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By E. Nejati, S. Khoshkooei, V. Firouzdor, M. Akbari, F. Khomamizadeh

In this study the effects of Si content on mechanical and thermal fatigue properties of Al-Si casting alloys were investigated. Repeated heating and cooling cycles were applied on the samples at 230°C to develop thermal fatigue cracks. Crack growth mechanisms and microstructural influences were investigated by optical and scanning electron microscopy. Thermal fatigue behaviors were improved successively by increasing of silicon content up to 7wt%. However, addition of more than 9wt% silicon decreased the thermal shock resistance of the alloy. Silicon contents of about 9wt% presented the best mechanical and thermal fatigue resistance in the alloy.

Jan 1, 2006

By J. A. Jr. Carpenter

Expanding world economic prosperity, probable peaking of conventional petroleum production in the coming decades and environmental concerns require efforts to increase the efficiency of, and the development of alternatives to, petroleum-based fuels used in automotive transportation. In January 2002, the U.S. Department of Energy (USDOE) and the U.S. Council for Automotive Research (USCAR) of the "Big Three" traditionally-USA-based automakers, DaimlerChrysler, Ford and General Motors, formed the Freedom Cooperative Automotive Research (FreedomCAR) Partnership to fund high-risk, high-payoff research into advanced automotive technologies with the potential for eventually lowering the USA's nearly complete (95%) dependence on petroleum, 55% imported, for its transportation fuels. FreedomCAR replaced the Partnership for a New Generation of Vehicles (PNGV) which existed from 1993 to 2001. In January 2003, the energy-supply industry joined with the FreedomCAR Partnership forming the FreedomCAR and Fuel Initiative (FC&FI) to develop the technologies needed for the mass production of fuel-cell vehicles using hydrogen as fuel and the infrastructure needed to deliver the hydrogen to the consumer. The goal is to enable the automotive and energy-supply industries to make commercialization decisions in 2015 on large-scale introduction of such vehicles and on developing the infrastructure beginning in 2020. In addition to work on fuel cells and hydrogen infrastructure, the FC&FI conducts research on technologies with the potential for nearer-term energy efficiency and environmental benefits, such as new engine concepts, lightweight materials, and engine-electric hybrid propulsion systems. Lightweighting is seen as crucial for shorter and for longer term benefits because hybrid and fuel-cell powertrains are expected, at least in the early stages of adoption, to be heavier and more costly per unit of power than the standard internal-combustion, gasoline- or diesel-fueled powertrains they replace. Research and development (R&D) on casting of aluminum automotive components were major parts of the PNGV and R&D on casting of magnesium automotive components have been and are so under FreedomCAR. This presentation will review those efforts.

Jan 1, 2006

By M. Kolahdoozan, H. Noori

"Molybdenite flotation at the Sarcheshmeh Copper Complex has been studied as a function of pulp potential controlled using two types of sodium sulfide (mineral and chemical origin). Air and either plant or laboratory nitrogen was used as a flotation carrier. Potential measurements were taken in the rougher cells as it was proved to be vital for molybdenite flotation. Flotation test with reducing potentials between -525 and -575 mv gave the highest molybdenum recovery (93%) and the lowest copper recovery of between 4 to 15% can be achieved. These potentials did not change considerably by adding increasing amounts of sodium sulfide. At more oxidizing potentials, i.e. more than -450 mv, the recovery of copper increases while the recovery of Molybdenite drops.INTRODUCTIONThe average copper ore feed grade to the Sarcheshmeh flotation circuit is typically set at about 1.2% Cu. to be delivered to processing unit is set at 1.2%. There is no control of molybdenum (Mo) which usually varies between 0.01 and 0.04%. During concentration, a Cu-Mo concentrate is produced by one stage of roughing, one stage of scavenging and two stages of cleaning. Final concentrate contains 0.5% of Mo and 32% of Cu while the particle size is 90% under 42 microns (325 mesh). Because of the high grade of Mo in this concentrate and economic interests, a molybdenite flotation circuit plant was built in 1984. This plant was designed to treat 1432 tons of Cu-Mo concentrate (on dry basis) and consists of one stage of roughing followed by seven stages of cleaning. After dewatering the concentrate contains 53.7% Mo which is dried and shipped overseas.The majority of molybdenite production worldwide comes as byproduct of copper porphyry ores. The Mo grade typically varies between 0.01 and 0.06% and accompanies chalcopyrite and chalcocite. Due to the hydrophobic nature of molybdenite, it can be floated along with copper sulfides. Thus the overall concentrate of Cu and Mo contains 0.2-1% of molybdenum as well as 20-42% of copper. To separate the Mo, Cu and Fe minerals, depressants are used. The most important of which are sodium sulfide, sodium hydrosulfide, Anomal D, sodium cyanide, ferropottasium and ferro-cyanide. The first three regeants have been extensively used for successfully treating porphyry ores [1]. In the molybdenum plant of the Sarcheshmeh Copper Complex only sodium sulfide has been used to date."

Jan 1, 2006

Caterpillar said it will produce a Cat line of ac electric drive mining trucks. The world’s largest manufacturer of mining and construction equipment said the addition of an AC electric drive truck line will provide its customers with products to fit key applications. “We are very proud of the strong leadership position that Caterpillar has attained with its mechanical drive trucks, and we will continue to invest in strengthening that position,” said Chris Curfman, president of Caterpillar’s Global Mining Division and Caterpillar Inc. vice president. “We also recognize that there are unique applications that would make the addition of ac electric drive an important and attractive complement to our current truck line.” This is the largest investment Caterpillar has made in mining trucks in its history.

Jan 1, 2006

By Linli Wu

During the measurement of contact angle, a misty band was observed near the substrate. Hsien-Nan Ho and Shinn-Tyan Wu thought this was because the oxygen atoms on the interface migrate to the droplet surface to form an oxide band near the substrate. But from our experiments misty band appeared before the drop reach to the substrate. Theoretically speaking, the oxygen partial was the same everywhere in the vacuum furnace. So there was no condition to provide enough oxygen forming oxide. This appearance would be explained more reasonably with the optics principle. Most reflected light would be absorbed by the substrate and the light cannot reach the observation area, so the misty band formed.

Jan 1, 2006

By Jin He

Based on the simple-beam theory, a stress analysis model was established for undermining in multiple seam strip-pillar mining when the strip pillars were not columnized; the effects of various mining factors (e.g., mining depth, inter-burden thickness, recovery ratio, etc.) on inter-burden stability were analyzed; the changes in inter-burden stress distribution were investigated; and the important role that the inter-burden spacing and the mining width of the lower seams on inter-burden stability was studied. Finally, the actual practice used in Feng Feng Mine area was used as an example to demonstrate the rational mining width for a fixed mining depth.

Jan 1, 2006

By L. I. Kiss, S. Perron, S. Poncsák, A. Perron

Aluminium industry has an increasing interest in the diminution of the energy consumption of the Hall-Heroult process by the reduction of the anode bottom covering with gas. Electrically isolating carbon-dioxide bubbles, produced at the anode, increase the ohmic resistance of the cell. As the gas production rate is determined by the applied current density, anode covering can be decreased only by a faster evacuation of the gas from the inter-electrode space. Among others, the inclination and curvature of the anode bottom promotes the release of the bubbles and thus decreases the mean value of the covering. Indeed, anode, insert in the molten cryolite bath has a square shape with horizontal bottom. However, inhomogeneous anode consumption, electro-erosion, bath circulation and the inclination of the bath-metal interface modify this shape gradually during electrolysis. Anode bottoms become inclined with rounded comers. This concentrates the gas generation to the center zone of the anode. As the bubble layer cannot be observed directly because of the hostile environment and the opacity of the bath, real scale air-water systems are used to study the impact of the anode geometry on the anode covering and the bubble induced flow. However, the physical properties of such a system are different than that we can found in the real cells. A simulator using the Lagrangian description of the bubble layer has been built and presented in earlier papers. This tool was used to investigate the effect of the anode inclination on gas covering and bath velocity, for both C02-cryolite and air-water system. Results obtained for the second system were compared to experimental data .

Jan 1, 2006

By Muhannad T. Suleiman

Temperatures below freezing significantly enhance the soil shear strength and stiffness and to a lesser extent increase the compressive strength of concrete as well as the yield and ultimate strength of reinforcing steel. Consequently, the lateral load resistance of bridge columns supported by drilled shafts becomes dependent on seasonal weather conditions. To investigate the effects of seasonal freezing on the behavior of bridge columns supported by drilled shafts, large-scale field lateral load tests were conducted at 23°C (73.4°F) and -10°C (14°F) on two identical units at an field test site, which consisted of glacial till soil classified as low plastic clay. The bridge column-drilled shaft systems were subjected to cyclic lateral load with the maximum lateral column top displacements reaching approximately ±30 cm (±11.8 in.). The soil at the test site was characterized at different temperatures using unconfined compression tests in the laboratory as well as in-situ Cone Penetration and Pressuremeter Tests. Using these test results, the lateral load behavior of the column-drilled shaft systems were analyzed utilizing numerical models that consisted of beam elements representing the concrete column and the shaft and lateral springs representing nonlinear p-y response of soil. This paper focuses on comparing the calculated responses of test units with different p-y curves that were developed for the soil near the ground surface using the laboratory and in-situ tests. From the experimental study, the response of the unit tested at -10°C (14°F) was found to show 44% increase in lateral force resistance and 0.84 m (2.76 ft) upward shift of the maximum moment location compared to the response of the identical unit tested at 23°C (73.4°F). Theoretical behavior that included the temperature effects on soil, concrete and steel properties provided good correlation with the measured responses when the soil near the ground surface was modeled using the unconfined compression test or the Cone Penetration Test data, but not the Pressuremeter test data.

Jan 1, 2006

By S. Yue, P. Vo, M. Jahazi

The flow behaviour and microstructure development of a near-alpha titanium alloy during beta working has been investigated. Typical cogging conditions were simulated through compression testing of IMI834 at temperatures of 1025°C-1100°C, strain rates of 0.01 s-1 - 1 s-1 and post-deformation heat treatments up to 4h. Using a synthesis of available literature models, a finite element model has been developed and validated through quantitative measures of flow stress-strain data and beta grain characteristics. Flow behaviour was analyzed through a self-consistent method while the microstructure development was considered with regard to the kinetics of beta recrystallization. Deformation at beta or high alpha/beta working temperatures (T>l025°C) produced minor flow softening with complete grain refinement achieved through metadynamic recrystallization.

Jan 1, 2006

By R. Hart

In this paper, problems that have been experienced with the rockpass system at Kloof Mine No. 3 Shaft are described. Actions that have been taken to overcome the problems are also described. These include the use of slugshots to remove hang-ups, the abandonment and waste filling of passes, and design criteria adopted for an alternative pass system.

Jan 1, 2006

By A. F. Abd El-Rehim

The behavior of both transient and steady state creep of Al-4.5 wt% Cu and Al-4.5 wt% Cu-0.1 wt% In alloys was investigated using a constant stress where torsional oscillations of different frequencies and shear strain amplitudes were operated at various working temperatures. An augment in both transient and steady state creep rates was observed by increasing both frequency and shear strain amplitude of the applied oscillations. The mean values of the activation energy of both alloys for both creep stages were found to be equal to that quoted for dislocation intersection mechanism.

Jan 1, 2006

By P. Mengé

The covering of a hydraulically filled goethite pond is discussed from a geotechnical point of view. The characteristics of the goethite were defined in order to allow a detailed study of the procedure for the construction of the cover on top of the soft material and a verification of the stability of the cover and side slopes after construction. These characteristics and the main results of the studies are given, as well as the experiences and observations made during the execution of the work. Finally, the monitoring plan, during and after construction, is also discussed and some results are given. The 'Design and Construct' contract form was used to allow the contractor to choose the optimum and most economical method to realize the closing of the pond, based on his experience with similar projects. The works were carried out between mid 2003 and the end of 2004. The paper will, amongst others, discuss the special method of working that had to be developed to allow the covering of the whole pond in a relatively short time period, without soil improvement methods such as vertical drains or stabilization by in situ treatment. Fill material was used to establish a platform on top of the soft material so that the cover liner and finishing layer could be installed on top of the fill layer. The 'floating roof' principle was used; subsidences were allowed to occur during the installation of the impermeable top liner and soil cover.

Jan 1, 2006

By Kazimierz Gwizdala

In recent years, in Poland the ATLAS piles have been successfully applied for some constructions near Gdansk. The piles have been used as foundations for housing and another areas of civil engineering, in delta Vistula geotechnical region, characterized by weak, highly compressible soils represented by mud and peat, lying in sub-surface layers, several meters thick. Usually below are dense sandy soils or gravel. In all cases, the base of ATLAS piles rested on sandy soils. The analysis of pile bearing capacity has been discussed and verified by static pile load tests (SPLT). The load-settlements characteristics obtained were satisfactory. In the paper, the results of geotechnical investigations as well as calculations and load tests are shown. The ecological aspects of ATLAS piles application within highly urban areas of the cities and complex geotechnical conditions are emphasized.

Jan 1, 2006

By Rivera Jose Antonio Ore

Top Submerged Lance (TSL) smelting technology is currently used in a wide range of applications in the non ferrous and waste product treatment industries. The use of TSL technology for tin concentrates smelting has been successfully applied at the Minsur Tin Smelter and Refinery at Pisco, Perú. The process is based on the air-cooled top entry submerged Sirosmelt lance, developed by Dr. John Floyd at the CSIRO division of Mineral and Process Engineering in the 1970?s. Advantages of the process include flexibility to operate the lance, main burner of the Sirosmelt furnace, with different levels of combustion stoichiometry which allows us to get from highly reducing to highly oxydising atmospheres in the smelting reactor according to the type of feed we are processing, ability to utilize cheap energy sources such as natural gas, low capital cost and an environmentally friendly operation. This presentation summarises the application of the Submerged Sirosmelt technology for smelting tin concentrates and a variety of tin containing materials like iron dross, copper dross, tin residues, low tin/antimony slags by applying recent metallurgical developments at the Minsur smelter. The impact of new feed conditions and level of impurities on reactor performance with features of process and operation control are described. As a result of these recent advances in tin smelting using TSL technology, the Minsur Tin Smelter and Refinery improved its overall tin recovery, substantially reduced tin inventories and became the second largest tin smelter in the world, currently producing more than 40,000 metric tones of refined tin per year.

Jan 1, 2006

By H. Boghosian

This paper presents the design and construction of a deep basement in a steeply sloping site in glacial till in Glasgow city centre. Existing foundations, adjacent structures and services, in tandem with asymmetric loading, presented particular challenges in the planning, execution and design of the project. The construction methods and temporary works, analysis by the Finite Element method and monitoring carried out are all described.

Jan 1, 2006

By J Field

Many aspects of water use in mining are driven by the technical requirements for water. There has been little consideration given to both the safety and the health requirements. Workers in the mining industry are exposed to water from a range of treated and untreated sources. The intended use of this water dictates the required quality of the water, sometimes with limited consideration for contact with miners. Particularly for underground workers, there is exposure while working in and walking through groundwater possibly contaminated by hazardous substances. Where controls are inadequate the outcomes of this exposure can result in disease, illness and injury û the costs of which can be significant. The situation could also arise where, due to the lack of human exposure, the controls are unwarranted and the financial cost unjustified from a health perspective but warranted from an equipment management standpoint. In addition to the health aspects, water can impact on a range of safety issues resulting from high pressure usage, dust suppression, fire fighting and other processes. The protocols and procedures in place need to consider the safety issues in addition to managing water usage. The current state of water management in mines from an occupational health and safety perspective has been ascertained from a survey targeting underground and surface coal and metalliferous mines. This survey considered the health and safety issues associated with water use, the types of surveillance, control protocols and the strategies that the mines have in place to manage the health and safety risks associated with water systems. The results assisted in the identification of potential occupational health and safety risks associated with water systems and the management processes that may be appropriate from a risk management perspective. Health and safety issues are often neglected but remain critical issues affecting the value of water to the mining industry.

Jan 1, 2006

By J. Marks

The measurement of greenhouse gas (GHG) emissions from primary aluminium production and inventory of these emissions of carbon dioxide and PF Cs have become an important issue for primary aluminium producers. Most global producers have either voluntary emission goals or emissions limits established through national regulatory requirements. International good practices for inventory of these emissions for national governments are established through the Intergovernmental Panel on Climate Change (IPCC). The current good practices, last updated in 2000, are being revised and are expected to be adopted by governments in the spring of 2006. There are a number of changes expected in the guidance that will impact how facilities account for their GHG emissions. This paper describes the changes to the guidance and the implications of these changes for aluminium producers.

Jan 1, 2006

By Luo Yang

It has been known that after initial pile driving, pile capacity gain over time (set-up) could constitute a significant portion of the total pile capacity. In the past, there has been very little guidance for incorporating pile set-up capacity in design. This may be due to large uncertainties involved in predicting the pile set-up. A comprehensive statistical database is developed to describe the increase of pile axial capacity with time, known as set-up, when piles are driven into sand. Based on the collected pile testing data, pile set-up is significant and continues to develop for a long time after pile installation. The statistical database shows that a lognormal distribution can be used to describe the probabilistic characteristics of the predicted set-up capacity using Skov and Denver?s equation. The main objective of this paper is to incorporate the set-up effect into a reliability-based Load and Resistance Factor Design (LRFD) of driven piles in sand. A First Order Reliability Method (FORM) is used to derive separate resistance factors that would account for different degrees of uncertainties associated with the measured short-term capacity and the predicted set-up capacity from the proposed semi-empirical equations. The incorporation of set-up effects in the LRFD helps improve the prediction of the total capacity of driven piles, resulting in more economical design. A practical design procedure within LRFD framework to incorporate the pile set-up effect is outlined at the end of the paper.

Jan 1, 2006

By J. Dufour

Although the recovery of nitric and hydrofluoric acids from stainless steel pickle liquors has been solved by several methods, such as solvent extraction, acid retardation, evaporation or pyrohydrolysis, metals (mainly iron, chromium and nickel) are usually obtained as a waste or by-product that has to be disposed. Alternatively, the treatment requires a high liquor flow to be economical, as is the case for pyrohydrolysis. A new process has been developed for metals recovery, that produces metal oxides with a low fluoride content. This new technique is based on a selective precipitation mechanism, which produces nickel hydroxide with a purity of 90%, separate from a mixture of iron and chromium oxides and hydroxides suitable for recycling. The reaction mechanism is based on the precipitation of fluoride compounds of iron and chromium, K2FeF5 and CrF3. For this purpose, free fluoride must be added as potassium fluoride. Also, solid fluoride compounds are hydrolysed, releasing free fluoride. A part of the fluoride is recycled to the selective precipitation operation and the remainder is fed to the acid recovery stage. Nickel does not react in this operation; it remains in solution giving a high separation yield.

Jan 1, 2006

By Daojin Cao

Aiming at many controversial reports on Raman spectral pattern of heptamolybdate ion in aqueous solution appearing in the literature and the absence of its standard pattern, the comparative investigations on Raman spectral pattern of saturated solution of ammonium heptamolybdate tetra hydrate were done. The results showed that the main vibrant frequencies of Raman spectral pattern of the saturated solution were in good agreement with those introduced in the literature, and that the intensity ratio (4.4) of the strongest peak to the second strongest peak recorded in Raman spectrum of the saturated solution had three obvious characteristics: it was greater than each of the results (ranging from 3.7 to 1.3) reported in the literature, much closer to that (4.7) of crystal and well conformed to the change rule of Raman spectra occurring in the process of the first-step polymerization of acidified molybdate solution. It was found that Raman spectrum of heptamolybdate ion in aqueous solution was determined by not only the main vibrant frequencies but also the intensity ratio, which is also the crucial result in this study. The comparative investigations indicate that the pattern of Raman spectrum of the saturated solution is the standard pattern of Raman spectrum of heptamolybdate ion in aqueous solution essentially. The affirmed standard pattern is reliable and can be used to the identification of heptamolybdate ion in aqueous solution, applied in the research of the equilibrium of acidified molybdate solution and the exploration of the best technologic condition for the production of high quality heptamolybdates.

Jan 1, 2006