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By G. R. Waters

"The technology behind industrial applications such as Hydrometallurgy continues to evolve, as do the corresponding regulations and specifications that ensure the safety of workers and the environment. Valves make up key aspects of this technology, and often represent the single point of failure for entire operations. More often than not, the valves being used in Hydrometallurgy applications are known as Severe Service Valves (SSVs) due to their ability to withstand the extreme conditions. Most experts agree that SSVs are identified by applications, and that these applications are challenging to the valve’s ability to provide a minimum acceptable level of performance over a minimum acceptable duration. The Manufacturers Standardization Society (MSS) of the Valve and Fittings Industry has designated Ross Waters, President of CGIS, as Lead to the Task Force put in place to determine the minimum requirements a valve needs to be able to perform to when faced with extreme conditions, whether from pressure, temperature, toxicity, solids, or usage. This paper serves to determine what the minimum requirements are for SSVs in Hydrometallurgy applications. It will draw on five decades of industry experience from one of Canada’s leading valve experts.INTRODUCTION Severe Service Valves Severe Service Valves (SSVs) mean different things to different people. Until today, defining SSVs had little if any global agreement or recognition. That is about to change as the Manufacturers Standardization Society (MSS) has accepted an application to produce a Standard Practice so defining them. This paper provides information about the selection of SSVs in all industries but focusses on metallurgical processes and applications and offers examples to illustrate the successful and unsuccessful use of these valves. All of this with the purpose of raising the awareness of the industry on all sides, from the suppliers and manufacturers, specifiers and to the users and owners of them. It also supplies tools to understand where and why to separate SSVs from general purpose or commodity valves (GPVs). SSVs are often identified by applications, and these applications are challenging to the valve’s ability to survive. Within these applications the elements that make the service severe are being analyzed, quantified and qualified. From this, we expect to offer objective and repeatable definitions and guidance to improve the experience of SSVs, reduce unnecessary costs, provide longer service life and process runs, improve safety and reduce environmental issues."

Jan 1, 2017

By Yuanping Cheng, Jingyu Jiang, Qiang Zhang

"With the increase of mining depths, deep-seated coal seams face threats from high ground stresses, high gas pressures, high gas content, and low seam permeability, which significantly increase the likelihood of coal and gas outbursts. Challenges continue to grow in coalbed methane (CBM) extraction fields, especially for short-distance gassy multiple-seams. Research has proved that the most effective way to increase coal seam permeability is to decrease the ground stress. Protective seam mining technology is a surrounding rock control technology, which can effectively reduce the ground stress and increase the permeability of the protected coal seam. In this paper, we try to use upper protective seam mining technology to simultaneously extract coal and gas. Findings are based on a FLAC3D simulation of stress variation during the mining of the No. 12 coal seam in the Daxing coal mine, Tiefa Coalfield, China. Results indicate that, after mining the upper protective seam, the pressure-relief effects of the rock mass generated three belts and five zones below the protective seam, providing the space and time for gas pre-extraction engineering. Within the protected area, the numerical simulation indicates that the stress of the No. 13/14 coal seam reduces 95.84% and 88.25% respectively, while the expansion deformation of the protective seams reach 6.87 ‰ and 6.70 ‰ respectively, which demonstrate that the protective mining technology can provide a significant pressure-relief effect to the outburst-prone coal seam. Combining stress relief in this manner with pressure-relief from engineered gas drainage (performed by crossing boreholes from the floor rock roadway) applied before the mining of the protective seam, it would not only be beneficial to CBM drainage but also can reduce the gas outburst risk of the protected seams.INTRODUCTION Internationally, since France used protective seam mining technology to control coal and gas outburst in 1939, it has been promoted and applied in many countries (?????, 1966). Since 1958, China has taken the mining test and engineering practice of protective seam mining technology in the Beipiao, Tianfu, Nantong, Zhongliangshan, Songzao, Huainan, Huaibei, and other coalfields (Yu, 1992). Long-term theoretical research and mining practice of outbursts and dangerous coal seams show that protective seam mining technology is the most effective, safest, and most economical outburst prevention measure (Cheng, Fu, and Yu, 2009; Hu et al., 2008; Cheng and Yu, 2007). Under the condition of high gas content coal seams, the safety and efficiency of simultaneous extraction of coal and gas can be realized through a reasonable mining sequence and an effective gas extraction method (Cheng and Yu, 2003). The in situ stress distribution of the protective seam (No. 1 coal seam) and protected seam (No. 2 coal seam) during protective seam mining in the Haishiwan coalfield formation (Figure 1) (Li et al., 2014). A comparison of the stress and displacement (five zones and three belts) of the rock mass below the protective seam, and in a multiple-seam context in the Dalong Mine, is shown in Figure 2 (Jiang et al., 2015). After mining protection coal in a close-distance seam group, the small spacing between the coal seams causes the protective coal and the protected coal between part of the rock to crack through each other until the protective layer of gob is through the area. This provides a desorption of gas to the protective layer of the mining space channel, making the coal seam permeability increase to several hundred times and improving the gas discharge capacity (Zhai, 2008)."

Jan 1, 2017

By Olanrewaju A. Ojo, Xu Wang, Jian Xin Dong, Lina Zhang, Jerzy A. Szpunar

"The influence of crystallographic orientation on the pitting corrosion behavior of Ni-Fe-Cr alloy 028 was studied by a combination of X-ray diffraction (XRD), electron backscatter diffraction (EBSD), potentiodynamic polarization technique and atomic force microscopy (AFM). The results show that there is anisotropy of pitting corrosion that strongly depends on crystallographic orientation of surface planes. The distribution of pits frequency in standard stereographic triangle shows that the crystallographic planes close to {100} are more prone to pitting corrosion compared to planes of {110} and {111}. The calculation of surface energy (001) and (111) shows that the planes of high packing density of atoms have low surface energy with concomitant strong resistance to pitting corrosion. A correlation function between crystallographic orientation and pitting corrosion susceptibility suggests a method not only to predict the pitting resistance of a known textured materials, but also to improve corrosion resistance by controlling materials texture.INTRODUCTIONNickel-iron-chromium(Ni-Fe-Cr) alloys are widely used in various industries and engineering sectors due to their combination of good mechanical properties and high corrosion resistance(Hibner, 2001; Thomas, 2006; Ghosh, 2005).Ni-Fe-Cr alloy 028 (alloy 028)has such important characteristics worth mentioning. Alloy 028 contains high amounts of nickel, copper and molybdenum which improve its resistant to corrosion attack in reducing medium, and presence of high level of chromium makes it more resistant to oxidizing species. Moreover, alloy 028 is less expensive because of higher amount of iron compared to other similar alloys. Currently, alloy 028 is manufactured as evaporator tubes applied in the phosphoric acid production; production tubing and casing used in deep and sour gas wells; heat exchangers employed in nuclear power plants, and seawater-carrying piping and seawater-cooled heat exchangers (Bankiewicz, 2012; Kivisäkk, 2003; Gómez, 2003; Xian, 2012; Bellezze, 2004)"

Jan 1, 2017

By L. C. So, S. Faucher, S. Mostaghel, A. Triwahyuono, D. Sauter, S. -Y. Oh, S. K. Lee, K. Aswin

"Molten hauling and water granulation are the commonly used slag treatment methods in the production of nickel. Water is present in these processes either to accelerate cooling of the dumped slag or in the granulation itself which creates an inherent safety risk of explosions. Even good design and operation are not sufficient to prevent explosions or injuries from occurring. Several dry methods to treat slags have been intensely studied. However, most of these technologies have never been commercialized due to numerous challenges including scalability, cost, low heat recovery efficiencies, and difficulties in heat utilization. Ecomaister-Hatch has recently developed and commercialized a reliable and simple Dry Atomization process, which eliminates water and allows for heat recovery. As part of the development towards other sectors, laboratory-scale and pilot-scale trials have been completed in a number of base metals and PGM facilities. Recently, Dry Atomization of a nickel laterite slag was successfully demonstrated at the laboratory-scale. The current paper introduces the technology and reports the test results obtained from atomization of the nickel slag.INTRODUCTION The processing of nickel laterites produces vast amounts of slag with over 90% of the feed to the furnace reporting as slag. Slag handing is therefore of critical importance to a laterite smelter. Traditionally there are two ways in which the slag is handled (1) Molten hauling, dumping, cooling and quarrying (2) Water granulation, dewatering, stockpiling. There are inherent disadvantages of both methods that will be outlined in this paper. An alternate route of Dry Atomization provides distinct advantages over the two conventional routes that are of particular interest to the nickel producer such as elimination of molten hauling, dumping and quarrying, elimination of water and improved safety. There is also the potential to convert the slag, which is typically regarded as a waste product, into a value added product and the continuous nature of slag tapping makes it amenable to heat recovery. Hatch has recently conducted laboratory-scale test work on laterite slag to demonstrate its viability for Dry Atomization. Results of this work are presented."

Jan 1, 2017

By María Rocha, Benjamín Cebrián, Roberto Laredo

"Ring blasting designs have to achieve different goals in order to become efficient whether is done in up hole or downhole fashion. Ore recovery/dilution control, fragmentation and drift integrity all have to be taken into account when selecting parameters such as burden, spacing, linear explosive density and stemming. Blast energy simulation allows identifying contours of rock breakage and fragmentation, thuschoosing a combination of spacing at the end of holes and appropriate burden. Also, simulations are keyto concentrate energy levels on the mid part of the ring while making sure there is not too high of energy concentration around the drift, which integrity is needed for a safe ore mucking."

Jan 1, 2017

By G. Granata, C. Tokoro, T. Kato

"The goal of this study was to evaluate the effectiveness of mechanochemical activation by planetary milling as method to enhance the recovery of cerium from rare earth ores. For this purpose, a weathered ore was first ground by planetary milling and then leached by sulfuric acid. The influence of planetary milling was investigated by assisting the experiments with X-ray absorption fine structure (XAFS) in cerium LIII-edge and inductively coupled plasma spectrometry to measure the concentration of cerium dissolved by leaching. Results showed that, by increasing the grinding time, although the particle size of the specimen increased due to agglomeration, the recovery of cerium significantly increased. This finding clearly indicated that a smaller particle size actually hinders the recovery of cerium. In particular, XAFS analysis revealed that the longer the grinding time, the more tetravalent cerium could be converted into trivalent cerium and such conversion, also called mechanochemical reaction was beneficial to the recovery of cerium. Based on the obtained results, it was confirmed that approximately 70% of cerium could be recovered by mechanochemically activated leaching of rare earth ores.INTRODUCTION Rare earth elements (REEs) are a group of 17 chemically similar metallic elements comprising lanthanides, scandium and yttrium. Since REEs have various unique physical and/or chemical properties, they have become essential materials for advanced application (Adachi, 2015). REEs used in industry are usually supplied as rare earth minerals. In the last decades, flotation, gravity separation, magnetic separation and leaching have been widely applied to recovery of REEs from rare earth minerals like monazite (Archana, Rekha, Manis, Jitendra, & Jin, 2015). Among these operations, leaching has been widely studied in the recent years to improve the state of the art (Archana, Rekha, Manis, Jitendra, & Jin, 2015; Xiao, Feng, Huang, Huang, Chen, Liu, Wang, & Long, 2016; Farzaneh, Fereshteh, & Ahmad, 2017). Aiming to enhance recovery of REEs from rare earth minerals, a possible advancement of leaching technology could be the mechanochemically activation of the ore by high-intensity milling (Alorro, 2016). In the mechanochemical activation, an improvement of the leaching performances can be achieved through high-intensity milling operations which result into a dramatic decrease of the mineral particle size with a consequent improvement of the physical kinetics of leaching. Furthermore, the high mechanical energy provided to the sample during milling can determine the rupture of the crystal structure of the mineral, thereby transforming it into a more leachable form."

Jan 1, 2017

By T. W. Camm

"We hear all the time about the value of hard work and perseverance, and the part they play in the professional life of successful people. What we do not hear so much about are the many professionals who work hard and persevere, yet never seem to quite reach the level of success they aim for. Some current authors are beginning to give more attention to the part luck/black swans/outliers play in success. This is not a new phenomenon, Machiavelli had a lot to say about it back in the Renaissance. So how can knowledge of this dynamic help in a modern organization? INTRODUCTION Work hard and you will succeed. Go to the right school, major in the right degree, study hard, and get a good job. Look at the lives of successful people, and do what they do. Be all that you can be. You can be anything you want to be. Really? Those who are successful always get attention, people want to know what they did to reach such a high position. Invariably, at least part of their narrative will include hard work, wise insight, taking advantage of opportunities, etc. If they are of a more generous nature, they might also allow that building the right friendships and collaborations also played a role. All of this may be true; what we do not often hear are the stories of those who did all of these very same things, but did not find success. An example from pop culture: The Voice. I have watched this show occasionally the past couple of years. One of the things I like about the show is that the initial screening of contestants is based solely on their singing voice (hence the name of the show), and not on their appearance. At the time of this writing (early November), the judges have just finished elimination rounds for their final teams to go on to the live shows. Here is my point—in almost every case the judges agonized over choosing who would go forward and who would be eliminated. And the reason is because all of them are really talented singers. It is impressive how gifted they are. At the end of each season, only one is declared a winner, out of that gifted pool of singers. When you hear their stories, they are all talented, hard-working individuals sacrificing for their art. And as far as I know, none of them has ever become a star. Hard work, dedication, sacrifice, talent—sometimes it is enough, sometimes not. I will be looking at the part uncertainty/luck/black swans play in our lives, but I want to make it clear at the beginning that I am not saying everything that happens to us is out of our hands or beyond our control. Taleb makes this same point (2007, p. 52): “This problem is chronic: if you tell people that the key to success is not always skills, they think that you are telling them that it is never skills, always luck.”"

Jan 1, 2017

By Kirk Ellison, Eric S. Lindquist, Peter Faust, Stephen M. McLandrich

"The 181 Fremont Tower will be an 800-foot high-rise with a 60-foot deep basement located in a dense urban part of downtown San Francisco. The design and construction methods of the subsurface elements navigated a variety of site constraints such as loose fill and soft estuarine soils, shallow groundwater, contaminants, historic obstructions, small work area, proximity of adjacent buildings, and the on-going excavation and build-out of the adjacent Transbay Transit Center (TTC) train box. Design of the approximately 260-foot-deep drilled shafts (some of the deepest foundations ever constructed in San Francisco) was proven by a full-scale load test that provided unique data on the frictional capacity of the deep soil and Franciscan Complex bedrock in the region. Design and construction of the shoring system for the 5-story basement excavation was exceptionally challenging because of the on-going construction for the TTC. To allow for flexibility during construction, hydraulic rams were placed in a transfer waler along the shared TTC shoring wall that could adjust the forces transferred through to the TTC excavation if required. Open and steady communication between the shoring engineer, the geotechnical engineer, and the shoring/foundation contractor was crucial in order to satisfy the complex constraints of this site.INTRODUCTIONThe 181 Fremont Tower is a new build mixed-use tower, currently under construction in the dense urban core of the South of Market District of San Francisco, California. This high-rise will consist of 54 above ground floors with the roof level 700 feet high. Atop the roof will be some architectural features including a spire that will top out at just over 800 feet, which will make it the second tallest building in San Francisco upon completion.The tower is being developed by Jay Paul Company and the architectural design is by Heller Manus. The structural engineer and geotechnical engineer for the project is Arup North America Ltd (Arup). The shoring designer is Brierley Associates (Brierley). The general contractor is Level 10 Construction (Level 10) and the specialty foundation contractor and excavation contractor is Malcolm Drilling Co., Inc (Malcolm)."

Jan 1, 2017

By Alper Turan, Hesham El Naggar

"The use of aggregate pier foundation systems has become widespread as the engineering practice moves towards cost-effective ground improvement solutions that provide accelerated construction schedules. Increased bearing capacity, effective settlement control and potential for liquefaction mitigation are commonly acknowledged benefits of aggregate piers. This paper studies the mechanisms by which aggregate piers interact with each other and with the surrounding ground when excited by seismic loads. A particular emphasis was placed on the response of a raft foundation supported on a site improved using aggregate piers. Three-dimensional nonlinear finite element analyses were conducted using commercial software package, ABAQUS. Non-linear soil behaviour is modelled using a three-dimensional total stress-based bounding surface plasticity model, which is able to simulate stiffness degradation and damping increase in the soil. The soil stratigraphy considered in this study was a 30 m deep soil deposit that comprised a very stiff base layer and a shallow soft surficial clay layer. Ricker Wavelet time histories with different frequency contents are used as the excitation force in the analyses. Various area replacement ratios (ARR) for aggregate piers are studied for a square plan layout. The results presented in this study are considered to be of interest to researchers and designers in evaluating the seismic ground response of the sites improved using aggregate piers. INTRODUCTIONThe schedule and cost limitations imposed by the traditional over-excavation and replacement method for the stabilization and settlement control for poor soils resulted are underlying factors for the significant increase in the use of aggregate pier foundation system, particularly in the last two decades. Various well known advantages of aggregate pier systems including increased bearing resistance, settlement reduction, and increased uplift capacity have been studied by various authors. The use of aggregate pier systems for settlement control in soft soil deposits was studied by various researchers including Lawton and Fox (1994), Lawton et al. (1994) and Wissmann et al. (2001). Lien and Fox (2001) studied the behaviour of aggregate pier systems supporting embankments and retaining walls. The stabilization of slopes by means of aggregate piers was studied by Lien and Fox (2001), Wissmann et al. (2002). Thompson et al. (2009) reported on a performance monitoring study of aggregate pier systems supporting MSE walls. The interaction mechanism between the aggregate pier system and the surrounding soil attracted attention of various researchers. Handy and White (2006a) and (2006b) studied the changes that occur less than 2 m from centers of the piers, and further away, respectively. The support mechanism of aggregate pier systems subjected to compressive loading were studied experimentally and numerically by White et al. (2007) and Pham and White (2007), respectively."

Jan 1, 2017

By I. Moreno-Ventas, G. Ríos, J. C. Fernández-Caliani, M. Bacedoni

"This paper delves into the constraints on the nature, origin and thermal evolution of the accretions formed in the uptake shaft of the flash smelting furnace operated by Atlantic Copper in Huelva, Spain, outlining recommended practices for preventing accretion buildup. The accretions were investigated using quantitative electron probe microanalysis, X-ray diffraction and digital imaging techniques, and the experimental data on mineral composition, crystal chemistry and textural relationships were interpreted in terms of thermodynamic phase equilibrium in the SiO2-Fe-O-S system. The results suggest that two distinct types of accretions were formed by the fractional crystallization of two coexisting immiscible melts, under changing conditions of oxygen partial pressure (pO2). The type I accretion of magnetite + delafossite ± cuprite ± tridymite ± metallic copper crystallized from a fractionating copper-rich melt at pO2 above about 10-5 atm, while the type II accretion of magnetite + fayalite + metallic copper + chalcocite derived from a melt with lower copper concentration when pO2 levels dropped below that critical level. Phase compositions and textures were consistent with a cooling history of both compositionally contrasting liquids from about 1,250 °C, the liquidus temperature of magnetite, to eutectic or near-eutectic temperatures of around 1,100 °C. The maintenance of appropriate temperatures — above the liquidus temperature of magnetite — and oxygen partial pressure levels may be critical for the prevention of accretion buildup. IntroductionCopper flash smelting with oxygen-enriched air, an autothermal process developed half a century ago by Outotec (Espoo, Finland), formerly Outokumpu, currently accounts for about 50 percent of the world’s primary sulfide-based copper (Schlesinger et al., 2011). The partial reaction of copper sulfide concentrates produces two separate molten streams, copper-iron-sulfide matte and iron oxide-rich slag, and releases sulfur dioxide (SO2) gas. The matte is sent to converters to remove the remaining iron and sulfur, leaving blister copper with grade of about 99.5 percent copper (Cu), which is cast into anodes for electrolytic refining.The SO2-rich gas generated by the oxidation of sulfide feed particles contains a significant proportion of dust that is entrained in the process off-gas. The gas from smelting is transferred into a waste heat recovery boiler, where it is cleared of dust and cooled before it is converted into sulfuric acid. If the process is not operated properly, the dust-bearing gas may form accretions between the uptake shaft of the flash smelting furnace and the waste heat recovery boiler, causing severe problems in the gas handling system (Swinbourne, Simak and Yazawa, 2002; Miettinen, 2008; Stefanova et al., 2012). Removing the dust accretions usually requires a greal deal of time, effort and resources. Understanding the buildup of accretion may help in reducing the problems and optimizing the process"

Jan 1, 2017

By Takeshi Maki, Kh. Adeel Tariq

"The lateral resistance of the structure plays an important role during seismic event and it can be increased by using ground improvement. In this study an attempt has been made to investigate the effect of cement-treated sand on the lateral capacity of the pile. The behavior of piles surrounded by sand only and cement-treated sand confined in a steel box (30 x 30 x 50 cm) which is subjected to lateral cyclic load has been investigated. Piles having a diameter of 2.5 cm and embedded to a depth of 45 cm were used. Steel and aluminum piles were used to investigate the effect of flexural stiffness on the lateral capacity of the pile. Bottom supports of piles were also changed from pinned to fix. Well graded sand compacted to 70% of relative density (RD) was used. Cement-treated sand having a compressive strength of 3.7 MPa was used. Displacement controled lateral load tests were performed and cyclic loads were applied until pile displacement was 4%, 10%, 20%, 35%, 50%, 75% and 100% of pile diameter. Results evaluated are compared with common method of analysis like Brinch hansen (1961), Brom (1964), Poluos (1980) etc. Results have indicated that the stiffness of a pile affects its lateral capacity. The introduction of central cement-treated sand part increased 5 times the lateral capacity of piles as compared with a sand only condition.IntroductionPiles are used extensively around the world to support loads of structures. Piles are commonly used to carry axial load, but in some structures, the lateral capacity of the pile is more important than the axial capacity: for example piles supporting earth retaining structures, electric tower foundation, etc. Structures can be subjected to both axial and lateral forces, like structures constructed at harbor that are subjected to lateral force due to waves action; and structures built in earthquake prone areas like Japan."

Jan 1, 2017

By R. Shields

"Hard rock mines move large volumes of material. But the conveyors essential to this movement suffer lots of problems, including carryback, spillage, dust, and belt wander. Many of these issues are created at the transfer points where the belts are loaded. This presentation will start with an overview of the latest transfer point systems that incorporate safety and serviceability by design. It will then report on recent projects. One project is the Conveyor B Transfer at the Coeur Rochester silver mine near Lovelock, Nevada. Here performance was improved with the installation of belt support cradles, engineered chute walls with external wear liner, and a compact dust collector. A second project is the improvement of belt support idlers and skirtboard sealing in a long loading zone of a conveyor under the concentrator at an Arizona copper mine. THE IMPORTANCE OF TRANSFER POINTS Conveyors are essential in mine material handling. Their performance will often make the difference in mine productivity and profitability. A key to conveyor performance are the transfer points where the conveyor belt is loaded and discharges. At these transfer points, many of the problems encountered with the conveyor system are created. The problems that arise at the transfer stations include off-center and segregated loading, mistracking, blockages and plugging. And there are a variety of problems originating with fugitive material—cargo released in the form of carryback, spillage, or airborne dust—that are created or exacerbated in the transfer points. These fugitive materials turn into other conveyor-related problems, including shortened component life, unplanned outages for conveyor maintenance, unexpectedly high labor costs for maintenance and cleanup, worker health and safety problems, and issues with community relations. As estimate attributed to the U.S. Mine Safety and Health Administration (MSHA) notes that 85 percent of conveyor maintenance is a result of fugitive material at conveyor transfer points. TECHNOLOGIES TO IMPROVE TRANSFER POINTS A number of techniques to improve the performance of conveyor transfer points have been developed. They include: • Absorbing impact, to prevent damage to belt, belt support systems, and conveyor structure, and reduce spillage caused by the impact energy arising from long material drops or large lumps of material loaded onto the receiving belt. • Stabilizing the belt line, to eliminate sag that allows spillage and encourages material entrapment that can damage the belt. • Protecting the skirtboard seals, by sheltering the sealing strips from the mass of cargo pushing material toward the edges of the belt. • Using self-adjusting, multiple-barrier edge seals, to keep material on the belt by providing long-lived seal efficiency with minimum maintenance requirements. • Controlling and centering the belt’s path, to eliminate belt wander and the spillage and damage it can cause. • Allowing dust to settle, through the incorporation of chutework that provides expanded stilling zone and the use of dust curtains at the points where the belt enters and exits the transfer. • Adding supplemental dust control systems, through the installation of systems for passive dust gathering, water-based dust suppression, and/or active dust collection."

Jan 1, 2017

By L. Callele, C. DiGiovanni, L. Li, R. Driver

"Hot-dip galvanizing is a common procedure used to protect structural steels from corrosive environments. However, in a construction project involving welded structural steel platforms by a Canadian steel structures company, numerous connections were found with large cracks in the welded corner joints and T-joints after galvanizing. Historically, in other similar projects by the same industry partner, cracking did not occur making this an unforeseen and new phenomenon. The project explored the mechanical properties of the base material, the thermal stresses induced by the hot-dip galvanizing, and the fracture surface of the cracks. A key feature to note, the fracture surface showed intergranular cracking with no plastic deformation. Lab testing showed the base material exhibited intergranular brittle behavior when heated and fractured at the galvanizing temperature. The transition to a brittle fracture mode is due to temper embrittlement and the segregation of elements in the grain boundaries.INTRODUCTION Galvanization is a common practice for protecting steel structures from the corrosive environment. Hot-dip galvanizing is the most common approach to bonding the zinc layer to the steel, and it is highly cost effective. In the case of welded structures, it is common to do the hot-dip galvanizing process after welding. This is so the protective layer can be applied to the structure as a whole and over the welds. In a recent construction project carried out in industry, a steel frame platform structure measuring approximately 3 m x 7 m was galvanized after welding fabrication. The structure was built of CSA G40.21 350W and CSA G40.20/G40.21 300W plain carbon steels and welded using a metal core arc welding process for the flanges and a flux core arc welding process for the webs of the beams. Due to their size, the platforms underwent a double-dip galvanizing process meaning half of the structures were submerged in the molten zinc path while the other half was exposed to the ambient air. This was repeated for the remaining side. Shortly after the galvanizing process was completed, numerous large cracks were found in the welded joints. Given there was no history of weld cracks after galvanizing in previous similar frames that were double dipped, this failure posed a new and curious problem."

Jan 1, 2017

By X. Zhou

"Hydrogen induced failure and degradation in structural metals, namely hydrogen embrittlement, has been a long-standing industrial problem for more than one century and remains unsolved. Despite the proposal of numerous models, no consensus has been reached, and considerable discrepancies in experimental observations and theoretical calculations exist. One aspect that is central to the understanding of hydrogen embrittlement is the interaction between hydrogen and grain boundaries. In this study, we investigated the influence of several solute elements (i.e., Cr, Mo and Nb) on hydrogen segregation at the representative 9 grain boundary using first-principles calculations. Our results showed that the presence of Mo and Nb can reduce the tendency of hydrogen segregation at grain boundaries, while meanwhile enhance the grain boundary strength. This indicates that Mo and Nb are salutary elements that can be used to increase the material’s resistance to hydrogen embrittlement, providing new insights in designing hydrogen embrittlement resistant Ni alloys. INTRODUCTION Hydrogen embrittlement (HE), a phenomenon of hydrogen triggering premature failures in structural metals, has been a headache for industries ever since its first discovery one century ago (Johnson, 1874; Zhou, Marchand, McDowell, Zhu, & Song, 2016; Zhou, Ouyang, Curtin, & Song, 2016). It is well accepted that the segregation of hydrogen at microstructures such as grain boundaries (GBs) plays a key role in determining the occurrence and severity of HE. GBs are two-dimensional defects where significant local lattice distortion exist, which leads to large free volume and thus locations for hydrogen trapping and segregation. Numerous works have clarified GBs as the energetically preferable places for hydrogen segregation. For instance, Geng et al. demonstrated the preferential segregation of hydrogen at the S5(120) GB in several metals, and suggested a decohesion-type of HE in light of Rice-Wang thermodynamic theory (Geng, Freeman, & Olson, 2001). Birnbaum et al. illustrated that complete intergranular crack of Ni GBs can be induced by hydrogen segregation when the hydrogen concentration is sufficiently high, evidencing the significant role of hydrogen accumulation on GB weakening (Lassila & Birnbaum, 1987). Yamaguchi et al. demonstrated strong segregation hydrogen also occurs at S3 GBs in alpha-iron, showing that local hydrogen clustering (i.e., multiple hydrogen atoms, up to six, per unit cell) can be trapped at the S3 GB (Yamaguchi, Kameda, Ebihara, Itakura, & Kaburaki, 2012)."

Jan 1, 2017

By Chandramohan P. V., Ravi Kishore

"An underground reservoir was to be constructed at Doha in Qatar. Simsima lime stone is present at the bottom. When the reservoir is empty, there will be uplift at the bottom but this will change to downward load when it is full. The rock at the bottom had high bearing capacity to resist downward load. But uplift had to be resisted by piles or anchors. The reservoir has a size of 120mx80m. Shrinkage and creep of concrete coupled with thermal contraction imposed a horizontal movement of 26mm on the extreme piles. So, piles have to accommodate this as well. This unique situation needed a unique solution. The solution was to provide piles with flexible high tensile strands to take tension. An annular space near the head of the pile would facilitate horizontal movement as well. Compression load was directly passed on to the raft bearing on rock.INTRODUCTIONAn underground reservoir for storage of drinking water was to be constructed at Doha, Qatar. The reservoir was proposed to have a plan size of 120m x 80m. Clear height inside the reservoir was proposed as 17.2m, from the bottom of roof to the top of bottom raft. Overall height of the reservoir at the outlet from the top of the roof to the bottom of raft was to be 21.2m. For the sake of inspection and in order to prevent pollution from the surroundings a gallery was planned around the reservoir. This could accommodate pipelines as well. This gallery was 3.0m wide on three sides and 8.4m wide on the outlet side.The gallery had removable gratings as cover in order to facilitate maintenance. Capacity of the reservoirwas proposed to be 40million gallons. The reservoir is divided into four compartments with baffle walls in each one for water circulation. Roof of the reservoir is kept at 300mm above ground level. There are two levels of car park on top of the reservoir. Top of the reservoir roof is at +14.35. Bottom varies from - 6.68 to -7.08. Lowest water table is at +6.00. Concrete structure of the reservoir was designed by a local consultant. The Navayuga Engineering Company was entrusted with the construction. Please see Figs 1 and 2."

Jan 1, 2017

By Shahid Islam, Lucian Bogdan

"The maintenance of infrastructures has been of particular concern to the engineering community. As the world’s infrastructure expands and existing infrastructure ages, monitoring and evaluation of the structures have become more critical than ever. A large number of retaining walls, tie backs, slope stabilizations and piles are designed using pre-stressing steel. Many piles and drilled shafts are designed using reinforcing steel. There are few testing methods available to assess these tension and compressive forces. High cost, complicated equipment and limitation of space often prevent these methods from being implemented. DYWIDAG-Systems International (DSI) has been involved in the development, testing and utilization of DYNA Force® sensors to measure the force in the anchors during construction and at any time during the lifetime of the structure. They can be used for bare, epoxy-coated, galvanized and greased-sheathed steel in the bonded, un-bonded, grouted or un-grouted length of the anchor. The sensor is robust and requires no maintenance. Sensors have received attention in terms of accuracy, performance, ease in installation, durability, and cost effectiveness. This paper describes its application in tie-back and anchor force monitoring of retaining walls and bridge abutment and compression forces in drilled shaft reinforcing steel where the data were collected manually, automated and remotely.INTRODUCTIONOur infrastructure is expanding and the existing infrastructure is aging. Some structures are expensive to maintain and some occasionally fail. There is a large demand for implementing health monitoring of structures. Many tie-backs, retaining walls, dams and other geotechnical structures are post-tensioned and many of them need repair using a post-tensioned system. On many occasions during construction and service life of the structure, it is useful to know the force in the post-tensioning and anchor system. Many piles and drilled shafts are designed using reinforcing steel and the compressive forces in reinforcement are unknown. Although there are many methods to measure the tendon force, most of them are cumbersome, expensive, and the accuracy varies depending on the method used.The elasto-magnetic (EM) technology is a novel approach to monitor forces in steel elements. The DYNA Force sensor is built based on EM technology (See Fig. 1). It is composed of a primary coil and a secondary coil (sensing coil). By passing current through the primary coil, ferromagnetic material is magnetized. The sensing coil picks up induced electromotive force that is proportional to change rate of applied magnetic flux (Faraday's law) and relative permeability. As permeability of core changes, output voltage changes. The output voltage is calibrated to measure the force. A readout unit is designed to magnetically energize the steel through the sensor and measure the response of the steel to the process. The readout unit then converts the response into a direct force reading. The sensor has an embedded thermistor which allows for temperature compensation. Due to the diversity of the magnetic property of steel, calibration is done for each type of steel allowing the sensors to perform at their highest accuracy."

Jan 1, 2017

By Weijian Yu, Genshui Wu, Jian Zhang, Yong Ning

Aiming at characteristics of the soft coal roadway engineering geology and deformation, the exposure research of the soft coal seam, theoretical analysis, numerical calculation and program design were carried out. First of all, according to the disclosure, soft coal seam engineering characteristics and geological conditions in Xinxing coal mine were expounded. Meanwhile, the soft coal roadway bolt supporting axial effect, the bolt supporting transverse effect, the anchorage body mechanics strengthening mechanism and problems such as supporting strength have been analyzed. The paper pointed out that the soft coal with very small cohesive force can form a composite anchorage body under the combined action of the anchor cable group, the W-type steel band and the metal net. The soft coal body in the plastic damage area formed anchorage balance arch with a certain bearing capacity and adapted to the rock deformation, and which played an effective support role in the roof outside the balance arch of the roadway. Therefore, the full-cable support technology was proposed. And then, numerical calculation and comparative analysis were conducted on three schemes of the roadway with non-support, with combined support of “anchor bolt and cable” and the full-cable support. The results show that when the roof is supported by anchor cable, it not only controls the continued increase of the subsidence value of the roof, but also effectively suppresses the convergence amount of the floor heave value and the amount on the sidewalls of the roadway. Whether it is from the stress distribution situation, or the viewpoint of plastic zone scope, the combined support of full-cable is more reasonable than that with non-support and that with the combined support of “anchor bolt and cable”. Finally, based on the features of soft coal seam in No.2265 work face of Xinxing coal mine, the relevant support schemes were put forward, and its specific support parameters and cross-section designs were drawn as well.

Jan 1, 2017

By R. K. H. Falconer, Wood R. A., C. D. Castle

"A deposit of phosphate nodules is on the Chatham Rise approximately 450 kilometres to the east of Christchurch in the South Island of New Zealand. The deposit contains sufficient rock phosphate to supply New Zealand’s phosphate fertilizer needs for at least 20 years. It was first investigated commercially 50 years ago by Global Marine, followed by JBL Minerals in the early 1970’s. NZ and German government research and industry groups then took it up again, with major field programs in 1978 and in the early 1980s.Due to difficult global and local economic conditions the project ground to a halt in 2004.The project was resurrected in 2007 when Chatham Rock Phosphate applied for a prospecting licence. This was granted in 2010 and a successful subsequent mining permit approval followed in 2013. The initial application for the separately required environmental permit was declined in February 2015.A lot has changed then and the significance of this will be the subject of the presentation. Chatham Rock Phosphate is confident that an environmental permit will be successfully granted next time."

Jan 1, 2017

By Li Yang, Andre Cezar Zingano, Alberto Fronza

"Immediate roof control is very important to the security and stability of entries in coal mining. It is also the highest cost in the coal mining operation, and roof spalling is directly responsible for coal contamination. The immediate roof in the coal mines in the State of Santa Catarina varies in lithology and in the presence of structures, such as bedding planes, vertical fractures that cut lamination, sandstone, and siltstone boulders. The presence and crossing of these structures should influence the decision of the specification of the roof support. Furthermore, the variation of rock layer and quality of the roof must be immediately followed by the variation of support specification. This work aims to study the behavior of the immediate roof under different geological and structural conditions during the excavation of entries, including the changing of the geometry of the entry as a function of time. This includes the effect of vertical fractures that cross the bedding planes of the roof and the position of those fractures on the roof. The effect of time between excavation and installing support to stabilize the roof is also examined. This study uses empirical methodologies for support design and numerical methods to study the behavior of the roof when anchored to the different scenarios proposed. The results of this work show the importance of quality characterization of the roof in terms of the type of rock and its thickness and the presence of vertical fractures that cut the bedding planes of the roof immediately.INTRODUCTION The immediate roof in a coal mine can varies in terms of typology and structural features, like bedding plane spacing and vertical joints. The roof support must be specified based on the features of the roof layer and its classification. Unal (1983) and Mark, Molinda, and Dolinar (2001) suggest that the roof support design should be based on the rock mass rating (RMR) and coal mining roof rating (CMRR), which look at rock mass classifications. These methods are based on the beam-building approach, and the bedding planes are tied together using fully grouted bolt. The bolt can be pre-tensioned or not depending the time of the curing of the resin."

Jan 1, 2017

By Gregory M. Landry

"There is an old joke at Moretrench that defines dewatering as “that element of an underground construction project, which, when disregarded, will generate the low bidder.” Sigmund Freud wrote that all jokes are true, and the kernel of truth behind this one is that dewatering is often misunderstood or neglected until the last possible moment in the life of a project. The purpose of this article is to describe commonly used dewatering methods and to clear up a pervasive but fundamental misunderstanding about how to determine the amount of dewatering effort required for a project. The Tools of DewateringDewatering may be divided into two broad categories: (1) methods that remove water from the excavation after it has already entered and (2) methods that seek to exclude or intercept the water before it reaches the excavation. The former is generally self-performed by general or earth moving contractors using sumps and ditches, while the latter is usually done by a specialty contractor. SumpsProperly installed sumps can be an effective and economical way to control water inflow into a site. In this technique, groundwater is allowed to enter the site before being pumped away. Advantages of this method include lost cost, easy availability of equipment and the fact that a general contractor can self-perform the dewatering. However, caution should be used when deciding whether to use this method, and consideration should be given to the following factors:1. How will the soil behave under seepage forces? Will it run, potentially causing ground loss?2. How much groundwater lowering is required? If the groundwater only needs to be lowered a few feet, using sumps will be much more practical than for a situation that requires significant drawdown.3. Will the excavation subgrade soften or otherwise be damaged by allowing water to run over it?4. Is my workforce skilled enough to implement and manage the sumping plan?In the photo, the sump is capturing groundwater that has already entered the excavation by traveling under the sheets. In this instance, the house in the background of the photo was eventually purchased by the project owner after sustaining damage due to ground loss."

Jan 1, 2017