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By B. S. -J. Kang, M. A. Alvin, J. M. Tannenbaum

"A load-based micro-indentation technique has been developed for damage assessment and non-destructive spallation detection of TBCs at room temperature. This micro-indentation technology has been further extended to the development of a high temperature (HT) test methodology. Elastic modulus calibration tests performed on Hl 3 Tool Steel to 500°C and Haynes 230 at 1000°C displayed excellent agreement with reported values. Moreover, indentation creep tests of Haynes 230 at 1200°C were found to be in agreement with known creep exponents as well. Finally, a HT thermal flux indentation apparatus was assembled for conducting TBC turbine component testing under high temperature moisture-containing environments (= 50% steam with controlled gas content temperatures up to 1250°C). Description and design considerations of this test apparatus are discussed. Preliminary tests of ReneN5/MCrAlY/APS TBC coupons in steam/air environments with in-situ HT micro-indentation testing are conducted. Furthermore, the coupon is removed and examined for damage assessment at periodical intervals.IntroductionLoad and depth relationships acquired throughout the indentation process provide insight to material mechanical properties such as elastic modulus and hardness. Unloading segment analysis of these load displacement curves are utilized in the acquisition of a material's elastic properties. Yet, indentation tests are complex processes involving contact mechanics, material nonlinearity and even fracture mechanics. Thus exact analytical solutions for these processes are difficult to obtain. As a result, much of the current knowledge regarding the indentation process has been acquired through experimental methods and finite element simulations. Initial efforts by Tabor resulted in the application of spherical indentation to obtain post-yielding stress/strain relationships [1]. Soon thereafter, analytical load-depth relations for elastic indentation were developed [2], yet it was Lure who further derived the explicit relationships for both spherical and conical indenters [3]. Improving upon this, these interactions were later extended to indenters with various geometries by various researchers [ 4]. Additionally, by establishing the linearity of the initial unloading slope within the load-depth curve, a relationship between elastic indentation depth, maximum load, unloading slope and indenter geometry was established [5]. From this a theoretical method by which elastic modulus could be determined was established."

Jan 1, 2011

By Richard A. Allwes

This U.S. Bureau of Mines report presents the results of structural analyses and full-scale physical tests conducted on a steel-set arch and tri-set. The purpose of the analyses and tests was to evaluate the suitability of these structures for use in roof-fall prone areas. The arch canopy test and design procedures previously developed by the Bureau were utilized in this evaluation. Theoretical resistance functions were established for the steel-set arch and tri-set and were representative of the experimental behavior of the structures. The resistance functions were used to determine the energy absorption capacity of the structures and to predict their dynamic response to impact loading. The dynamic tests demonstrated that the arch canopy design procedure is appropriate for tri-sets and yields conservative designs for both steel-set arches and tri-sets. As a result of this work, it is recommended that these two structures may be considered for use in roof-fall prone areas and for rehabilitation work, provided the arch canopy design procedure is utilized for each application and the principles underlying the design procedure are understood.

Jan 1, 2010

By R. C. Gilmore

Computational fluid dynamics (CFD) has been used to model gas compositions in underground longwall coal mine gobs to study oxygen ingress and the development of potentially explosive methane-air mixtures that may form in the gob. The scenarios studied involve various headgate and tailgate ventilation and inertization schemes and controls. In a project sponsored by the National Institute for Occupational Safety and Health (NIOSH), researchers at Colorado School of Mines have used an innovative meshing approach, allowing easy adaptation of the CFD model to adjust to a variety of bleeder and bleederless mining geometries, with gob porosity and permeability scalable over a wide range. This paper presents the methodology of the meshing and scaling approach along with recommendations for using CFD modeling in longwall gob ventilation applications. The new meshing technique was utilized to evaluate the function of a back return in a progressively sealed gob. The back return was successful in maintaining sufficient oxygen concentrations in the tailgate corner of the longwall face.

Feb 23, 2014

The United States has not begun commercial operations to tap its largest poten-tial sources of oil supply - oil shale and coal. The reason is that domestic petrol-eum has been plentiful in the past and liquid products probably could be produced from it at the lowest cost. In view of the ever-increasing need for petroleum in the United States, the critical international situation threatening foreign supplies, the growing demands for steel, and the heavy costs to industry of constantly discovering and developing new oil fields, it is believed that the prompt development of a synthetic fuel industry based on oil shale and coal is not only requisite to safeguard our oil supply but is an economically sound course for the foreseeable future, To neglect its development is to close our eyes and minds to our own resources at a time when they are needed critically. It also is apparent now that neither the Government nor industry would be taking any considerable economic risk in starting the initial plants, especially as measured against their potential value in meeting critical oil and chemical demands and in building a new industry in the West.

Jan 1, 1951

By Thorsten Müller

In order to increase the production of Advanced High Strength Steel (AHSS) as well as to fulfill the growing expectations of various industries served, steelmakers must have wide- ranging know-how in terms of plant technology, operation, processes, quality control and, last but not least, know-how for AHSS including certification procedures. MET/Con is highly focused on the production of coated AHSS with tensile strengths higher than 600 MPa. Common heating and cooling technologies are unable to handle high alloyed steel grades – pre-oxidation and rapid cooling technologies have been developed to face these new challenges. MET/CON and Drever International have the knowledge to produce newest steel grades with these technologies.

Jul 30, 2018

By S Russell

The completion of the $1.1 B Cape Lambert Upgrade project is the second ‘pillar’ in Rio Tinto Iron Ore’s expansion program that has enabled Rio Tinto Iron Ore to effectively double iron ore shipping capacity from the Pilbara between 2003 and 2009 to 220 million tonnes per annum (Mt/a), following the successful completion of the Dampier Port upgrade project two years earlier.The Cape Lambert Upgrade has built on and enhanced many of the engineering achievements of the Dampier Port upgrade project, as well as developing innovative and unique engineering solutions for this complex ‘brownfields’ project that presented its own challenges, particularly in this distinctive open-water port environment.The project was implemented in two phases to achieve an increase in port shipping capacity from 55 to 80 Mt/a – an enhancement phase and an expansion phase.The initial enhancement phase, which provided an increase to shipping capacity from 55 to 60 Mt/a, focused on increasing the utilisation and effi ciency of existing plant and equipment with a relatively small capital expenditure.The expansion phase, which provided the increase in shipping capacity to 80 Mt/a, included extending the existing iron ore wharf by 256 m to create four shipping berths, a new shiploader, an expanded stockyard (including a new fourth bucket wheel reclaimer) and a new surge bin facility to maximise outloading tonnage rates.The Cape Lambert Upgrade project was implemented whilst the port remained fully operational and continued to ship record tonnages of iron ore throughout the project duration. This achievement required signifi cant upfront planning and sequencing of construction activities to support the operation of the port. Innovative design and construction techniques were used to mitigate the impact and enable construction activities in and around the operating plant.Throughout the project, new benchmarks in engineering design and construction practices were established, which have since been adopted for new iron ore port facilities currently in planning phases.

Jul 11, 2011

By C. A. Cole

This work consists of research in cable fault location and the construction of four field-test units based on the research. Swept-frequency sounding of mine cables with RF signals has been the technique most thoroughly investigated. The swept-frequency technique is supplemented with a form of moving target indication (MTI) to provide a method for locating the position of a technician along a cable and relative to a suspected fault. Separate, more limited investigations involved high-voltage time domain reflectometry and acoustical probing of mine cables. Particular areas of research included microprocessor-based control of the swept-frequency system, a microprocessor-based fast Fourier trans-form for spectral analysis, RF synthesizers, transmit-receive switches, RF receivers, cable dispersion-compensation techniques, low-voltage multielement display systems, and techniques for injecting or recovering RF energy through cable walls in support of clamp-on fault locators.

Jan 1, 1982

By Jurgen H. Kleinau

This paper details Keeler/ Dorr-Oliver's experience with the application of fluid bed combustion technology to the burning of coal-mining waste. The designs of two stage fluid bed combustors/dryers are demonstrated as useful in the drying of coal, slag and coke, using coal and coal refuse (gob) as fuel. Anthracite mining refuse (culm) is more than abundant in Northeastern Pennsylvania. After demonstration at Shamokin, Pennsylvania, a full commercial-sized fluid bed boiler using culm is used for district heating in Wilkes-Barre, Pennsylvania. Limited research work has shown the utility of using fine coal as filter aid in sludge in¬cineration. With the rising avenues of the suitability of coal as auxiliary fuel in fluid bed sludge incineration, an expansion of these concepts combines the use of coal or coal refuse as filter aid and auxiliary fuel. Lime¬stone addition controls SO2 emission.

Jan 1, 1985

By G Capes

A novel open stope design approach is presented that delivered improved performance in a mining area with poor ground conditions at the Olympic Dam mine. During 2019, a large open stope had an unplanned caving event resulting in the inability to extract the planned tonnes and subsequent sterilisation of nearby stopes. A design limitation was the lack of data and understanding around the alteration domain extents, the rock mass strength controls and limits, the failure modes controlling stope stability in the local area, and the use of conventional stope shapes. From the available data and failure observations, it was inferred that the dominant caving failure mode resulted from a blocky rock mass impacted by structure and alteration causing an unravelling failure mechanism. Numerical and empirical analyses were conducted to test this hypothesis and establish strength limits for design. The strength limits for the design were then used to provide a range of outcomes from which future stope design shapes such as chamfered backs could be selected. Three alternate chamfered geometries were selected to trial the innovative designs. The application of this methodology in 2020 resulted in overbreak reduction from >100 per cent in the initial caved stope to

Mar 29, 2023

If the Journal is to fulfill its mandate to the mining and metallurgical industry, it needs to expand its readership and, by implication, membership of The South African Institute of Mining and Metallurgy. This we hope to do by increasing the appeal of the Journal to a wider audience through the inclusion, in addition to our high-quality research papers, of equally high-quality papers, articles, and contributions that will be of interest to our less research-minded members.

Jan 1, 1990

This report, the second in an annual series, summarizes information on latest technological developments and advances, and identifies trends in mining and metallurgy based on a review of activities in the minerals industry in 1971. Exploration and mining data obtained from an annual canvass are presented for 1971 and are compared with similar data obtained over the past decade.

Jan 1, 1973

By Mirko Jurkovic, Thomas Hueper, Jens Kempken

The high competition scenario pushes the steel producers business. Zero defect requirements from customers force the operators for additional efforts in process control and quality management. PQA® has been developed as an advanced process and quality management assurance solution. It is focusing on the analysis of process data, equipment information, inline quality measurement devices and trend analysis. The paper describes the structure of the advanced process and quality management assurance solution PQA®; it gives insights on the expert know-how, process and quality evaluation and points out the benefits like cost reduction, improvement yield and customer satisfaction increase.

Oct 1, 2019

By Joshua Hoffman, William Chad Wedding, Braden Lusk

The emergence of electronic detonators as viable products for use in production mine blasting has enabled mining professionals to rethink the traditional blast design methodologies that pertain to timing. In many ways, electronic detonators can allow great advances in productivity, cost effectiveness, fragmentation, and safety. There are a number of commercially available systems that enable users to program delay times, usually in one-millisecond intervals, according to design decisions. While manufacturers have performed internal studies pertaining to the accuracy of these systems, an independent study quantifying the accuracy of the systems has not been completed to date. The mining industry is in the business of production and any quality control endeavors to independently confirm the accuracy studies performed by the manufacturers would only detract from their bottom lines. Furthermore, limited information is available concerning the accuracy of modern pyrotechnic delay based detonators. In 1985, the Bureau of mines completed a study of three manufacturers’ electric millisecond delay detonators (Bajpayee, 1985). This was the most recent extensive independent study performed on detonators, which unitized pyrotechnic delays, from numerous manufacturers. Advances in the manufacturing process for pyrotechnic delays may have increased the accuracy of detonators using these technologies in recent years. It is commonly accepted that electronic detonators are more accurate than both shock tube type non-electric as well as electric detonators, but the relative accuracy was not objectively and adequately quantified.

Jan 1, 2011

By A. Stawsky

Effective use of diesel vehicles in underground mining requires attention to improved control of diesel exhaust pollutants such as particulate (soot), oxides of nitrogen and sulfur and carbon monoxide. An experimental survey Is made of diesel emission aftertreatment control techniques including water scrubbers, catalytic converters, exhaust gas recirculation (EGR) and soot filters. Use of two or more techniques in combinations are tested for optimum control of all exhaust pollutants. Dynamometer data is developed for steady state and computer controlled simulated mines duty cycles operation of Deutz F6L-714 and F8L-413 engines. Exhaust Quality indices (EQIs) are calculated from dynamometer data for comparisons among the control combinations examined. The Corning diesel particulate filter (DPF) is shown to be the most promising and practical device. The Corning DPF in combination with EGR provided the best (lowest) EQI from the test data. Use of the DPF requires additional regeneration mechanisms such as a catalytic filter coating or fuel additives. A metal mine field test is made of DPFs on an operational scoop tram to test practical applicability. Further development is proposed for application to various mine conditions and for improvement of DPF regeneration techniques including coating with newly available catalysts.

Jan 1, 1987

By Irene Bendanillo, Canon Cheung, Justin Lianides, Derek Penrice

The SLAC National Accelerator Laboratory’s two-mile-long particle accelerator generates the world’s brightest X-rays from its Linac Coherent Light Source (LCLS) freeelectron laser. This facility has driven groundbreaking discoveries in medicine and industry. The LCLS-II-HE project will provide a significant increase in laser energy, allowing cutting-edge research in fields including biology and environmental science. A key project component is the Low Emittance Injector Tunnel (LEIT), a 240-foot-long tunnel to be built alongside the existing accelerator and connected to it via a 30-footlong Transfer Tunnel. This paper discusses site and scientific constraints that led to the selection of the LEIT configuration: tunnels to be constructed using the sequential excavation method in mixed-face conditions comprising native rock and placed backfill, and critical design considerations including protection of overlying and adjacent historic structures and structural accommodation of near-fault seismic loading.

Jun 13, 2023

By R. F. Hadley

Alluvial valley floors constitute a valuable land resource and have been important to ranching operations in semiarid western United States. This resource may be in jeopardy locally if the alluvial deposits are disturbed by surface mining of coal deposits. Erosion problems caused by poor land-use practices can cause trenching of the unconsolidated alluvium with a consequent lowering of the water table and depletion of soil moisture needed to support vegetation. Historical evidence of this sequence of events is abundant in geologic literature and serves as the basis for assessing potential impacts of surface mining. The potential geomorphic impacts of surface mining on alluvial valley floors with regard to fluvial processes are: (1) disruption of the longitudinal profile followed by valley trenching and high sediment yields downstream and (2) replacement of the excavated alluvium with unconsolidated material that does not have similar physical characteristics and may be susceptible to erosion. Mining may disrupt the existing hydrologic framework affecting streamflow, ground-water levels and water quality of both surface water and ground water. Although functional hydrologic and geomorphic processes are similar, each valley represents a complex environment that does not submit to broad generalizations.

Jan 1, 1978

By A Walker

The presence of high noise levels in many industries, together with the fact that countries are becoming increasingly concerned with the health of its citizens, has contributed to the importance of the problem of hearing loss. This problem has become the focus of scientific research, law and medicine, and the object of this thesis is to present the means whereby noise may be detected, with its resulting effects and possible means of control, in mining operations. 0BJECTIONABLE noise is a particularly prevalent by-product of the mining industry, and, al-though a dangerous noise level has been recognized, it is believed that at no time now, or in the future, will it be possible to enumerate a single over-all decibel figure at which hearing impairment will oc-cur. Individual susceptibility must be recognized in any study of occupational loss of hearing aimed at the setting of standards and criteria for industrial noise control.

Jan 1, 1963

By R. S. McClellan

Western Talc Company, Inc., with headquarters in Los Angeles, Calif., has just completed an extensive modernization and expansion program at its talc mine near Tecopa, Calif., and at its talc and clay mills at Dunn Siding, Calif., the nearest rail shipping point to the mine. The basic objective of the program was to provide facilities necessary to produce 300 tpd of a wide range of ground talc and clay grades for the ceramic, paint, paper, rubber and other industries. In the planning of the program every effort was made to provide a system which would permit a high degree of quality control and uniformity of the finished products, along with efficient operation. Several years ago, R. T. Vanderbilt Co., Inc. purchased Western Talc Co. after a comprehensive investigation of its properties, including an extensive diamond drilling campaign. Western Talc's properties embraced a number of claims in the Resting Springs mining district in the northern part of San Bernardino Co. and the southern part of Inyo Co., Calif., some seven miles southeast of the town of Tecopa. Operations by the original company were started on a small scale in 1913 and production from that date to the time of purchase of the company by Vanderbilt is estimated at 250,000 tons. The major part of this output was sold to the ceramic wall tile industry.

Jan 3, 1968

By M. E. Coleman, G. Money

"Clyde Materials Handling is an established customer-driven solutions provider, which utilizes its knowledge, expertise and technologies to transform the production processes of its customers, who operate in the ferrous and non-ferrous metals industries.With over 30 years experience in the process improvement industry, Clyde Materials Handling has helped their global customer base transform the way in which they operate their processes, which has enabled them to generate sustainable economic benefit and maintain their positions as leaders in their respective markets.Clyde Materials Handling has supported operators within the metals market by developing and deploying pneumatic conveying and pneumatic injection technologies. These environmentally supportive and sustainable solutions have been used to transport raw materials within operating facilities, from storage to silo, as well as injecting these materials directly into the heart of production processes.Clyde Materials Handling has worked closely with their customers, such as Codelco in Chile, where their pneumatic solutions have been used to inject a consistent, pulseless and accurate flow of copper concentrate into a bath smelter, which has helped to fuel the operational capacity, availability and productivity.This paper will discuss and highlight the ways in which pneumatic injection technologies, created by Clyde Materials Handling, and applied in partnership with their customers, have helped to improve the operational performance of the production processes of operators across the non-ferrous metals markets with specific reference to applications in the Peirce Smith Converter.Clyde Materials Handling has applications injecting Electronic Scraps, Dusts, Reverts, and other additives to the Peirce Smith Converter. They also have experience of modified PS Units used for Slag Cleaning. There experience with the Codelco Teniente Converter is also directly related to this area of operation."

Jan 1, 2009

By E. S. Chalpin

On 25 August 1971, the U.S. Bureau of Mines contracted with the Aerojet Liquid Rocket Company to perform an engineering research program to be completed on 25 May 1972. The program objective was to evaluate the advantages and disadvantages of the underground use of several power sources including but not limited to a closed cycle diesel, electric cable/motor, rechargeable battery/ motor and exhausting diesel for mine shuttle cars, with emphasis on health and safety. This report, Research in Advanced Power Systems for Mining Health and Safety consists of four (4) main parts: (1) Hazards and Safety Analysis of Mine Power Systems, (2) Evaluation of Closed Cycle Diesel Power System for Mine Applications, (3) Closed Cycle Diesel Power System Consumables Compatibility, and (4) Concluding Remarks and Recommendations. The hazards introduced to a mine by shuttle car power system failure modes were evaluated and reported. A "fault tree" analysis was generated for each power system and the probability of death or injury during an eight (8) hour shift and for a week of operation (105 hours) were estimated. Advantages and disadvantages were also reported for each system studied. Aerojet's assessment, based on a "forced decisions analysis," of the four shuttle car power systems as to their relative health and safety is that the exhausting or open cycle diesel is preferred, followed by the closed cycle diesel, the electric cable/motor and the rechargeable battery/motor. The assessment was based on ten parameters pertinent to the health and safety aspects of shuttle cars. Drawing layouts of two typical mine shuttle cars incorporating closed cycle diesel powerplant concepts are included in this report. The performance parameters established for the two concepts are tabulated. A study was made of the logistics involved in transporting and replenishing the consumables needed to operate a shuttle car equipped with a closed cycle diesel. The closed cycle diesel powerplant consumables -oxygen, potassium hydroxide, and diesel fuel - were analyzed as to their compatibility with materials found normally in a gassy coal mine. Spill tests simulating inadvertent leakage of liquid oxygen in a coal mine were performed. A critical evaluation of existing oxygen sensitivity data and the relationship to the use of oxygen on a shuttle car in a coal mine environment is presented.

Jan 1, 1972