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By Arthur Barnes, Mika Muinonen, M. J. Lavigne

"The carbothermic reduction of chromite ore to produce high carbon ferrochromium is among the most energy intensive metal extraction processes performed, due not only to the highly endothermic nature of the reduction reactions but also the very high operating temperatures required for the smelting operation to separate the chrome-containing alloy from the discard slag.KWG Resources and XPS have collaborated over the last 3 years in developing a patented (Winter) processing alternative to the traditional smelting operation in which all processing takes place in the solid state at temperatures many hundreds of degrees lower than those required for liquid processing. Amongst the attractions of the process are much lower capital costs, as well as reduced operating costs, particularly of energy.A techno-economic study on the new process identifies a reduction in overall energy consumption of 70% against conventional processing and approximately 40% lower than the current best practice. By utilising more natural gas than coal based energy sources, the KWG process is able to show an overall 50% reduction in greenhouse gas emissions compared with the most energy efficient current practice. The impact of the new process on future processing is therefore regarded as highly significant, with global energy reductions equivalent to the effect of completely eliminating energy demand from a country the size of Italy.The study concluded that the potential for this process to completely revolutionise the global ferrochrome industry should not be underestimated. Its impact reaches far beyond exploitation of a regional natural resource."

Jan 1, 2015

By Russell J. Denny

"A 25m deep cut-off wall is required for environmental remediation of a Former Chlor-Alkali Plant. Extensive trials were conducted to verify the effectiveness of the mixes proposed, with the requirements of the cut-off wall to include limiting criteria for hydraulic permeability, vapour permeability and strength, over a 100 year design life. A limited number of field CSM trial panels were installed on a nearby site with similar stratigraphy, and a variety of mixes and mixing methodologies were used, together with the extraction of deep wet grabbed samples from the panels, which were tested for strength, hydraulic permeability and gas permeability. Test results obtained from these trials revealed a trend which allowed the construction methodology to be decided. Further to this, the mix design needed to be resolved, together with sensitivity analysis on the variations in the mix which might occur during construction, as a result of normal unavoidable variations in construction technique. Laboratory sampling would be used at lesser expense, to resolve the final mix design and analyse the sensitivity of the possible mix variations. An initial series of laboratory mixed samples were prepared using soil samples and groundwater obtained from the site, and testing carried out. However the test results in this initial series of laboratory tests could not match the results which had been achieved in the field trials. Closer scrutiny and investigation and rounds of sampling and testing, then revealed laboratory techniques for mixing and sampling which provided a logical way to match the actual field test results. CSM Construction is due to commence soon and will provide more extensive results which can be compared back to the laboratory trials. This project provides a valuable opportunity to resolve methods of laboratory sampling so that they compare well with results from in-situ deep mixing.INTRODUCTIONThe former chlor-alkali plant at Botany, NSW, which operated from 1945 until 2002, used mercury cell technology and brine solution to manufacture chlorine, caustic soda, hydrochloric acid, sodium hypochlorite and ferric chloride. Mercury contamination is present in the permeable alluvial soil profile beneath the site. The mercury is present in the form of elemental and inorganic mercury, together with dissolved methyl mercury in the groundwater and soil profile beneath the site and also down-gradient of the site, to depths of up to 25m. Residual clay and sandstone bedrock at approximately 25m depth are relatively impermeable and limit the contamination plume. A cap and contain approach has been recommended by consultants Golder Associates, and this involved a subsurface containment wall, or cutoff wall, to restrict groundwater ingress and egress, and lateral subsurface vapour migration. The cut-off wall is situated on the perimeter of the site, with a total length of 430m and passing through alluvial Botany Sands, with a nominal key into the underlying residual clay or sand stone at 20 to 25m depth. An HDPE liner insert was proposed for the upper 7m of wall above the water table, to further limit gas permeability."

Jan 1, 2015

By David F. Gearhart, Khaled M. Mohamed

"Trusses are primarily used as passive roof supports in coal mines. They are constructed of three main parts: two grouted bolts installed at opposing forty-five degree angles into the roof so that they are anchored over the ribs and a cross member that ties the angled bolts together. There is also hardware used to assemble these components. The capacities of the angled bolts are typically 30 to 40 tons and the tensile capacity of the cross member is also 30 to 40 tons. Importantly, the direction of the immediate roof loading on the cross member is unlike the direction of the loading on the angled bolts. The load on the cross member is transverse to the longitudinal axis instead of along it, and therefore the cross member is loaded in the weakest direction.Previous tests conducted on truss systems applied loads such that the increasing tension in the two diagonal bolts increased the tension in the horizontal cross member, resulting in a stiff response. By contrast, if the load is applied directly to the cross member, which then transmits those forces to the diagonal bolts, it results in a much softer response.Based on this difference, laboratory tests to apply transverse loads and measure the vertical load capacity of three different types of cross members were conducted using the Mine Roof Simulator (MRS) located at the National Institute for Occupational Safety and Health (NIOSH) in Pittsburgh. The length of the samples was about 16 feet. Single-point load tests, with the load applied in the center of the specimen were conducted to verify the performance of the test arrangement and the finite element models. Double-point load tests, with a span of eight feet, were also conducted. This arrangement replicates the performance of the cross members with a distributed load. Both of these test arrangements were conducted on one-inch-diameter threaded steel bars and 0.7-inch-diameter cable and 0.6-inch-diameter cable cross members.For the single-point load configuration, the yield of the one-inch bar was nominally 22 kips of vertical load, achieved at 17 inches of deflection. For both sizes of the cable cross members, yield was not achieved even after 18 inches of deflection. Peak vertical loads were about 20 kips for the 0.7-inch cables and 15 kips for the 0.6- inch cables. For the double-point load configurations, the one-inch bar cross members yielded at 33 kips of vertical load and 10 inches of deflection. The 0.7-inch-diameter cable cross members broke strands at 30 kips of vertical load and 10 inches of closure, and the 0.6-inch-diameter cable cross members broke strands at 25 kips of vertical load and 10 inches of closure. Finite element models of each of the six different configurations were developed and show the variation of the vertical capacity of the cross members and the difference of the behavior of the bar versus the cables."

Jan 1, 2015

By D. Moronkeji, R. Maharidge, D. A. Curry, B. J. Davis, U. Prasad, J. Franquet

"Proper shale characterization is crucial in shale gas drilling, exploration, completion and production. Unlike porous sandstone and carbonate reservoirs, the challenge with shales comes from their micro- to nano-darcy permeability ranges and the anisotropy of their mechanical and hydraulic properties. Most porosity-dependent logs are not sensitive enough to capture the true behavior of shales. Consequently, mineralogy and other strength and stiffness-related properties must be determined to characterize magnitudes and variances in shale mechanical and flow properties. In addition, these properties must pass quality assurance/quality control (QA/QC) practices to give confidence in their use in subsequent log calibrations, during geomechanical modeling, or in fracture design models. This paper presents a technique to integrate shale properties that are measured by various methods, and a methodology to perform QA/QC on the data before application.Shale properties originate from various sources, including downhole and laboratory measurements. Physical samples for laboratory testing are usually limited to a few depths. Lab tests are often costly, and replicating in-situ conditions can be difficult or impossible. In addition, results frequently show wide scatter, reflecting inherent depth variability and lateral heterogeneity. Wireline logs provide nearcontinuous data, but rarely yield direct measurements of rock strength properties. Although geomechanical and fracture models use log data, calibrating it with reliable and previously verified lab-measured properties is important. This paper presents a process to perform QA/QC on lab-measured data using various crossplots.Ten mechanical, microstructural and physical properties are graphically displayed to visually characterize shale strength behavior in ambient and in-situ conditions, whether measured or modeled statically or dynamically. These properties are often sourced from different departments. The properties are integrated but are individually subject to the previously mentioned uncertainties. Pairs of property values are crossplotted and compared with correlations from the literature or previously established with qualified data from related formations. Conformance with these correlations gives confidence in the data, whereas outliers are flagged as questionable. Repeating the process with questionable data crossplotted against other parameters for the same depth highlights the property with the greatest uncertainty. The determination of its value is investigated to locate the source of the inconsistency and establish a more reliable value. Where this is not possible, the user has a rational basis for rejecting that property value."

Jan 1, 2015

By Michael Kynett, Francke Walberg, Richard Millet, Khaled Chowdhury, Mary Perlea

"Cutoff walls are the most common seepage improvement measure for levee flood control projects throughout California’s Central Valley. Cutoff walls are widely used because they can be implemented within an existing right of way in either heavily urbanized areas with limited access, or in high-value crop agricultural areas. The most commonly used seepage cutoff wall types are soil-bentonite (SB), soilcement- bentonite (SCB), and cement-bentonite (CB). Contract values for cutoff wall rehabilitation projects in the Central Valley range from several millions of dollars to hundreds of millions of dollars, and play a significant role in the reduction of flood risk in urban and rural areas. However, recentlycompleted construction of several levee improvement projects has shown limitations and inconsistencies among the commonly used technical specifications for construction of seepage cutoff walls. These limitations were evaluated by practicing engineers involved in different stages of cutoff wall design and construction. This paper describes the specification areas that typically generate design and construction issues. Recommended improvements to specifications are suggested to address these issues. The paper’s topics include: the applicability of the different types of cutoff wall materials and construction methods, quality control testing requirements, backfill gradation requirements, mixing procedures, and settlement criteria for backfill.INTRODUCTIONFlood control projects on the Sacramento and San Joaquin rivers in the Central Valley region of Northern California consist of a large system of reservoirs, bypasses, and levees. The thousands of miles of levees within the system were largely constructed and raised by local entities as need arose; this construction occurred prior to the development of modern design and construction techniques. The majority of these levees were initially constructed to protect land for agricultural development; however, a significant portion of these areas have become or will soon be urbanized. This urbanization has historically occurred in locations right up to the levee footprint. This expedient form of historical levee construction, when combined with adverse riverine geomorphology, urban development, and productive agricultural regions, has led to a levee systems with severe seepage performance issues in a real-estate-constrained setting."

Jan 1, 2015

By K. E. Waters, N. Brodusch, R. Gauvin, A. Jordens, Teng. C., H. Demers

Rare earth elements (REEs) become increasingly significant for renewable energy devices and high-technology electronic products because of their large-scale popularity and applications. In this project, a field-emission scanning electron microscope was used to characterize the composition and distribution of REEs-bearing minerals. X-ray elemental maps were acquired with a large area x-ray detector (60 and 80 mm2 collecting area) and annular detector (60 mm2 collecting area), which allow fast x-ray acquisition at high count rate. These elemental maps were transformed into phase maps, which are used to identify the composition of the mineral phases and the REEs distribution over a large area. The phase maps are an easy way to distinguish the phases with and without REEs and compare the efficiency of different REEs extraction processes. Different methods (manual and automatic) for producing phase map were studied by comparing the distribution of REEs obtained from the same area.

Jan 1, 2015

By Paikowsky, Samuel G.

"Due to the way drilled deep foundations are being constructed, their structural integrity and geotechnical capacity are highly variable. Drop weight systems are increasingly being used to dynamically test the capacity and integrity of drilled deep foundations. Conventional pile driving hammers are often either inadequate or not economical to test these foundations and drop weight systems have therefore been developed to allow for dynamic testing.The advantages of the tests include high mobility, short testing time, low cost relative to static load tests (allowing multiple tests at a single site), and integrity/construction quality evaluation concurrent with capacity determination. The dynamic testing method for drilled deep foundations encounter several difficulties including: the need for a pre-testing analysis for matching pile, soil and testing system, adequate mass and drop height to reflect the mobilized capacity without structural damage, test interpretations for irregularly shaped and/or non-uniform piles, need for reliable dynamic measurements depending on the impact and the distance between the impact and the measuring point, and limited knowledge about the accuracy of the predictions.The principles of the tests are presented using simplified models and demonstrated via a case history. Drop weight systems are reviewed. Dynamic measurement principles are explained and the construction and testing quality effects are outlined and demonstrated via numerical modeling and case histories. A comparison of dynamic and static tests is presented via a database, case histories and finally a short review of relevant codes is provided.1 IntroductionTraditional static axial load test is performed by a slow application of a force produced against independent reaction, imitating structural loading. It is the most reliable method to determine the pile’s performance as commonly required under typical service conditions. The major limitations of this testing are: (i) high cost associated with set-up, test duration, interpretation and construction delays, and (ii) inability to obtain information about the pile-soil interaction along the pile without additional testing means (e.g. tell tales, strain gauges, etc.). These limitations are acute when high capacity foundations are involved."

Jan 1, 2015

By M. Hooman, W. M. Marx, R. C. W. Webber-Youngman

This paper discusses a study that investigated different underground bulk air heat exchanger (>100 m3/s) design criteria. A literature review found that no single document exists covering all design criteria for different heat exchangers, and therefore the need was identified to generate a guideline with decision analyser steps to arrive at a technical specification. The study investigated the factors influencing heat exchanger designs (spray chambers, towers, and indirect-contact heat exchangers) and the technical requirements for each. The decision analysers can be used to generate optimized, user-friendly fit-for-purpose designs for bulk air heat exchangers (air cooler and heat rejection). The study was tested against a constructed air cooler and heat rejection unit at a copper mine1. It was concluded that the decision analysers were used successfully. This tool (decision analysers) can be used by engineers for the efficient and cost-effectively design of heat exchangers.

Jan 1, 2015

By H. M. Kim, J. Rutqvist, D. W. Ryu

"Demand of high pressurized gas storage in underground rock caverns is increasing. Compressed natural gas (CNG) and compressed air energy storage (CAES) are one of the promising examples after since lined rock cavern (LRC) concept has been verified through in-situ pilot tests. Two key essential concerns of high pressured gas storage in underground rock caverns are mechanical stability of the cavern against high inner storage pressure and the risk of gas leakage from the caverns.In this study, we introduce our results of numerical simulations so as to investigate the potential of monitoring for gas leakage at a pilot facility for CAES in underground LRCs. The pilot facility was constructed at a comparatively shallow depth of 100 m, compared to the previous cases with several hundreds of meters, aiming at validating the feasibility of the LRC storage concept in which inner sealing liners, consisting of steel plate and concrete linings, are installed inside the excavated rock caverns (KIGAM, 2011). Compressed air may leak through either initial defects of inner containment liners such as imperfect welding regions and in-situ construction joints of the liners, or through structurally damaged points of the liners during the CAES operation where compression and decompression of the caverns are necessarily repeated and their structural robustness can be deteriorated.For this perspective, we carried out a coupled thermodynamic and geomechanical deformation analysis using TOUGH-FLAC simulator, and investigated the effectiveness of strain monitoring method in detecting mechanical failure of liners which may provide major pathways of air leakage. We therefore used an equivalent continuum model to relate the localized tangential strain to fracture permeability changes, which was developed in our early work (Rutqvist et al, 2012). In detecting and characterizing the leakage location, we tested a cross correlation technique using the synthetic pressure responses monitored in case of the failure of the inner liners. From the investigations, we showed that tangential strain, rather than radial, monitoring especially at the inner face of the sealing liners can be more effective in detecting the mechanical failure of the liners.In localizing the leakage point, we noted that the interface between the inner liners and surrounding rock may not be perfectly bonded so as to increase permeability through which any leaking air pressure may migrate more dominantly. We also demonstrated that the cross correlation of the time histories of pressure measurement especially at these interfaces can be useful in identifying the leakage point. These results may provide useful information in overall design of monitoring and alarming system of our upcoming CAES pilot facilities."

Jan 1, 2015

By Habib Zughbi, Paul Zulli

"A key step towards sustainability in iron and steelmaking is to optimise the use of raw materials and energy consumption, and consequently minimise CO2 emissions. Models based on a Process Integration (PI) approach play a key role in evaluating various scenarios and the impact of introducing changes in raw materials and operational conditions on the overall energy consumption and CO2 emissions. BlueScope uses a PI based comprehensive model for its Port Kembla Steelworks (PKSW), called the Integrated Steelworks Energy and Emissions Model (ISEEM). ISEEM is tightly coupled to the configuration of PKSW. It is based on mass and energy balances as well as thermodynamic relationships. ISEEM is a steady-state model and is used to predict overall and detailed unit-by-unit energy consumptions and CO2 emissions. It is also used for plant-based scenario modelling. This paper investigates the impact of major changes to PKSW configuration, including the shutting down of a blast furnace and cokemaking battery, on the energy consumption and CO2 emissions of the plant. It discusses some of the issues involved in updating the model and some identified opportunities."

Jan 1, 2015

By D. Botha, J. F. Cronjé

"SynopsisAlthough women all over the world have been involved in mining activities for centuries, mining has always been considered a very masculine industry due to its heavily male-dominated workforce as well as the physicality of mining work. The mining industry has not been an obvious career choice and preferred place of employment for women; women were mainly employed in administrative and advisory positions. Until 1994, women were legislatively prohibited from being employed in underground operations in South Africa, but the Mines Health and Safety Act, No. 29 of 1996, removed these restrictions. In addition, new mining legislation (the Mineral and Petroleum Resources Development Act, No. 28 of 2002) and the accompanying Mining Charter make specific provisions for the inclusion of women in core mining activities and require 10% of core positions to be filled by women.This article voices perceptions of the physical ability of women employed in core mining positions. Findings are drawn from empirical work undertaken at platinum, phosphate, and copper mines. Quantitative and qualitative research paradigms are used. It is evident that women find it extremely difficult to perform mine work that requires physical strength and stamina. Practical recommendations, informed by the literature review and empirical findings, are made with the objective of contributing to the sustainable deployment of women in the mining industry.IntroductionFor many years, mining has been considered the foundation of the South African economy. Although the mining industry in South Africa is currently under considerable pressure and experiences various challenges, including escalating operational costs, electricity tariff increases, safety-related issues and associated production stoppages, poor productivity, labour unrest, and reduced demand both globally and domestically, it remains a key contributor to the national economy and development of the country (IDC, 2013, p. 9).Until 1994, women were legislatively prohibited from meaningful participation in the mining industry and were denied access to skills and jobs, self-employment, and entrepreneurship. The newly elected democratic government in 1994 initiated substantial socio-political and economic transformation in South Africa. Nearly every sector in the country was transformed and re-shaped, primarily through sector-specific legislation, but also through negotiations between government, industry, and labour unions to create and refine the so-called sector charters, which included the Mining Charter. The vision of the new regime, the African National Congress (ANC), was to ‘transfer power to the people and transform society into a non-racial, non-sexist, united, democratic one, and change the manner in which wealth is shared, in order to benefit all the people’ (ANC, 2007)."

Jan 1, 2015

By Arthur Miller, Andrew Weakley, Heather E. Lawson

"IntroductionDynamic failure events in an underground coal mine, or “bumps,” are defined as “the sudden, violent bursts of coal from a pillar or pillars or a block of coal, resulting in a section, the whole pillars, or the solid block of coal being thrown into an open entry” (Peng, 2008). Reports of disastrous and often fatal dynamic failure events date back over one hundred years in the United States. Mining practices and technologies have significantly evolved over the course of the last century, yet these events continue to occur. The events at Crandall Canyon, Utah (Gates et al., 2007) and Brody No. 1 Mine in West Virginia (Barker and McNeely, 2014) are two recent failure events that resulted in a total of eleven fatalities. These events testify to the fact that dynamic failure remains an imperative safety concern. Furthermore, their continued occurrences indicate that engineering controls have proven inadequate at wholly mitigating the problem.Multiple conditions have been associated with the occurrence of dynamic failure phenomena, including• thick, competent strata that can create a bridging effect, resulting in high abutment stresses (Rice, 1935; Holland and Thomas, 1954; Iannacchione and Zelanko, 1995; Agapito and Goodrich, 2000; Peng, 2008; Whyatt, 2008; Whyatt and Varley, 2010)• overburden thicknesses greater than 500–700 ft. (Rice, 1935; Peng, 2008)• a strong coal that is resistant to crushing (Rice, 1935; Peng,2008) or that is “uncleated or poorly cleated, strong…sustains high stress and tends to fail suddenly” (Agapito and Goodrich, 2000)• the presence of sandstone channels or rolls that can serve to concentrate stresses (Iannachione and Zelanko, 1995; Agapito and Goodrich, 2000)• fracturing of strong units above or below the coal seam (Whyatt and Varley, 2010)• slip along pre-existing discontinuities (Peperakis, 1958; Whyatt and Varley, 2010)• multiple seam mining interactions (Campoli, Kertis, and Goode, 1987; Iannachione and Zelanko, 1995; Newman, 2002; Peng, 2008)• mining sequences that can cause anomalously high stress concentrations (Campoli, Kertis, and Goode, 1987; Iannachione and Zelanko, 1995)"

Jan 1, 2015

By J. Lee, K. B. Min, J. Rutqvist

Shear slip of fractures in fractured rock masses is a critical issue for many geological engineering applications, such as the design of underground nuclear waste repositories, enhanced geothermal systems (EGS), and geosequestration of CO2. This paper presents new development of the TOUGH-UDEC simulator for analysis of coupled thermal-hydraulic-mechanical (THM) processes in fractured porous media. As an alternative to developing a single coupled THM code in discontinuum, two existing wellestablished codes, namely TOUGH2 and UDEC, are coupled to cover coupled THM analysis of multiphase fluid flow, heat transfer, and deformation in fractured porous media. TOUGH2 is widely used for modeling heat transfer and multiphase, multicomponent fluid flow, and UDEC is a well-known discrete element code for rock mechanics, which have been verified and used by many groups all over the world. Although a sequential coupling of two codes is less efficient than having a single code in principal, a big advantage with coupling of TOUGH2 and UDEC is that both codes are well tested and widely applied in their respective fields. When linking two codes, the coupled equations cannot be solved simultaneously; they should be solved sequentially, with coupling parameters passed to each equation at specific intervals. After solving thermal-hydraulic equations through the TOUGH2 model, pressure (P) and temperature (T) information is delivered to UDEC model. Pressure information is directly stored at the center of each UDEC zone and domain, however, temperature information is interpolated from zone-centers to the corners nodes. After solving the mechanical equation through the UDEC model—considering new pressure and temperature—calculated fracture apertures are converted to equivalent permeability and porosity for TOUGH2 flow analysis. The solution was calculated by iteratively following an explicit sequence for numerical efficiency. Verification examples are presented to demonstrate the capabilities of the coupled TOUGH-UDEC simulator.

Jan 1, 2015

By C. Schmidt, M. Kohnk, C. Siemers, J. Kiese

The application of conventional titanium alloys is limited to 550°C due to their poor oxidation resistance. In addition, severe grain growth is observed in single-phase titanium alloys in long-term runs at elevated temperature leading to a degradation of their mechanical properties. In exhaust applications in automotive or aerospace engineering, products are often manufactured by cold-deformation like deep-drawing or rolling which is normally difficult in oxidation-resistant titanium alloys due to the presence of titanium-silicides. Therefore, in the current study, titanium alloys based on CP Titanium Grade 1S (soft grade) were developed showing (1) improved oxidation resistance due to a concerted addition of silicon, iron and niobium, (2) microstructure stability by the precipitation of hafnium-silicides mainly on the grain boundaries and (3) good cold-deformation properties. The industrial production route was developed so that the new class of Ti-Si-Fe-Nb-Hf-alloys is now ready for application in exhaust systems of planes or cars at minimum 800°C.

Jan 1, 2015

By R. Duinker

"This paper, an update to the 2003 paper titled "Knowledge, Technology and Profit" (Twigge-Molecey, 2003) analyzes 45 "problem projects" from the mining and metals industry over the last eleven years representing $133 billion in CAPEX. The projects have been designated as "problem projects" as they did not meet their owner’s initial expectations for project performance as defined in the paper. This paper explores some of the challenges that were present, through interviews with the knowledgeable individuals that were familiar with the projects and investigations using publically available information. The aim of the exercise was to identify the key challenges faced by the projects, and the contributing factors that led to the project failures so that the lessons can be applied to future projects.The project challenges have been categorized into four themes, technical, organizational, environmental & social and missing "homework" prior to board approval. Of noteworthy interest is that environmental permitting aspects have risen to become a significant and notable contributor to problem projects in 11 years from 2003 to 2014. It is further observed that many projects have been challenged by increasing size and complexity and with execution in more remote locations since the previous paper.It is a reality that every project will face challenges. Some projects are simply more challenging than others, and success or failure of the project is often determined by whether the project team is fully prepared to respond to the challenges. This in turn is largely dependent on whether the project "homework" was adequately completed and considered for all aspects of the project."

Jan 1, 2015

By J. Pancher

"Stainless steel castings are used in abundance in the mineral processing industry. In rotary kiln-based processes, these castings are typically exposed to high loads, corrosive elements, mechanical abrasion and cyclical temperature exposure. In the processing of iron ore pellets, it is typical to use a traveling grate preheater or a straight grate furnace to heat the pellets. Both machines have a conveyor that is mainly comprised of high temperature stainless steel castings. It is these castings which are the focus of this study. The expected life of these castings can be quite short, their cost quite high and the effort to replace them very labor intensive. The goal of this study was to gain a better understanding of the failure modes of these castings. With that basic understanding, modifications to the alloy content could be made to achieve a new operational paradigm. That paradigm could be a cheaper casting, a longer lasting casting or a casting tailored to special operating conditions (for example, highly corrosive gases or sudden temperature shocks). Over the past 4 years, Metso Minerals has sought to achieve a better understanding of the failure modes through modeling, laboratory testing and sampling of used castings from various end-users. In addition, we have tested new alloys in a laboratory setting and also in the field to see how they would perform compared to the existing ""standard casting"". Our testing has revealed interesting data concerning the impact toughness, sigma phase content and formation, chloride attack and other performance attributes of various grades of stainless steel when exposed to cyclical temperatures. Interesting results were also obtained concerning the addition of rare earth elements (Niobium, Boron, etc), nitrogen and manganese to a typical ASTM A297 grade of stainless steel. To date, a few hundred test castings have been installed in iron ore pellet plants worldwide. Many of these test castings have already experienced a year or more of operation with good results.INTRODUCTION Cast stainless steels (ASTM A297 and similar) are a main constituent used in the construction of iron ore pelletizing equipment. A typical straight grate pelletizing machine would contain upwards of 160,000lbs of ASTM A297 Grade HH castings. With a typical casting lasting only two to four years, and a casting costing around $35USD, it is easy to see that the castings are a main contributor to the overall cost of producing the pellets. Grade HH and HI (see chemical composition listed below) became the “go to” materials in the 1960’s and very few changes have been made to this day (the exception being plants that switched to flux pellet production in the 1980’s)."

Jan 1, 2015

By P. Scinto, A. Festa

"Orway Mineral Consultants Ltd (OMC) as a consultancy has specialized in comminution circuit design for over 30 years. The OMC Power Model is OMC’s in-house software for specific grinding energy power-based circuit calculations. The model uses ore hardness parameters from testwork, circuit configuration, equipment geometry and operating conditions as inputs. The model combines proprietary and published power models to predict the total specific energy and the specific energy for each of the components of the comminution circuit. This makes the software a valuable tool for the design and validation of JKSimMet modelling or actual plant performance. Proprietary calculations have been developed and reconciled with over 100 plant benchmark projects encompassing a variety of comminution circuit configurations.This paper describes the OMC approach for determining power requirements for the design of grinding circuits. The accuracy of the OMC Power Model software is confirmed through plant survey benchmark performance and comparisons are made with other power modelling techniques. Practical examples are presented, showing applications for single stage SAG (SS-SAG), SAB and SABC circuit configurations.IntroductionConventional low throughput grinding options, consisting of multi-stage crushing followed by rod and ball mills, have almost become obsolete in the move to higher milling rates required to process lower metal grades. Grinding circuits with fully autogenous (AG) or semi-autogenous (SAG) mills, often combined with ball mills are now the standard to meet the high capacity requirement for processing ores with lower metal grades. Simulation software and power-based equation methodologies have been established for designing AG/SAG based grinding circuits and predicting their energy requirements.Presently, power-based equations remain the principal method for designers to size mills and estimate the power requirement for comminution circuits. The technique is simple and it relies on the design to specify a feed and product size plus a hardness index to produce a specific energy value (kWh/t). The desired throughput of the mill is multiplied by the specific energy to give the mill power requirement, which is used in turn to size a mill for dimensions, internal geometry and loading conditions to match the power draw."

Jan 1, 2015

By Wei Yin, Yu Wu, Xiexing Miao

"For engineering problems of “three under” coal (coal trapped under buildings, waters-bodies and railways) exploitation, environment protection and gangue separation from raw coal underground exist in Tangshan Coal Colliery. By analyzing concrete technical problems, a technical approach of closed cycle “coal mining-gangue washing-backfilling-coal mining”, i.e. integration of coal mining, gangue separation and solid backfilling, is put forward with key technologies including gangue transportation with great depth, gangue separation from raw coal underground and integration of coal mining and backfilling. Based on the specific geological conditions of Tangshan Coal Colliery, 591m vertical feeding transportation system with great depth is designed; meanwhile, for efficient gangue transportation, ancillary wear-resisting pipe size and buffer equipment are optimized. Underground gangue separation system is created to be joined with the existing production system and backfilling system; besides, as per separation characteristics of coal and gangue, buddle jig is adopted for gangue roughing of raw coal underground. By cooperation of backfilling hydraulic support and other key equipment, the designed stope backfilling system completely realizes integration of coal mining and backfilling. Engineering practice shows that, through the research and implementation of the above key technologies, integration of coal exploitation, gangue separation and solid backfilling is successfully implemented in Tangshan Coal Colliery; moreover, it completely solves the three major engineering problems and realizes waste disposal, underground washing and separation, and ground surface subsidence control.INTRODUCTIONSo far, “three under” coal (coal trapped under buildings, watersbodies and railways) and key state-owned coal resources trapped under villages in China have reached 13.7 billion t and 5.22 billion t, respectively. With the development of coal enterprises, China currently has more than 1,600 gangue dumps (Miao et al., 2010a) with accumulated stack amount of 4.5 billion t, occupying a land area of 150,000 km2; moreover, surface subsidence caused by mining activities has damaged the environments of industry, agriculture, transportation and living, while new environmental pollution sources formed by coal related industries also result in damage to ecological environment (Huang et al., 2011a). On the one hand, due to large scale coal mining, some coal collieries suffering from resource exhaustion are faced with survival problems; on the other hand, coal mining has caused and been faced with increasingly prominent environmental problems, such as “three under” coal exploitation, waste disposal and ground surface subsidence control (Miao et al., 2010b; Zhang et al., 2009)."

Jan 1, 2015

By J. -M. Bosgiraud, G. Armand, S. Dewonck, L. Richard-Panot

"The Meuse/Haute-Marne Underground Research Laboratory (URL) is located on the eastern boundary of the Paris Basin. The URL started to be built in 2000 (shaft sinking operations) in the framework of ANDRA’s (French national radioactive waste management agency) research program aimed at determining the feasibility of a reversible deep geological disposal of high-level and intermediate-level long-lived radioactive waste (HLW, IL-LLW). Its underground drifts are used to study the Callovo- Oxfordian claystone layer between 420 m and 550 m in depth.The ongoing research program (started in 2006) following the “Technology Readiness Level” (TRL) Scale is more dedicated to technologies improvement and demonstration issue of the different disposal components, even if characterization and monitoring studies are still ongoing.In rock mechanics, at the main level of the URL (located at 490 m), construction and evolution of disposal cells of different size are studied for HLW and IL-LLW packages. A step by step approach, started in 2006, is carried out based on comparison of HM behavior of parallel drifts excavated/supported by different construction methods. These various configurations give insight of the influence of construction method on the EDZ extent and evolution and on the progressive loading of the support, which are key issues to design the Cigéo disposal drifts and excavations.The concept of disposal cells studied for HLW consists in horizontal steel lined micro-tunnels 80 m long and 70 cm in diameter. Several campaigns of tests have been carried out since 2009 in order to demonstrate the feasibility of excavating such micro-tunnels and study their behavior under different conditions (with and without back filling the annular gap between the rock and the casing, watertight or not casing). A full scale demonstrator representative of the benchmark concept has also been excavated, to study its behaviour under thermal loading with heat produced by electrical heaters."

Jan 1, 2015

By S. Bastola, Y. P. Chugh

"This research determines shear strength and stiffness properties of bedding planes and joints in the roof strata rocks within 7.5 to 9 m (25-30 ft.) overlying the Illinois #6 coal seam (within the pressure arch zone). A shear test loading device was designed into a 1.334 kN (150 t) Forney Compression Loading Machine to perform direct shear tests in accordance with ASTM D5607-08 “Standard Test Method for Performing Laboratory Direct Shear Strength Tests of Rock Specimens under Constant Normal Force”. The data were used to determine peak and residual friction angles and the dilation angle. A total of 49 bedding plane samples were tested, out of which 46 (36 intact and 10 relatively weak and loose) samples passed QA/QC procedures in accordance to ASTM D5607. Samples from eight (8) different bedding planes- shale/limestone (SL), shale/sandstone (SSs), shale/bone (SB), laminated sandstone (LS), shale/shale (SS), bone/bone (BB), bone/limestone (BL), and limestone/limestone (LL) were tested. The number of samples tested for each bedding plane were: SL- 11, SSs- 8, SB- 5, BB- 4, LS- 6, SS- 9, BL- 1, and LL- 2. Peak and residual shear strength values at 2.75 MPa normal stress range 1.06 – 6.26 MPa and 0.82 MPa to 0.82 – 4.14 MPa, respectively. The average normal and shear stiffness values are about 11.98 GPa/m and 3.11 GPa/m. Dilation angles are low (<10?) and negative in some cases. Angle of sliding friction values range from 9? to 42?. Joint Roughness Coefficient (JRC) values were less than 10.INTRODUCTIONRock mass may be defined as the total in situ rock medium containing bedding planes, faults, joints, folds and other structural features. Therefore, it is discontinuous and may have heterogeneous and anisotropic engineering properties. Upon creation of an excavation in a rock mass, bedding planes and joints are the most likely points of failure initiation. The failure typically occurs either in tensile or shear mode. Upon failure initiation stresses are transferred to the neighboring rock mass and the failure progresses until stability is achieved through equilibrium of stresses and strength. An example of this mechanism is development of the pressure arch. This study determined the shear strength and stiffness properties in shear and compression of bedding planes and joints in the immediate roof strata rocks within 7.5-9 m ( 25-30 ft.) overlying the Illinois No. 6 coal seam (within the pressure arch zone). Since such data are currently not available for Illinois Coal Basin mines, researchers and engineers have been using estimated values for design purposes. The immediate roof lithology in the proposed mining area consists of shale 0.62 m; Bone 0.09 m (0.3 ft.); Limestone, 0.10 m (0.33 ft.); Shale 2.37 m (7.9 ft.); and sandstone 0.55 m (1.83 ft.). The bedding plane samples were provided by a mine in south-eastern Illinois operating at a depth of about 180 m (600 ft.)."

Jan 1, 2015