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By K, J. MAUNDERS

This paper briefly describes a computerised model of the South African electricity system which has been developed jointly by the Atomic Energy Board and the Electricity Supply Commission. The results of an analysis of this system have been subjected to a fairly extensive sensitivity analysis which reveals that up to the year 1990 between 680 and 700 million tons of coal will be required for electric power generation, together with between 7 000 and 10 000 tons of uranium. This result is fairly insensitive to data variations, but the prediction of a cumulative requirement up to the year 2000, of between 1 300 and 1 800 million tons of coal and 25 000 to 70 000 tons of uranium, proves to be very data-sensitive.

Jan 1, 2014

By Don Ibana

Supported by the Minerals Council of Australia (MCA) through the Minerals Tertiary Education Council (MTEC), three Australian universities–Curtin University, Murdoch University and the University of Queensland–have formed the Metallurgical Education Partnership (MEP) to jointly develop and deliver an engineering design capstone unit–Metallurgical Process and Plant Design–in their respective undergraduate programs in extractive metallurgy, in order to enhance the students’ educational experience. A unique feature of the program is the close interaction of the students in all three universities and a significant involvement of industry professionals. Now in its sixth year, it is clear that this unit is achieving its objectives

Jan 1, 2014

By Mark William Kennedy

Modern metallurgical plants typically have complex flowsheets and operate on a continuous basis. Real time interactions within such processes can be complex and the impacts of streams such as recycles on process efficiency and stability can be highly unexpected prior to actual operation. Current desktop computing power, combined with state-of-the-art flowsheet simulation software like Metsim, allow for thorough analysis of designs to explore the interaction between operating rate, heat and mass balances and in particular the potential negative impact of recycles. Using plant information systems, it is possible to combine real plant data with simple steady state models, using dynamic data exchange links to allow for near real time de-bottlenecking of operations. Accurate analytical results can also be combined with detailed unit operations models to allow for feed-forward model-based-control. This paper will explore some examples of the application of Metsim to real world engineering and plant operational issues.

Jan 1, 2014

By Markus Reuter, Antoinette van Schaik

In this paper the link between process metallurgy, classical minerals processing, product centric recycling and urban/landfill mining is discussed. The depth that has to be achieved in urban mining and recycling must glean from the wealth of theoretical knowledge and insight that have been developed in the past in minerals and metallurgical processing. This background learns that recycling demands a product centric approach, which considers simultaneously the multi-material interactions in man-made complex ‘minerals’. Fast innovation in recycling and urban mining can be achieved by further evolving from this well developed basis, evolving the techniques and tools that have been developed over the years. This basis has already been used for many years to design, operate and control industrial plants for metal production. This has been the basis for Design for Recycling rules for End-of-Life products. Using, among others, the UNEP Metal Recycling report as a basis (authors are respectively Lead and Main authors of report), it is demonstrated that a common theoretical basis as developed in metallurgy and minerals processing can help much to level the playing field between primary processing, secondary processing, recycling, and urban/landfill mining and product design hence enhancing resource efficiency. Thus various scales of detail link product design with metallurgical process design and its fundamentals.

Jan 1, 2014

By Xiaojie Gao, Shufeng Yang, Jingshe Li, Chengsong Liu

In the blast furnace process, the dust entrained in the blast furnace gas enters into the down-comer, flows through the gravity dust separator (to eliminate coarse particles) and then is collected in a bag-house. The powder collected by the baghouse is called bag dust, while both fractions are called blast furnace dust whose main components are C and Fe. The dust also contains small amounts of nonferrous metals such as Zn and Pb, which have some value. Also, due to the small particle size and low density the dust is easily suspended in air and so can endanger human health. Therefore it is necessary to develop a process to both treat the dust to recover the metal values and to dispose of the residue – preferably by recycling to the blast furnace itself via the sinter strand. These objectives will result in good economic, environmental and social benefits [1].

Jan 1, 2014

By Kai Tang, Casper van der Eijk

Natural gas has been used as reductant in the production of iron for several decades. Recently, the use of natural gas as reductant for other metals has been drawing attention because of the low price of natural gas, as well as the reduction of CO2 emissions compared to the use of coke and coal. In this work, the reduction of a mixture of Ti- and Ni-oxides by natural gas has been studied. Within the Ni-Ti system, the intermetallic compound Ni3Ti is thermodynamically the most stable one. Therefore, powders of Ni-oxide and Ti-oxides were mixed in an atomic ratio of three to one and subsequently pelletized. Reduction was performed in a TGA furnace at constant temperature with varying reducing gas atmospheres. In a natural gas containing atmosphere, the Ni-oxide was easily reduced to metallic nickel while the Ti was reduced to Ti-oxycarbides or Ti-oxynitride when nitrogen was present. Depending on the process parameters, several percent of Ti was dissolved in the nickel-based solid phase.

Jan 1, 2014

By Arthur E. Morris

The primary market driver for improving process technology is innovation, which requires a skilled and educated workforce. However, many Materials Science and Engineering departments have eliminated extractive metallurgy and chemical thermodynamics from their curricula, yet these topics contain the necessary fundamentals for process innovation. As a result, most MS&E students are ill-prepared for careers in processing. The dearth of processoriented MS&E curricula has prompted some Universities to develop a “shared” effort to offer distance education between multiple institutions [1]. A target audience for a shared process simulation course would not only benefit students, but also be a basis for an on-line course for practicing engineers faced with new or changing career choices. To fill the gap, the basics of a process simulation course was developed in an abbreviated form as series of eleven articles and Excel workbooks published in Industrial Heating magazine between July 2012 and July 2013.

Jan 1, 2014

By Mark Cross, Diane McBride, Nick Croft

Extractive metallurgical processes rate amongst the most complex from the perspective of computational modeling. They typically involve multi-phase and multi-component fluid flow in very complex geometries, heat transfer driven by a number of interacting phenomena, solidliquid- gaseous phase change and mass transfer together with complex thermodynamics and associated chemical reactions. Beyond the model building itself, key challenges have always involved being able to identify the phenomena present together with interactions to characterize processes and experimental laboratory and plant data to parameterize the arising models – it is in this milieu, which require considerable process understanding and subtlety of thought, that David Robertson has made his contributions. We will review the achievements, over the last couple of decades, in computational modeling of extractive metallurgical processes and address some of the remaining challenges to enable simulation based process design, as we move through the 21st century.

Jan 1, 2014

By Xue Sun, Dengfu Chen, Yuting Chen, Mujun Long, Song Xu, Helin Fan

In order to seek an effective extraction process for vanadium, the recovery of vanadium from a high Ca/V ratio vanadium slag was studied by sodium roasting and ammonia leaching. In the present paper, the oxidation and leaching process of vanadium slag was investigated by X-ray diffraction (XRD), scanning electron microscopy and energy dispersive X-ray spectrometry (SEM/EDS) techniques. The effects of ammonium carbonate concentration, leaching temperature and leaching time on the leaching ratio of vanadium were discussed. As indicated in the experimental result, the optimal (NH4)2CO3 concentration was 120g/L, leaching temperature was 60°C and leaching time was 20 min. Approximately 92% of the vanadium was recovered under the optimal conditions. Furthermore, by means of X-ray diffraction analysis, the phase transformations of the vanadium slag during roasting and leaching processes were analyzed and discussed.

Jan 1, 2014

By Thomas P. Battle

Modern-day direct reduction of iron first developed as a small-scale, low capital and operating cost alternative to the blast furnace. Since commercialization of continuous DR technology in the late 1960s, the market for the products of direct reduction has grown to more than 74 million tonnes in 2012. The initial advantages of DR plants over BF facilities have grown over the years, for several reasons, including the increased size of DR modules, lower energy and emissions (particularly CO2), along with the flexibility to use a number of different reductants. The development of DR technology over the past forty years will be emphasized in this presentation, including recent developments that allow for even more direct sustainability comparisons with the iron blast furnace – and even combine the two technologies for improved synergies. Also briefly discussed will be the possibilities of using direct reduction for non-ferrous ores.

Jan 1, 2014

By John Snowberger III, J. Brent Hiskey

The electrochemical dissolution of super alloys containing different amounts of rhenium was investigated. The initial part of the investigation focused on the anodic dissolution of rhenium from second-generation (3% Re) and third-generation (6% Re) nickel based alloys. Exploratory electrochemical tests were conducted to evaluate solution chemistries and to establish fundamental dissolution behavior of the alloys. These included rotating disc electrode (RDE) cyclic voltammetry, linear sweep voltammetry, and chronoamperometry tests. Electrolytes comprising sulfuric acid, hydrochloric acid, and ammonium sulfate were examined. Of these, a 0.1 M HCl solution proved to be extremely effective for electrochemical dissolution of samples of CMSX-4, CMSX-10, and SC-180 alloys. This paper discusses in detail the electrochemical behavior of these alloys.

Jan 1, 2014

By Nina Bianco, Diana Drinkwater

MetSkill is a professional development program for metallurgical engineers that integrates with normal duties in their first one or two years of service. Graduates work together on a structured technical project, facilitated by specialists and supported by formal learning, and ultimately reported to their technical managers. The program enables graduates to “fill the gaps” in their undergraduate education, which is increasingly pertinent as engineering degrees become more general. Participants report that they enjoy the focus on more challenging (rewarding) aspects of their jobs and feel more confident about problem solving. Sponsor companies add that the relationships developed with external technical specialists enhances opportunities for innovation and development. MetSkill was delivered to two major resource companies in Australia in 2012. This paper provides an outline of the program and the reasons for its success, and demonstrates how the learning model could be applied to groups of graduates in other engineering disciplines.

Jan 1, 2014

By Ben Bowman

For certain ferroalloy furnaces, such as ferrochrome or ferromanganese, there is still doubt about the mechanisms operating under the electrode tips. In this paper a model is built that does not call upon an arc. The medium is best described as an electrically conducting slurry, a mixture of liquids, solids and gas. There are two sources of propulsion, the Lorentz force within the conducting part and buoyancy generated by CO bubbles, creating two opposed poloidal circulation loops, downward below the electrode axis and upward further out.

Jan 1, 2014

By Joshua Micah Hoffman, Catherine E. Johnson

The recruitment and retention of future talent into the explosives industry is becoming increasingly important. One potential area from which future talent can be recruited is local student chapters. Many of the student chapters are closely connected with engineering programs. While this makes sense and both entities benefit from these arrangements, there is a trend of job placement primarily in the engineering industry. Before the explosives industry can begin to compete with other industries, it should be determined what is drawing the students into these other fields. The work presented in this paper sought to better understand the collegiate student population from which a portion of future explosives professionals will emerge. This was done through the use of an anonymous online survey distributed to the student members of the International Society of Explosives Engineers, as well as, members of SEE student chapters. The survey contained questions about future job and career plans, ideal job placement, and expectations of salary. The purpose of the survey was to determine what these students expect or require from a career in the explosives industry. This information can help steer recruitment activities and job offers. Through understanding what is incentivizing these students who have accepted or plan to accept jobs in other industries the explosives industry can better posture itself to be more competitive in recruiting from the collegiate talent pool.

Jan 1, 2014

By Alessandro Bertero, Stefano Valagussa, Filippo Maria, Wesley Schmutzler, Leoni

"Abstract The Deep Mixing Method (DMM) represents a viable solution to improve the adverse geotechnical properties of foundation soils. Differences and the importance of performing pre-construction laboratory and field tests will be highlighted. Comparative analyses and interpretations between the various lab and field stages, along with accumulated information about soil properties and QC results, allowed fine-tuning of the production parameters throughout almost the entire project.Two projects where the US Army Corps of Engineers selected the Deep Mixing Method (DMM) for the required stabilizations, and a third project completed in Italy, will be illustrated:•,?the LPV 111 Project (New Orleans - LA – USA); DMM was used for groundimprovement/foundation strengthening and consequently stabilize and support the burden of the new levee.•,the Rio Puerto Nuevo Project (San Juan - PR - USA); DMM was applied to improve the soils adjacent to a 90” forced sewer main relocation and to improve the soils for the base of a new drainage channel•,the new Italian high speed railway project (Florence Italy); DMM technology was applied to realize a a TBM break in/break out, foreseen originally by jet-grouting.IntroductionThe Deep Mixing Method (DMM) represents a viable solution to improve the adverse geotechnical properties of foundation soils. The effectiveness of working parameters depends largely on the physical and mechanical properties of the soil to be treated. Therefore, well designed laboratory and field test programs, aimed to disclose the interaction between the site-specific soils and the mixing parameters, are essential to achieve the desired end product."

Jan 1, 2014

By Dena Morgan, Emre Biringen

"Abstract This paper discusses the execution of pile installation and design issues at two environmentally challenging industrial sites in North America. Environmental regulations set constraints on the design and require versatility in choice of technology.For a proposed bridge, due to protected fish habitat, performing soil borings within 30 m of the creek embankment was prohibited. The limited subsurface profile indicated a thick upper layer of granular material, thus driving H-piles was considered. However, to limit generation of vibration and noise in the protected area, drilled piles had to be used. During execution, the subsurface profile differed from that in the borings 30 m away. Very soft, saturated silt was encountered at the bottom of the caisson and the length had to be redesigned very quickly while the contractor waited for instruction. For a new structure in uncontrolled fill area, performing soil borings was not allowed. It was known that a layer of peat was present in the area, but no information regarding the thickness and extent. The subsurface profile generally consisted of granular material overlying a thick compressible silt layer. Somewhere within the granular layer peat would likely be encountered. Franki piles were chosen to penetrate the peat and bear in the underlying granular material. During environmental sampling in the area, methane gas was encountered and Franki piles were no longer a viable option due to safety concerns. The foundation system was changed to steel H-piles driven to bedrock, which was more than 50 m below the ground surface and sloping. Rock shoes that would work to significant slopes had to be used in order to increase the likelihood of good embedment within the bedrock. Also, due to obstruction of an approximately 3 m thick debris field that was encountered in the upper granular soils, some of the piles had to be relocated and extra piling needed to compensate for such differences. The results of PDA testing to estimate compressive capacity and a series of lateral load tests are presented.INTRODUCTIONThe design issues that are encountered during construction can be quite problematic and have a significant impact on schedule. In order to avoid such impact on the project, a thorough subsurface investigation should be considered prior to design and construction. Better understanding of environmental regulations also prevents costly changes to the foundation design. This paper discusses the execution of pile installation and the design issues at two environmentally challenging sites in North America.BRIDGEDuring the subsurface investigation for a proposed industrial building complex, several boreholes were drilled within the footprint or in close proximity of various structures, with Standard Penetration (SPT) sampling of the upper coarse-grained soils (sand/gravel) and undisturbed sampling of the lower fine-grained soils (silt/clay). The SPT blow counts (N60) were corrected by a factor of 1.35 in order to incorporate the SPT automatic energy transfer ratio. When Modified California Sampler was used, a correction factor of 0.44 to 0.64 was also applied. N60 values were further corrected for gravel to avoid artificially high blow counts during the analyses due to spoon samples contact with gravel and cobbles, and the corrected values of (NG)60 (limited to a maximum value of 50 blows/300 mm) were used for design. The information from the SPT boreholes was then used to assess the subsurface conditions beneath the structures, as well as for a nearby bridge that was designed to cross over a creek. Since performing soil borings within 30 m of the creek embankment was prohibited due to the protected fish habitat, the investigation with regard to the bridge abutments was limited to two deep boreholes (B10-33 and B10-34) at the bridge location and two additional boreholes (B10-35 and B10- 36) located approximately 200 m upstream. The bridge location and two sets of boreholes are"

Jan 1, 2014

By A. Galley, R. Tosdal, F. Robert

The Canada Mining Innovation Council (CMIC) Exploration Innovation Consortium developed a 10-year business case for developing new discovery criteria, exploration techniques, and better data management and analysis to improve exploration success in deep, remote, and covered terrains. Within this context, the CMIC devised a five-year project proposal to create improved multiparameter exploration tools to detect ore systems and more efficient vectoring toward high-grade mineralized cores. The Footprints project was approved March 2013. More than CAD$13 million funding was provided through the CMIC-led joint sponsorship from 30 companies and the Natural Sciences and Engineering Research Council. Consistent industry leadership and integration of dedicated industry and academic expertise has the project on track for reaching its well-defined objectives.

Jan 1, 2014

By B. R. Conard

Copper refining at Vale Canada (previously known as Inco) has been associated with Ni production. Because Cu and Ni carry risks for adverse health endpoints through inhalation exposure, it is critical that their aerosol levels, and the metallurgical processes through which they enter the air, are understood. Because certain Ni substances have been linked to respiratory cancers, it is also important to characterize the amounts and types of Ni compounds in occupational settings. This paper describes electrorefining and electrowinning operations near Sudbury, Ontario (1930–present), and gives aerosol measurements (1978–present).

Jan 1, 2014

By A. Vervoort, A. Govaerts

Geostatistical concepts are often difficult for students to understand, even those with a strong mathematical background. One of the main problems is the link between the variation of the parameter value in space or time and the calculated experimental semivariogram. Another challenge is differentiating between directional and omnidirectional semivariograms and their interpretation. For these reasons, interactive tools were developed based on the free public domain software R. The use of these interactive tools is limited to educational situations only (i.e., to visualize basic concepts). The interactive modules can be accessed at www.bwk.kuleuven.be/geostatistics.

Jan 1, 2014

By Hong Yong Sohn

A novel flash ironmaking technology is under development at the University of Utah under the support of U.S. Department of Energy (DOE) and American Iron and Steel Institute (AISI). The history of the development from the conception of the idea to the current status will be discussed. The flash ironmaking process produces iron directly from fine iron ore concentrates without requiring cokemaking and pelletization/sintering, which will enable the technology to significantly reduce energy consumption and carbon dioxide emissions compared with blast furnace ironmaking. Unlike other gas-based ironmaking processes, this technology will not suffer from the problems of solid sticking and fusion. Current work is focused on the method of supplying the energy required to maintain the necessary temperature, as an intermediate step to determine the scalability for larger, industrial-scale pilot trials.

Jan 1, 2014