation. Two different collectors were tested: a phosphoric acid ester and a fatty acid type collector. In small scale test work a chromite concentration suitable for the smelting process was achieved. On this basis Primetals Technologies will develop a pilot-scale test program to research recirculation effects and upscale potential of the process. Keywords: Mineral processing, tailings beneficiation, flotation, density separation, process development, chromite

Jan 1, 2020

By Jose Agapito

Roofbolts with expansion anchors have been used at White Pine for more than twelve years, but always with an understanding that their performance was not entirely satisfactory. Some bolts fell out, some were obviously loose, and, when roof failures did occur, very few bolts actually broke. Obviously, there was an anchorage problem. A program was started in May, 1967, to define the problem and to solve it. This paper describes briefly those parts of the program which led to the development of a roofbolt assembly which performs much better in the medium-hard rocks at White Pine. As a result of the changes, significant improvements were found in the torque:tension, tension loss, and pull tests.

Jan 1, 1970

By P. Wearden, K. Bryner, K. Vrana, V. Castranova, R. Dey, R. Reist, J. Blackford

"Summary: Fibroblast proliferation and enhancement of collagen synthesis are key steps in the development and progression of pulmonary fibrosis. The current investigation presents a fibroblast proliferation assay to detect the release of competence factors from pneumocytes. The specific objective of this study was to define cell culture conditions for fibroblasts that would allow selective detection of competence factors in test media. The results indicate the following: (a) fibroblasts should be cultured for 2 days in plasma-free medium rather than 2% plasma to assure complete quiescence; (b) 1% plasma was optimum for producing progression activity for the bioassay of a competence factor, while 0.5% plasma did not produce sufficient progression activity (yielding false negatives) and 2% plasma often contained significant competence activity (yielding false positives); and (c) fresh plasma should be used since the progression activity of plasma was adversely affected by freezing and thawing. Under these conditions, this bioassay can be employed with either rat or human lung fibroblasts to detect competence factors such as platelet-derived growth factor (PDGF), at levels as low as 25 ng/ml.Fibrotic lung disease, as a consequence of occupational exposure to silica dust. is characterized by the development of concentric hyalinized nodular lesions in the lung and the progressive loss of pulmonary diffusion capacity. Proliferation of pulmonary fibroblasts and enhanced synthesis of collagen by these pneumocytes have been shown to be key steps in the development of chronic silicosis ( 1 ). The regulation of lung fibroblast proliferation by cytokines released from alveolar macrophages may be an important pathogenetic mechanism in the development of the fibrotic process (2). Some cytokines stimulate fibroblast proliferation by activating specific phases of the cell cycle (3,4). In particular, platelet-derived growth factor (PDGF) promotes fibroblast proliferation by inducing the movement of quiescent (G0 ) cells into the G1 phase of the cell cycle (5). Insulin-like growth factor (IGF) and transforming growth factor-P (TGF-P). on the other hand, regulate the rate of transition of fibroblasts from G 1 into the S phase (5,6). These two classes of cytokines have been termed competence and progression factors, respectively. One approach used to examine the release of cytokines from macrophages is the fibroblast proliferation assay in which quiescent fibroblasts are exposed to culture supematants from macrophages exposed to various stimuli. In most of these assays, the supernatant contains fetal calf serum (FCS), which provides the competence factor(s) necessary to facilitate the proliferation of fibroblasts (7-9). Recently, a fibroblast proliferation assay using platelet-poor .plasma [lacking competence factor(s)] as a substitute for FCS bas been described (I 0, 11 ). In this assay, the release of a competence-inducing PDGF-like growth factor from rat and human macrophages can be distinguished from other cytokines that act as progression factors."

Mar 1, 1992

By S. Sinha, S. Ganguly

"In an opencast mine explosives are used for fragmentation of rock. Inefficient use of explosive energy in an opencast operation produces excessive ground vibration, which is measured by peak particle velocity (PPV). To mitigate ground vibration, it is essential to develop a model to predict PPV. At present empirical models are used. These models are based on only a few input variables, hence they fail to take into account the effects of the myriad factors that cause ground vibration. Due to lack of explicit knowledge about the complex mine blasting system the scope of application of mathematical and statistical modeling techniques is limited. The artificial neural network (ANN) technique is a learning algorithm that can remove some of these limitations and can be applied to predict PPV. In this paper an ANN model is developed for prediction of blast vibration using 248 data records collected from three coal mines with diverse geomining conditions. The correlation coefficient between measured PPV and model output was found to be 0.96 and the average error percentage 11.85. The ANN model output was compared with the output of three empirical models that are widely used for prediction of PPV. The correlation coefficient between the PPV predicted by an empirical model and measured PPV data was 0.63 and the relative error percentage 38.47. This result demonstrates the superiority of the ANN model compared to empirical blast models. By using site-specific structural discontinuities as input the model performance can be further improved. Sensitivity analysis and 3D plotting were used to gain further knowledge about blast-induced ground vibration. IntroductionIn an opencast coal mine explosives are used for fragmentation of coal and overburden. If the explosive energy is not fully utilized it causes blast-induced ground vibration, which may damage nearby structures. Ground vibration is expressed as peak particle velocity (PPV). During different stages of mine planning and operation, it is necessary to use a ground vibration prediction model for blasthole design. Selection of the modelling technique is crucial. Mathematical and statistical modelling techniques have limited application because of the lack of explicit knowledge about the complex mine blasting system. Vogiatzi (2002) highlighted the problem of multicollinearity in case of statistical modeling techniques. Mutalib et al. (2013) stated that mathematical models are unable to capture the nonlinear relationship between several blasting-related parameters due to the complexity of the model input data. However, the difficulty involved in modelling complex blast vibration problems can be removed by adopting an alternative soft computing modelling approach. One of the soft computing techniques is the artificial neural network (ANN). Ragam and Nimaje (2018) developed an ANN model for predicting PPV using six input variables. Kosti et al. (2013) stated that the conventional predictors fail to provide acceptable prediction accuracy. They showed that a neural network model with four mine blast parameters as input could make significantly more accurate on-site predictions. Sayadi et al., (2013), using a database from Teheran Cement Company limestone mines, found that a neural network resulted in maximum accuracy and minimum error. Khandelwal and Singh (2009) developed an ANN model using 150 data records from an Indian coal mine with site-specific rock characteristics and geomining setting. Khandewal and Singh (2007) built a ground vibration prediction model for a magnesite mine using four prediction variables with 20 data records. Kamali and Ataei (2010) predicted PPV in the structure of the Karoun III power plant and dam using an ANN. El Hafiz et al. (2010) evaluated ground vibration predictors using data from a single-station seismograph at a limestone quarry in Egypt."

Feb 1, 2019

By Paul Worsey, Matthew K. Coy

New blasting mat designs are currently tested in the field on actual blasting jobs and only undergo qualitative rather than quantitative assessment. The majority of matted blasting occurs in trenching in which the blast designs and field conditions vary considerably. In order to assess a new blasting mat material and design, a new standard test was devised.

Jan 1, 2015

The U.S. National Institute for Occupational Safety and Health (NIOSH) conducted a study to determine the effectiveness of a filtered air delivery system to reduce respirable dust exposure of roof bolter operators in underground coal mines. When performing roof bolting operations, roof bolter operators may experience exposure to high levels of respirable dust during a working shift, especially when working downwind of the continuous mining machine. While drilling and installing roof bolts, this filtered air system supplies a clean curtain of air over the roof bolter operator by means of a plenum mounted beneath the canopy. This experimentally designed air curtain, adapted for roof bolting machines used in this study, is based upon previous design prototypes, computational fluid dynamics (CFD) simulations and trial-and-error testing. Both the prototype and final designs were tested in the full-scale mining galleries at the Office of Mine Safety and Health Research (OMSHR) in Pittsburgh, PA before being taken underground for field testing. Test results of the system in both laboratory and field studies show reductions in operator exposure to respirable dust when the operator is positioned directly under the protected zone of the canopy.

Jan 1, 2012

By V. G. Papangelakis, J. E. Dutrizac, G. Azimi

A new model capable of predicting the solubility of calcium sulphate solid phases in zinc sulphate processing solutions from 25 to 95°C was developed. The model uses the Mixed Solvent Electrolyte (MSE) model of the OLI systems software to calculate the mean activity coefficients of the electrolyte species. The model was tested using recently developed experimental measurements. It was shown to predict accurately the solubility behaviour of calcium sulphate in multi-component zinc processing solutions containing ZnSO4, H2SO4, MgSO4, MnSO4, Fe2(SO4)3, Na2SO4 and (NH4)2SO4. The model can also explain the complex effect of coexisting metal sulphates on the solubility of the CaSO4 phases. The model is a practical tool for assessing the process chemistry of a wide variety of complex aqueous processing streams.

Jan 1, 2008

By Hiroyuki Sano

A closed recycling process for the low-grade scrap of Al-based composite materials was developed. In this process flux treatment with water-soluble halide is a key technique. In the present work, flux treatment conditions were discussed from the viewpoint of the separation and the recovery of the base material, reinforcement and flux. Optimum separation condition was obtained for the NaCl-KCI-KF flux treatment. The recovered aluminum alloy can be recycled for various usages. The recovered SiC particles cannot be reused as reinforcement because of the coexistence of the contamination, therefore it is necessary to eliminate these contaminates or to find another use. The recovered flux is reusable with supplemental addition of fluoride.

Jan 1, 2003

By M. Evertsson, E. Hulthén

"In aggregate production and mining the operators are responsible for controlling and monitoring the process to maintain high plant throughput and safe operation. Operators have to make different decisions to control the process due to changed demand on the operation from both management and conditions of the process. The quality of the response and the time it takes for an operator to respond to altered demand relies on what information is available and the experience of the operator. In this work a dynamic simulation platform has been developed to be used for operator training. Models for representing production units and process control for plant simulations have been developed and implemented in MATLAB/SIMULINK to simulate time-dependent plant behavior. Stochastic and scheduled events are included using the discrete events simulation toolbox SimEvents. The human-machine interface was developed using the human-machine interface software ICONICS. The operators’ cognitive process, in interpreting the plants semantic, has been studied by observations and with informal interviews with operators. This was done to get information about the daily operation and the problems that occur in the process. By interacting with operators that experience different physical interactions with the process; more qualitative e-learning software for supporting operator training in a dynamic operator environment could be developed. The quality of the operator training environment was evaluated with a usability study that was performed with operators and others within the production."

Jan 1, 2014

By J Caron, M Athayde, F Lavoie, R Joyce

Decarbonisation has become a major challenge for the global steelmaking industry, turning towards new technologies aimed at carbon footprint reduction, which on its own accounts for approximately 9 per cent global emissions. The iron and steel industry represents a ‘hard to abate’ sector, where much of efforts are currently being deployed into initiatives aiming to decarbonise the ironmaking through the use of green hydrogen, carbon capture utilisation and storage and state-of-the-art operation of current technologies, while little efforts being deployed to find carbon-efficient solution to iron ore burden preparation, where high-grade iron concentrate will increase in importance to ironmaking regardless of the chosen reduction route. Quebec Iron Ore (QIO), a subsidiary of Champion Iron Limited (Champion), produces high-grade hematite concentrate with one of the lowest carbon global footprints. Still, QIO is partnering with its clients to the development of burden solutions to minimise CO2 emission, in the seek for a decarbonised steel. In a strong technological partnership, Binding Solutions Limited (BSL) has developed a novel, coldbinding technology to provide a cleaner, more cost-effective alternative to induration. The technology allows miners and steel producers to reduce Capex significantly and reduce energy consumption and CO2 emissions by 90 per cent. QIO and BSL have partnered to adapt the disruptive cold binding technology developed by BSL to QIO’s concentrate to produce a high-quality low emissions iron ore agglomerate. This paper describes the efforts taken to further develop BSL’s cold binding technology and its application to QIO’s high-grade iron ore concentrate to produce a hematite cold bonded briquette (hCBB) showing comparable performances with high quality seaborne fired pellets.

Nov 8, 2021

By G. V. Sirianni, G. E. Viens, R. A. Campbell, G. N. Banks, R. L. Sachdeva

"A combined shaft-electric furnace for the smelting of ores and the melting of metallized iron pellets is being developed. The materials are preheated, and in some cases pre-reduced, in the shaft before being transferred to the electric furnace, where melting or smelting is completed. It has been demonstrated that this combination of equipment will enable much of the relatively expensive electrical energy to be replaced by cheaper energy in the form of oil or natural gas, and preliminary experiments indicate that the total energy requirements for a melting or smelting operation are significantly reduced. Projections based on results obtained from the preliminary experiments indicate that further improvements will be possible when certain modifications to the equipment are completed."

Jan 1, 1968

By W. Stark

Many developing countries with little or no previous environmental regulation are now promulgating air quality regulations which require facilities to demonstrate compliance with both process parameter based emission limits and ambient air quality standards. For many companies with operations in developing countries, an air quality compliance program at the facility level is lacking and these companies have very little background information to work with in developing a program for assessing and maintaining compliance. This paper will present a methodology for development of a comprehensive air quality compliance program for operations located in developing countries with new environmental regulations. The experiences of the authors in developing an air quality compliance program for a mining operation located in South America will be used as a basis. A program for meeting new air quality requirements can be developed in seven steps. The seven steps are: (1) regulatory review and project scope; (2) design and implementation of a baseline air quality monitoring program; (3) site visit, (4) development of a complete air emission inventory; (5) dispersion modeling; (6) compliance analysis and compliance plan; and (7) project completion.

Jan 1, 1998

By Y L. Ma, Y Yang, M Chen, W Bruckard

To improve the understanding of the reactions and mechanisms occurring during the leaching of sulfide ores at high temperatures a range of advanced characterisation and sensing tools have been combined to provide a sophisticated and powerful methodology to examine sulfide leaching systems. These include advanced electrochemical methods, surface chemistry and materials characterisation techniques such as synchrotron X-Ray Absorption Spectroscopy (XAS), X-Ray Photoelectron Spectroscopy (XPS), Scanning Electrochemical Microscopy (SECM), and in situ X-ray diffraction (XRD), together with new robust solid state chemical sensors for in situ real time monitoring of key aqueous chemical parameters. The methodology was employed to investigate various sulfide mineral leaching processes. For example, oxidation of arsenopyrite at elevated temperature involves complicated multiple reactions and the process is strongly influenced by the solution conditions, component speciation and mineralogy. The methodology was used to study this system both ex situ and in situ to gain a detailed understanding of the complex chemical reaction mechanisms operating. These mechanisms are discussed in terms of the observed leaching efficiency. The application of this methodology enables complex sulfide leaching systems to be understood more fully such that process efficiency can be improved.

Aug 24, 2022

By D. McElhinney, J. Winfield, G. Buchan, B. Slaker, A. Iannacchione, T. Minoski, G. Rashed, M. Van Dyke, M. Murphy

"The National Institute for Occupational Safety and Health (NIOSH) has previously established pillar design guidelines for the underground stone mining industry. These guidelines were created from an empirical database of pillar observations and were largely drawn from shallow, flat-lying mining operations. Current trends forecast a great amount of underground stone mines developing under deeper cover, higher seam dips, and more frequent multiple-seam mining configurations than in the past. The complex loading conditions and limited experience in these environments presents a substantial increased risk of ground failure. To investigate these loading conditions, NIOSH has installed a pillar and roof monitoring system at an underground limestone mine in central Pennsylvania. The mine is operating in a seam with dips ranging from 13 to 18 degrees and overburdens ranging from 275 m (900 ft) to 425 m (1,400 ft). Instrumentation installed in an undeveloped pillar and in surrounding strata is currently measuring pillar and roof behavior in response to stress redistribution during excavation. Laser scans are being used to measure ground displacement and changes in conditions associated with local mining conditions and significant geological features. Initial stress measurements show a gradual increase in stress in response to mining, and stress changes that correspond with blasts. The seismic system is operational, with calibration events signaling on each of the 18 sensors. INTRODUCTION Improving mine-wide ground control stability can help reduce the potential for catastrophic failure of underground structures. The National Institute for Occupational Safety and Health (NIOSH) has conducted prior research in stone pillar design and has established fundamental pillar design guidelines for the underground stone mining industry, which resulted in the development of the S-Pillar program (Esterhuizen et al., 2011; Esterhuizen and Murphy, 2015). The data that constitute the S-Pillar program were derived from past mining experience that was almost exclusively drawn from shallow, flat-lying, single-level mining operations1. Stakeholder interactions with NIOSH researchers have indicated that increased numbers of underground stone operations are expected to mine under significantly deeper cover, with greater seam dips, and under multi-level operating conditions (Slaker and Murphy, 2016). The complex loading conditions and limited experience in these challenging environments present a substantial increased risk of ground failure. Inadequate pillar design in these new and challenging environments could result in catastrophic wide-area pillar collapses and an increased safety burden to miners working in the U.S. limestone mining industry. To develop design guidelines and prevent inadequate pillar designs for these challenging environments, NIOSH is currently conducting detailed pillar response investigations at case-study mine sites operating in challenging environments."

Jan 1, 2018

By V. Duddempudi, B. Goertz, J. Brune, G. Bogin, F. S. Barreto

"INTRODUCTION In designing a new pneumatic Dust Sampling Device (DSD) for coal mines, it was essential to analyze the air and particle flow inside the device in detail using Computational Fluid Dynamics (CFD) modeling. Several CFD models were developed to simulate the air and dust flow and sample collecting process of the DSD. These CFD models were developed to assist in the design of the DSD instrument prototypes for laboratory testing. Nozzle and injection parameters such as geometry, air velocity and pressure, were varied across a wide range to obtain the optimal settings to accurately simulate the fluid dynamics of the multi-phase flow within the DSD. Accordingly, these parameters were used as a guide for the design of the DSD and to verify the dust scouring dynamics, which is designed to represent the dust entrainment during an actual methane or coal dust explosion. BACKGROUND The 2010 explosion at the Upper Big Branch mine has demonstrated the destructive violence of a coal dust explosion. A major contributing factor for this disaster was that the mine operators did not have a reliable, direct-reading method to collect mine dust and determine inert content and combustibility. This led to the development of a new prototype handheld, pneumatic mine dust sampling device (DSD), which blows a puff of air and entrains the mine dust by mimicking the entrainment process during a mine explosion. A computational Fluid Dynamics (CFD) model is used to analyze the air and dust flow inside the DSD. The objective of the CFD modeling effort is to find the optimum design of the DSD prototype, nozzle orientation, air pressure and pulse length by analyzing and varying these parameters so that the scouring action collects a valid, representative and repeatable mine dust sample. CFD MODEL DESIGN Figure 1 shows a wireframe image of the DSD which is utilized in the setup of the CFD model. The DSD has a triangular cross section and is 10 cm wide. Two nozzles with cross-sectional dimension of 2.8 cm by 0.25 cm act as inlets at the narrow end of the triangular cross section. The CFD model includes a reference plane 6 cm away from the nozzle to measure the quantity of dust collected. The geometry shown in Figure 1 was created for the model and it matches with the design of the actual device shown in the figure 2. Symmetry, along the plane X-Y through the center of the device, is used to reduce the number of computational cells in the CFD model. Figure 2 shows the prototype device used for experimental testing. CFD MODEL SETUP Figure 3 shows a hexahedral mesh with a cell size of 0.8 mm and the total number of cells is around 650,000. The ANSYS Fluent® pressure based solver with a transient case was used with a total duration of 40 ms. The 40 ms simulation time is based on experimental measurements to capture the injection of air and initial scouring of dust."

Jan 1, 2016

By Ben W. Burdett

The operation of an electrolytic refining tank house is an art as well as a science. If the electro-refining industry is to progress, a better understanding of the refining process is necessary. This would help to reduce the amount of training necessary to produce competent tank house operators who, in turn, would be able to increase both quantity and quality of the tank house product. To aid in understanding this process, quantitative relationships between the critical tank house variables must be established. The inherent major contributor to inefficiency in most tank houses is short circuits. By quantifying the effect of short circuits on each of the other variables in the system, as well as their effect on over- all system performance, better decisions regarding manpower allocation can be made. Current distribution under short circuit conditions, which has always been somewhat of a mystery, can be studied in detail. The relative importance of electrolyte balance, proper anode-cathode spacing, low contact resistance at points of electrical connection, and other system variables can be determined, With a better understanding of these variables, the steps necessary to increase current efficiency are more easily defined. Relationships between most of these variables are described in qualitative terms in the literature, but quantitative relationships between tank house variables have never been established. A realistic mathematical model of the tank house could be used to test the effect of variations in a single variable on other variables in the system, and thus define the quantitative relationships between tank house variables. It is not the purpose of this paper to establish these relationships, but to describe a recently developed model that can assist in their establishment. A computer program implementing this model has been applied to examine the effect of short circuits on overall current distribution. Some of the results are given here as examples of the utility of this program.

Jan 1, 1973

By Henry Hu

In high pressure die casting processes, proper control of temperature die yields a high casting production rate and superior quality components, Die temperature is usually influenced by various die design and process parameters such as size and location of intemal water cooling lines, flow rates of cooling lines, and pouring temperature of molten metal. Among them, the cooling water flow rate plays a major role in controlling thermal pattern of the die_ In order to develop an effective control strategy, data of local die temperature must be collected and analyzed, In this study, a PC-based data acquisition and control system (DACS) for die temperature control has been designed, and established, The developed DACS has three input channels for temperature signals and one input channel for water flow rate signals, as well as one output channel for a water pump, and is capable of displaying data in both curve format and value format. Implementation of the DACS in a laboratory setup has also been attempted, It should be pointed out that more advanced control mechanisms can be potentially integrated into this system in future,

Jan 1, 2003

By D. G. Mason

During the design of copper refinery tankhouses, there is a need to develop mass balance calculations for many process components, so that optimum physical plant configuration is achieved. Each mass balance is complex, possibly with over 120 interactive variables as basic input data. Recent developments in tankhouse design (e.g. permanent cathodes) have greatly increased the design options available for any project, multiplying even further the requirement for calculations. In the past these calculations were tedious and susceptible to human error. A comprehensive computer program can now simplify the task of the process metallurgist, enabling more sophisticated and sensitive plant designs to be produced. The paper describes the successful development of a flexible mass balance program that originallly was used in a feasibility study which had to be completed within a short time schedule. The program has been further developed and used for design and energy calculations; it can be usefully applied to existing plants to assess the impact of variations in operating parameters. The software takes account of staged liberation, electrolyte purification bleed and generates a reliable process inventory listing: it can also cope with stripper starting sheet options and disparate commercial circuits.

Jan 1, 1987