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By A. J. DeArdo

Linepipe steels have come a long way in the past forty years. In fact, modern, high strength steels for large diameter linepipe applications represent one of the seminal accomplishments in metallurgy of the past half-century. The synergy of advanced steelmaking, alloy design including microalloying, hot rolling, and interrupted accelerated cooling has led to the marvelous steels being used today. The drive for higher performance pipelines has been motivated by the energy sector of our global economy who wanted both higher throughput capacity, i.e., larger diameters and higher pressures, and lower material cost, i.e., relatively thinner gauge wall thicknesses. These requirements led to new steels with higher strengths, better toughness and improved weldability. The goal of this paper is to trace the evolution of linepipe steels from the X60 grades of the small diameter pipelines of the 1960s to the (X80 - X120) grades used in the large diameter pipelines of today. The metallurgical triumphs permitting this success story, e.g., clean steel practices, controlled rolling, microalloying with Nb, and using IAC to obtain low temperature transformation products, will be highlighted and discussed.

Jan 1, 2005

By V Gupta, Z Huang, S K. Biswal

G-Cell is a new design modification of the Imhoflot pneumatic flotation technology, which utilises a self-inducing aerator inside a downcomer, where bubble-particle attachment takes place. The present study has investigated the suitability of the G-Cell technology for cleaning fine coal using a 0.8 m diameter prototype unit at a coal preparation plant operating in the Midwestern United States. A slip-stream obtained from the overflow of raw coal cyclones operating in the plant, containing nominally minus 150 micron size particles and having ash content in the range of 40 per cent to 50 per cent and sulfur content in the range of 1.30 per cent to 1.50 per cent, has been used as the feed for the G-Cell. The performance data produced from the G-Cell tests are found to be very close to the ideal performance curves produced from release analysis. A statistically designed experimental program has been conducted to investigate the parametric effects on various key process responses, such as combustible recovery, product ash and sulfur rejection. The empirical models developed in this study have been utilised to identify a suitable experimental region for achieving a desired combination of response targets.

Jan 1, 2005

By K. El-Ouassiti, M. Zouadi, C. Bazin, D. Hodouin

Data reconciliation techniques are used to attenuate the effect of measurement errors and estimate unmeasured variables. This paper illustrates the application of data reconciliation to hydrometallurgy processes using measurements from leaching and solvent extraction obtained from laboratory experiments. The application of data reconciliation provides an efficient way to detect gross and systematic errors and produces reliable performance indices for process evaluation.

Jan 1, 2005

By Joel Moskowitz, Jan Cermak

"New York City has unique geologic conditions which must be considered when designing pile foundations. Where shallow foundations are not feasible, the City's subsurface conditions require a variety of deep foundation systems, ranging from high capacity rock socketed piles, to piles end-bearing on bedrock, to friction piles bearing in alluvial or glacial deposits. Pile load testing is essential in confirming pile capacities as pile analyses include assumptions on soil and soil-pile response, and pile driving equipment. Load test results must be interpreted to estimate the long-term pile behavior. Except for lightly loaded driven piles, the New York City Building Code (the Code) requires that pile capacities be confirmed by static load testing. The Code provides the number of static load tests required, test procedures, and acceptance criteria. In the last few decades, methods other than static load testing have been developed including dynamic and rapid (pseudo-static) load tests. Recently, those methods have also been employed on several projects in New York City. The traditional approach to pile load testing in New York City is discussed herein including engineering involved in the analyses of test data with examples. In addition, several projects which included non-static load testing are discussed INTRODUCTIONPile load testing complements the subsurface information and pile design by providing further data on pile-soil interaction for the selected pile type and installation method. Traditional approaches to pile load testing in New York City involve static load tests to verify the design capacity of the piles for a given minimum factor of safety.In the late 1950's, Dr. Phillip C. Rutledge summarized his views on the philosophy of pile foundations in an unpublished, in-house document. He viewed pile foundations as good illustrations of pertinent and impertinent aspects of geotechnical engineering. In the analyses of piles he divided engineering into four general types:(a) Theoretical engineering in which decisions are made based on theoretical analyses. This represents ideal engineering, in which all factors affecting the pile design are well established or, at least, few simplifying assumptions with known effects on the analyses are made."

Jan 1, 2005

The National Mining Hall of Fame will induct five mining greats on Saturday, Sept. 17, 2005 at the Museum Convention Center in Leadville, CO. The 18thAnnual National Mining Museum and Hall of Fame Induction Banquet will begin with an open house and reception at 5:30 p.m., followed by the dinner and program at 7 p.m. The five inductees are Nathaniel Peter Hill, John Munro Longyear, John McDonald, Julius Eckhardt Raht and John Dennis Ryan. Nathaniel Peter Hill (1832-1900) built the first successful smelting operation in the Rocky Mountains in1867 at Black Hawk, CO. From 1879 to 1885, he was a U.S. senator. He also taught courses at the Colorado School of Mines.

Jan 1, 2005

Safety remains a critical priority for the Australian mineral resource industry and will receive increased focus in the future. This is particularly evident in underground coal mines where reserves are becoming deeper and more hazardous to extract. The CSIRO, through its Exploration and Mining Division, have recently delivered on two projects aimed at providing step-change capabilities in real-time risk management and hazard control. This paper describes the key outcomes of these projects.

Jan 1, 2005

By Huw Williams

"Power companies are always looking to increase the carrying capacity of existing transmission lines, and the preferred method is to string heavier capacity conductor lines. However this results in higher wind loading and the potential for towers overturning, if the existing foundations do not have the tensile capacity. On older lines, there is often a lack of information on construction type and dimensions and in practice the as-built foundation can differ considerably from design drawings, due to unforeseen ground conditions along the line route, and no record of the resulting change in design being made.Following successful trials in New Zealand, integrity testing with Frequency Response and impedance profiling techniques is now being used in the region to check concrete foundation properties in-situ and are enabling power companies to get the most out of their assets. INTRODUCTIONIn most regions of the globe, the US included, there is generally a requirement to upgrade transmission line capacities, to cope with increasing power consumption. Problems with under capacity only come to light for the public when blackouts occur, even in developed countries.A large number of transmission line towers are designed with a certain capacity redundancy and will be able to carry greater loads than originally designed for. Power companies are therefore looking for ways to assess their assets and to minimize the costs of upgrade work.Re-assessment of tower foundation capacities using design drawings may not be valid , as constructed foundations may differ considerably from design drawings, to accommodate local difficulties and in some instanced, particularly with earlier lines, there is no information whatsoever. This complicates efforts to determine the capacity of foundations considerably."

Jan 1, 2005

By Paul Gribbon, Greg Colzani, Jim McDonald

The $300 million West Side Combined Sewer Over?ow Project consists of over5.5 kilometers of soft ground tunnel, an 833-million liter per day (220-MGD) deep shaft pump station, 3 kilometers of micro tunneling, and other miscellaneous shafts and pipelines. The construction contract, underway since September 2002, is a reimbursable cost plus fixed fee contract that included a quali?cations-based contractor procurement process and has undergone some modi?cation since execution. This paper will describe the contractual issues addressed to date, dispute resolution, where improvements can be made, and how an Owner can evaluate whether this type of contract is the best approach for an underground project.

Jan 1, 2005

By J. MacFadyen

The U.S. cement industry experienced its best year ever during 2004 in terms of production and shipments of cement. Clinker, portland and masonry cements production and shipments were up considerably. Clinker production as reported to the U.S. Geological Survey (USGS) was 87.75 Mt (96.73 million st), an increase of 5.4 percent. Gray and white portland cement production from domestic and imported clinker was estimated to be 91.6 Mt (101 million st), up 5 Mt (5.5 million st) from 2003.

Jan 1, 2005

By J T. Smit

The theory of froth flotation developed slowly, in almost all cases lagging behind practical developments in the operation of flotation processes. This was largely the result of a lack of understanding of the required basic principles of chemistry and physics, many of which were being developed at the same time. A review of some of the early theories propounded is worthwhile, and should encourage those who are presently studying or practicing flotation to exercise some care in claiming a complete understanding of the underlying phenomena in the art. This paper considers theories presented up to and including those in Principles of Mineral Dressing by Antoine M Gaudin (1939). Of course, developments since that time are important, but they are beyond the scope of this discussion.

Jan 1, 2005

By Ashraf M. Eid

Most research dealing with the problem of laterally loaded piles has been the response of individual piles subjected to lateral loads and/or bending moments. However, piles are seldom used individually but are normally constructed in clusters or groups. Little information is available of the effect of pile-soil-pile interaction (PSPI) on the performance of the group. This may be attributed to the difficulty of carrying out full-scale tests. Such tests are prohibitively expensive and require special installations to provide the required large lateral loads. The problem of laterally loaded single piles or pile groups involves the complexity of extending the theoretical solutions to the limits where the actual soil behaves nonlinearly. As the load increases, the elastic soil behavior cannot be adopted for design. Nonlinear soil behavior or the elasto-plastic behavior is evident. This research consists of experimental and theoretical models. The experimental work was conducted on models of free head pile groups in different configurations. The piles were in a sand formation and compared to the behavior of a single pile. The possible factors that influence the group behavior could be visualized. The experimental data was also compared to the widely used theoretical approaches to determine their adequacy. The analytical model makes use of the finite difference approach to calculate the soil non-linearity. A new approach equates the measured ground deflection and maximum bending moments of each row at every load level with the analytical model of single pile. This is the Deflection-Moment Fitting (DMF). The most suitable non-linear soil modulus modes and row contributions could thus be determined. Design of pile groups can be based on data pertaining to soil characteristics of the single pile. Results of the analysis were consistent with other approaches and proved to be adequate for design.

Jan 1, 2005

Improved roof control in high deformation tailgate environments has been achieved over the last decade through development of stiffer and increased capacity standing support products. æThe CanÆ is one such development, being a steel cylinder containing a weak cementitious fill, designed to essentially fold in upon itself whilst maintaining strength. A laboratory study to better define the relative load contributions of the steel cylinder and fill, the confining interaction between these components and most importantly, the potential impact of varying the steel and/or fill properties is described. This would enable the support engineer to ædial-upÆ the desired strength and stiffness properties and optimise the standing support design with respect to load capacity, stiffness, weight (handling) and cost. Design curves to optimise strength based on steel casing thickness, fill strength (confined and unconfined) and æCanÆ geometry were established. Scaled-down (one-third) samples were used in the test program and found to adequately reflect the loading behaviour of full-scale versions, thereby providing significantly greater scope for further product development at less expense compared with testing full-scale products.

Jan 1, 2005

By Bill Elverman

Randy and Kenny Robison have visited every coal mine that would let them in the door, to survey the best mining practices. The brothers have spent nearly their entire lives working in coal operations. The Robison’s started out on lube and grease trucks and worked their way up to respected industry leaders in Alabama. The Robisons have owned MS&R since 1989. Since then, they have created a niche for themselves in providing coal for Alabama’s metallurgical coal market. A great deal of the knowledge the Robisons have amassed throughout the years has come from observing — taking note of what works and what does not. In early spring 2004, they commissioned a Komatsu America PC3000 Super Shovel. Outfitted with a backhoe attachment and a 16-m3 (21-cu yd) bucket, MS&R’s PC3000 is currently one of the largest mining excavators working in Alabama.

Jan 1, 2005

By Glen Mann, H. G. Vestberg, Robert D. Holtz

"Underpinning of residential and commercial structures is often accomplished using a number of driven-in-place small diameter steel pipe piles. These piles, at least in the Seattle area, are typically described as pin-piles and are driven with an air compressor operated jack hammer to a refusal criterion developed from an empirical basis. Over the past twenty years or so, the materials have improved in quality and strength, and the driving equipment has improved in efficiency and capability. These improvements have resulted in damage to the pin-piles during driving as well as to the driving equipment. The primary objectives of this load testing study were to develop a relationship between the driving penetration resistance of 2-inch diameter pin-piles and the ultimate bearing capacity when piles were driven at different penetration rates and, based on the load test results, to develop an opinion regarding an increase in the allowable axial load capacity [ultimate load capacity divided by a factor of safety] of a 2-inch diameter pin-pile over the currently used permissible load capacity of 4 kips in the Seattle area. Also, if feasible, a reduction in the present driving penetration rate was to be recommended to help reduce the rate and magnitude of pile and equipment damage whilst maintaining the allowable load capacity. The recorded ultimate bearing capacities were also compared with the Tagnent-line and the Davisson analytical methods in an effort to determine if either of these provided a reasonable determination of the pile load capacity.IntroductionThis paper describes the results of a series of load tests performed on small diameter, 2-inch, driven-in-place steel pin (pipe) piles and based on these results, provides the support for a modification to the presently used allowable axial pin-pile capacities.The intent of the load testing program was to determine how much influence the penetration resistance might have on the individual piles' ability to support the allowable axial load without undergoing any significant vertical deformation. For the purposes of this paper the ""allowable load capacity"" is considered to be the ultimate pile load capacity divided by a minimum factor of safety, typically considered to be 2.0 in this area. A pin (pipe) pile comprises an open or closed ended, schedule 80 steel tube which is driven-in-place, usually with an air compressor operated 90 pound pneumatic jack hammer. These jack hammers typically operate at a rate of about 1,200 blows per minute, (Haggard, Holtz and Mann, 2001 )."

Jan 1, 2005

By G M. Evans, C M. Phan

This paper presents an analysis on the dynamic adsorption of frothers and collectors onto air bubbles in flotation. The analysis was carried out using the theory on the surfactant transfer by diffusion and adsorption. The bubble size was considered when solving the diffusion equation for the dynamic surface excess. The adsorption kinetics was modelled employing the Langmuir adsorption isotherm and its extension with the inclusion of the lateral interaction of the adsorbed molecules (the Frumkin adsorption isotherm). The numerical computation was applied to solve the governing equations. The dynamic adsorption of the surfactants was measured in terms of the dynamic surface tension for sodium dodecylbenzene sulfonate (SDBS) and Dowfroth 250, using pendant bubble tensiometry. The results show that for air bubbles with diameter of the order of 1 mm, the bubble size effect on the dynamic surface tension is small and the solution of the diffusion equation for a planar gas-liquid surface can be used to describe the dynamic adsorption onto the air bubbles. The experimental data obtained with SDBS were well described by the Frumkin adsorption isotherm and the molecular diffusion. The model description for the experimental data obtained with Dowfroth 250 required the kinetic equations. The paper is relevant for further analysis of the role of the adsorbed surfactants in the particle collection.

Jan 1, 2005

By Lawrence M. Gochioco

One of the best kept technology secrets in U.S coalmining history involved a robust coal geophysics program used by a local coal company to detect and map various geologic anomalies and man-made structures ahead of mining for nearly 15 years. Several original mine plans were changed as a result of findings from two-dimensional (2D) and three-dimensional (3D) seismic data. They indicated the presence of geologic anomalies in reserve areas that could adversely impact future mine development and longwall production. By combining the surface seismic and exploratory drilling methods, the coal company learned how to properly leverage its risk by gathering a lot of useful subsurface information before making major commitments.

Jan 1, 2005

By Robert J. F. Goodfellow, William A. T. Meakin, Kevin Clarke, Eric Cole

INTRODUCTION New York City Water Supply—Background and History Since the 1840s New York City has been developing the largest, and perhaps, the best urban water supply and distribution system in the world in terms of quality and reliability. One of the engineering marvels of the modern world, the New York City water supply and distribution system serves a population of almost nine million, including residents in nearby Westchester, Putnam, Ulster, and Orange Counties of New York State. The average daily supplies presently are running at almost 60 m3/sec(about 1,350 million gallons per day). The watershed for the New York City water supply system, under the jurisdiction of the New York City Department of Environmental Protection (NYCDEP), consists of19 reservoirs and three controlled lakes, and covers an area of approximately5,000 square kilometers (about 2,000 square miles) north of New York City. The watershed total available storage capacity is about two billion cubic meters (560 billion gallons) and is divided into three reservoir systems: the Catskill and Delaware watersheds located West of the Hudson River; and the Croton watershed, located east of the Hudson River, see Figure 1. The first element of the system, the Croton Aqueduct, started operations in 1842.Through several updates and expansions, the present-day Croton system was in place by 1911, providing a potential maximum supply of about 15 m3/s (about 340 mgd). The system includes ten reservoirs and three controlled lakes. In the late 1800s, with the tremendous growth of the City, New York City water engineers began to look for additional sources. Between 1907 and 1929, the City acquired water rights and constructed a new 148 km (92 miles) Catskill aqueduct to convey water from the Ashokan Reservoir to the City. The Catskill system also included the construction of the Kensico and Hillview Reservoirs just north of the City,

Jan 1, 2005

By Gary Almeraris, Vincent Jr Tirolo

Traditionally, “Means and Methods” were the sole responsibility of Contractors. However, because of a number of litigious projects in the 1970s, Owners and their Engineers began including Suggested Methods of Construction (SMC) in Contract Drawings. By the late 1990s these SMCs were becoming baseline “Means and Methods” with Contractor recommended changes often considered as Value Engineering proposals. By 2004, the word “Suggested” was sometimes changed to “Prescriptive.” Owners are also purchasing TBMs and other mining equipment for Contractors prior to bid. Is limiting the contracting community’s innovation in developing their own “Means and Methods” and selecting their own equipment in the best interests of the Owner? Does it reduce the Owner’s, Engineer’s or the Contractor’s risk? Are claims reduced and finally what is the impact on the bid? A questionnaire was sent to more than fifty senior engineering field and management personnel representing more than 30 heavy construction companies to ask their opinion on these questions.

Jan 1, 2005

When I was first asked to give a paper on work-life balance in the mining industry I was both excited and aware of the incongruity of my position. I have never worked in mining operations nor have I had any experience that approximates the on-site lifestyle. IÆm not really an adventurer or a traveller, I prefer writing and research to hands-on activities and IÆve never worked further than twenty minutes away from home. The perspective I offer is thus largely an objective one. I say largely since I grew up in a family where my parents work arrangements involved long-distance commuting; my dad continues to work FIFO at a coalmine in Blackwater until this day. Perhaps my tortoise-like existence is a rebellion against his flighty movements. The analysis I will be presenting today draws together a variety of sources, from member anecdotes and research on FIFO and work-life balance to the popular philosophy writings of a bald Englishman with a French name. I am speaking of the famous writer, Alain de Botton, whose television show æThe Consolations of PhilosophyÆ you may have seen on the ABC. Work-life balance is a term that gets a lot of mileage in corporate brochures and at breakfast seminars. But like many terms that get bandied around in the human resources circuit, from æteam synergyÆ to æperformance optimisationÆ, I am frequently perplexed as to what it actually means. Corporate websites are at pains to emphasise the high priority that they place on the needs of the whole person. Yet in terms of substantive content, a commitment to work-life balance often seems to translate into little more than the option to take a few morning yoga classes in exchange for working a seventy-hour week. As extended work hours have taken their toll, leading to high attrition of professionals across all industries, employers are increasingly expending resources to discover just what lies behind this buzz word. The challenge for companies is to find meaningful strategies to help employees better integrate different aspects of their lives in a new era of work, as employees are sending the message that they are not willing to play work, social life and leisure off against each other in a zero sum game.

Jan 1, 2005

By V Novoselov, R Sabirov

Flotation processing technology of water-soluble minerals has made it possible to realise, since the 1960s, the wide scale industrial processing of potash and potassium-magnesium ores (about 200 million tonnes per year) as well as to create the multi-tonnage worldwide production of sylvite (KCl) for industrial and agricultural application. In this paper the particularities of the effect of reagents (blinders, collectors and frothers) during cation flotation in saturated saline solutions are outlined. New reagent modes for activating the effects of alkylamines during the flotation of KCl and the perfecting of technological flow sheets for processing potassium ore have been developed. The results of research on the reverse flotation of carnallite ore, with the help of alkylmorpholine û a new developing technology for benefication carnallite as raw material for the production of metal magnesium and fertilisers are listed. Examples are given of the industrial applications of processed reagent modes at potash flotation factories in Russia.

Jan 1, 2005