Search Documents

By C. J. Ramsburg

THE construction and operation of by-product coke-oven plants in America are essential to strong national defense and of the greatest importance to many widely diversified undertakings as well as to safety and health. CARBONIZATION PROCESS Coal used under a boiler or in a locomotive is consumed by combustion. Coal used in a by-product oven is distilled or carbonized, meaning that heat is applied to the coal, out of contact with air, causing a distillation that removes the volatile matter in the coal in the form of gas and vapor, leaving coke as a final product. From the gas and vapor distilled from the coal, many valuable substances can be secured, known as by-products. Hence the name "by-product oven." The simplest example of this principle can be shown by means of an ordinary clay pipe. If powdered coal is placed in the bowl of the pipe, the opening of the bowl is plugged with clay, and the bowl placed in a flame, the bowl will become hot, transferring the heat through the wall of the bowl to the coal within. When this coal attains a temperature of about 950°F., gas will begin to pour out of the pipe stem, and this gas may be lighted. A black liquid also will exude from the stem of the pipe. This is tar mixed with certain other products. What remains in the bowl after distillation is coke. A coke oven corresponds to the bowl of the pipe. A modern oven of the latest type is a refractory brick chamber approximately 42 ft. long and 14 ft. high, averaging 18 in. in width. The oven is filled with coal through closable charging holes in the oven top. Each end of the oven consists entirely of a self-sealing door, the removal of which permits the finished coke to be discharged by means of a power-operated pusher machine. The ovens are built in batteries, and the heating is effected by gas burned in vertical flues in the oven walls, each set of flues heating the walls of two adjacent ovens. Such ovens carbonize a charge of approximately 18 tons of coal in 18 hr., or have a daily throughput of 24 tons per oven, producing about I 7 tons of coke. In times of need, the output may be increased by raising the temperature of flues, thus shortening the coking time. There is one great essential difference in principle between distillation in a clay pipe and in a coke oven. In the 18-in. oven, the distillation proceeds from two parallel walls held at a high temperature (over 2000°F.) and instead of all the coal being heated at once, the distillation is a progressive one creeping inward. The average travel of this heating is 1/2 in. per hour from each vertical wall, and as the volatile products are formed progressively they must push away from the interior toward the wall through the previously formed hot coke, then up the walls and over the top of the coal charge, finally escaping through the outlet pipe. This results in a cracking of the components into many different and valuable substances not formed when the carbonizing temperature is low.

Jan 1, 1942

By C. J. Ramsburg

The construction and operation of by product coke-oven plants in America are essential to strong national defense and of the greatest importance to many widely diversified undertakings as well as to safety and health. Carbonization Process Coal used under a boiler or in a locomotive is consumed by combustion. Coal used in a by-product oven is distilled or carbonized, meaning that heat is applied to the coal, out of contact with air, causing a distillation that removes the volatile matter in the coal in the form of gas and vapor, leaving coke as a final product. From the gas and vapor distilled from the coal, many valuable substances can be secured, known as by-products. Hence the name "by-product oven." The simplest example of this principle can be shown by means of an ordinary clay pipe. If powdered coal is placed in the bowl of the pipe, the opening of the bowl is plugged with clay, and the bowl placed in a flame, the bowl will become hot, transferring the heat through the wall of the bowl to the coal within. When this coal attains a temperature of about 750°F., gas will begin to pour out of the pipe stem, and this gas may be lighted. A black liquid also will exude from the stem of the pipe, This is tar mixed with certain other products. What remains in the bowl after distillation is coke. A coke oven corresponds to the bowl of the pipe. A modern oven of the latest type is a refractory brick chamber approximately 42 ft. long and 14 ft. high, averaging 18 in. in width. The oven is filled with coal through closable charging holes in the oven top. Each end of the oven consists entirely of a self-sealing door, the removal of which permits the finished coke to be discharged by means of a power-operated pusher machine. The ovens are built in batteries, and the heating is effected by gas burned in vertical flues in the oven walls, each set of flues heating the walls of two adjacent ovens. Such ovens carbonize a charge of approximately 18 tons of coal in 18 hr., or have a daily throughput of 24 tons per oven, producing about 17 tons of coke. In times of need, the output may be increased by raising the temperature of flues, thus shortening the coking time. There is one great essential difference in principle between distillation in a clay pipe and in a coke oven. In the 18-in. oven, the distillation proceeds from two parallel walls held at a high temperature (over zooo°F.) and instead of all the coal being heated at once, the distillation is a progressive one creeping inward. The average travel of this heating is 35 in. per hour from each vertical wall, and as the volatile products are formed progressively they must push away from the interior toward the wall through the previously formed hot coke, then up the walls and Over the top of the coal charge, finally escaping through the outlet pipe. This results in a cracking of the components into many different and valuable substances not formed when the carbonizing temperature is low.

Jan 1, 1942

By R. T. Torgerson, W. A. Baginski

Alloying studies were conducted on modifications of Cb-10W-1OHf (C-129) alloy as part of a cooperative alloy development effort between The Boeing Co. and the Wah Chang Corp. The purpose of these studies was to develop a fabricable, high- strength columbium alloy with superior melding properties. The initial investigations of alloy modifications were conducted using laboratory-melted button ingots. An alloy with the composition exhibited excellent veld ductility, elevated-ternpevature strength, and fabricability. The yttrium-modified alloy was desigrzated C-129Y and was selected for further developrnetzt. Three prodziction heats of C-129Y weve processed into sheet. Welding, forming, and tensile proper-lies are presented for this material. Tungsten-are welds of. C-129Y exhibited a minimum bend radius of 1/2T in the as-welded conditioti compared to 8T for C-129 alloy. An investigation was conducted on Disil coating of C-129Y and test data are presented on oxidation resistance and effects of re-entry environments. The excellent combination of strength, fabricability, weldability, and low transition temperature of C-129Y alloy offers potential design advantages for use of this alloy in structures of aerospace vehicles. It is atiticipated that C-129Y will rapidly supplant C-129 and similar alloys clue to the versatility provided by its impvoved welditzg properties. COLUMBIUM alloys with improved properties are required to achieve better performance and efficiency of radiation-cooled structures for re-entry vehicles and recoverable launch systems. Cooperative work by The Boeing Co. and the Wah Chang Corp. resulted in the development several years ago of C-129 alloy, a high-strength Cb-W-Hf alloy.' This alloy has received favorable consideration for many advanced designs of high-temperature structures due to its excellent combination of properties. However, this alloy exhibits low weld ductility unless given a high-temperature stress-relief treatment. For this reason the development effort was directed towards modification of the C-129 alloy composition (Cb-1OW-1OHf) to eliminate the need for post-weld heat treatment. This paper describes the successful development of an alloy meeting this requirement. This new alloy was designated C-129Y and has a nominal composition of EXPERIMENTAL PROCEDURES Alloying Studies. Various Cb-W-Hf compositions were investigated using are-melted button ingots. These buttons were hot-forged using a protective glass coating and rolled into sheet specimens. Metal-lographic examination: tensile testing, and welding studies were conducted to evaluate properties of the experimental alloys. Sheet Fabrication. Three pilot production heats of C-129Y were fabricated into sheet to establish processing techniques and to determine sheet properties. The three heats consisted of 6-in.-diam ingots weighing from 140 to 250 lb. The ingots were prepared by electron-be am melting followed by vacuum-arc melting. The hafnium and yttrium additions were made during the are-melting operation by tack welding alloy strip additions to the Cb-W master-alloy electrode. The final ingots were machined into billets with samples of the machine turnings collected for chemical analysis. Ingot breakdown methods for the three heats are as follows: Ingot Ingot Heat Size Weiaht___Breakdown Method A 6 in. 250 lb Hot extrusion B 6 in. 140 lb Hot forging C 6 in. 250 lb Hot extrusion Sheet bars from the extrusion and forging operations were conditioned, recrystallized, and rolled into sheet. Initial rolling was conducted at elevated temperatures and final rolling was conducted at room temperature.

Jan 1, 1967

By Anthony S. Spearing

The vast majority of the estimated 100 million rock anchors installed in mines in the USA per year use resin cartridges (Tadolini and Mazzoni, 2006). About 4.5 million per annum of these are bolts with a mechanical shell that if properly installed become effective active supports on installation. In addition, cable anchors (mostly passive) are installed with typically 4 ft of effective resin anchorage length sometimes with mechanical shells, which further makes the installation more difficult. This is because the cable (even with a stiffener tube) is not very rigid. When installing bolts with mechanical shells and cable bolts in the holes, the back-pressure can be so high that the installation is unsuccessful often creating a ?spinner? (an un-tensioned bolt) at best or buckling the bolt thus requiring another bolt/cable to be installed, or leaving a poorly functioning unit. The installation problems can create a significant potential safety hazard and waste time and money. Using a purpose designed test rig that physically inserts different rock anchors into pipes with resin and measure the back-pressure developed with time during the insertion/ installation. The test installation procedure is designed to mirror that used underground by rockbolt operators in coal mines. In addition a computer model has been calibrated that can predict the approximate back pressure of new anchor and resin combinations acting as a screen before physical testing. This research has lead to an understanding and quantification of the insertion back-pressures and this already resulted in improved prototype designs that could lead to more reliable mechanical shell and resin bolt installations.

Jan 1, 2009

By L. W. Helle

The investigation, which was conducted at Iscor's Newcastle works (in Natal), was aimed at the development of reliable, consistent, and cost-effective methods of sampling. In the sampling of hot metal, it was found that lollipop and spoon samples had identical sulphur analyses, and negligibly different silicon analyses. Thus, spoon sampling of the hot metal was implemented, with a resultant saving of over RIOO 000 per annum on lollipop samplers. In the sampling of steel, aluminium -killed samples were found to have lower phosphorus analyses than titanium killed samples. Spoon sampling was rejected in this application since the use of titanium wire would be too costly. It was decided that titanium would be used as the deoxidant in lollipop samples of steel, and that the Leco carbon! sulphur analyser would be used as the sole arbiter of sulphur content.

Jan 1, 1983

By V. C. Pandolfelli, P. Bonadia, F. A. O. Valenzuela, L. R. Bittencourt

Refractories for aluminum cells, if not properly selected, can lead to increased energy consumption and even shorten the pot life. Based on recent advances in understanding the deterioration mechanism of cathode materials, several commercial bricks in the SiO2-Al2O3 system were compared to the one used by an Alcoa smelter. Both physical and chemical properties were considered in the selection of the refractories. A more reliable method of permeability measurement, which takes into account inertial and viscous effects during the fluid flow, was applied. Additionally, the traditional cup test and other characterization techniques, such as thermal conductivity, X-ray diffraction, and mercury porosimetry, indicated that a brick with a relatively low alumina/silica ratio, presenting low open porosity and low permeability, far exceeded the performance of the brick currently in use.

Jan 1, 2004

By A. Bouajila

To stay competitive in an open market, mineral industries have to optimise their processes, lower their production costs and improve the commercial value of their products. Up to a recent past, they were impaired in this attempt by a lack of adequate devices allowing reliable on-line and real-time process monitoring (detection or measurement). Process monitoring for process control and the product characterisation for quality control are quite different tasks. Planners and researchers should be fully aware of this when evaluating or developing monitoring equipment for on-line process control. This paper will comment on some aspects of sensor specifications, during the design and the evaluation steps, related to sampling, measurement (accuracy, sensitivity, delay and correlation to the process) and suitability to the exploitation environment. Examples of R&D projects promoted by COREM for various industrial applications will be presented.

May 1, 2001

By J. Patrick Powers, Arthur B. Corwin

Modern improvements in hydrogeology make it possible to predict with good reliability the performance and cost of ground water pumping systems in many tunneling situations. The testing and analysis techniques are presented. Data from the Buffalo NY LRRTS (1978-1980) illustrate the successful application of the technique for tunneling in rock. Data from the Red Hook Interceptor Tunnel in Brooklyn NY (1978) illustrate the application in soft ground. The Red Hook project also illustrates concerns for the side effects from dewatering, such as ground settlement and damage to timber structures. At Red Hook protective measures included compressed air, artificial recharge and controlled dewatering. Given the uncertainties of the underground, the possibility of unexpected situations must be considered. A hard rock sewer tunnel in Atlanta, Georgia (1982) illustrates an unexpected problem, and the emergency measures used to solve it.

Jan 1, 1985

The sudden. explosion of relatively inexpensive digital process control computers has accelerated interest in the possibilities of economic savings by their use. In particular the metalliferous industries have shown that they are willing and capable 6f grasping this new technology and putting it to good use. These industries have a number of problems which need special attention. In many cases the process is difficult to measure and a reaction is often controlled by measuring a secondary effect, computing its relationship to the reaction and then applying the necessary corrective action. This creates problems in building the process model, designing the computer to process interface and in the subsequent system development. Environmentally the metalliferous industries create conditions which severely test sophisticated electronic equipment. Care taken in locating and housing this equipment is a major factor in ensuring reliability in Operation.

Jan 1, 1977

By S. S. Deshmukh

An important element of evaluating a materials- handling system by simulation lies in being able to examine the details of the proposed operation in a fashion which closely approximates real behavior. The added factor of flexibility permits including or deleting those parts of the problem which can be shown to be important or trivial. Used carefully, simulation can match manpower and equipment far more efficiently than conventional calculations. The same is true of interacting equipment systems. This efficiency results from being able to simulate the real fluctuations in a system by using empirical probability distributions compiled from existing operations. Simulation eliminates guessing as to efficiency, absenteeism, bunching, and the broad host of delays that influence productivity and substitutes operating data in place of the usual factors. In this respect, simulation improves detail and confidence in the reliability of engineering estimates.

Jan 1, 1970

By J. Partyka, J. S. Stachulak

Dust produced during blasting in a copper/nickel based mine was studied and characterized. A stope utilizing the crater blasting technique, or the vertical retreat mining (VRM method), was examined. Two dust monitors were used to measure an airborne dust produced during blasting operations. The data collected in situ was primarily used to formulate the boundary value problem for a generalized equation that describes the transportation process of airborne dust from all places where dust is produced by the VRM mining method. The field data was also used to define the analytical forms for the initial and boundary conditions, to provide a simple and reliable equation for flow of dust in a stope vicinity, and to identify the non-measurable constants. The effects of the amount of blasting material and of the ventilation system in use on dust concentration are also discussed.

Jan 1, 1995

By J. Litsenberger, T. E. Marshall, P. R. Coyle, L. J. Prosser, A. T. Iannacchione

For the first time in an underground stone mine, the relationship between roof movement and microseismic emissions was examined in conjunction with two distinct roof fall areas. As roof monitoring increases in acceptance and monitoring technology advances, the goal of providing reliable roof fall detection systems to enhance the safety of underground mine workers moves closer to reality. Instrumental to reaching that goal is the ability to interpret accurately and completely roof movement and microseismic emissions, which can serve as precursors to roof falls. This paper examines the capabilities of convergence and microseismic monitoring systems to better understand roof rock failure mechanics and to anticipate roof falls. An understanding of how these techniques are used and how they interact with each other is critical in developing the most effective ground control strategy for our nation’s mines.

By Ronald L. Longwell

PROPERTY LOCATION Located in the Copper Creek area of the Galiuro Mountains, the Old Reliable is on ground first claimed for mineral value during the Civil War. The deposit was mined sporatically from 1880 to 1919 and again in 1953 and 1954, with a total of about 30,000 tons of ore removed. The ore body is a near vertical breccia pipe containing approximately 4,000,000 tons of 0.80% copper with mineralization occuring as chalcocite, chalcopyrite, malachite, chalcanthite, and chrysocolla. The host rocks are extrusive lavas of cretaceous age which were intruded and mineralized by Copper Creek Granodiorite, which is Laramide in age. The ore zone, which occurs on the toe of a ridge, is about 300 feet by 600 feet in plan, with the bulk of the deposit extending from the surface to a depth of 500 feet.

Jan 1, 1974

By Evangelos Spyridonos, Thomas Frommer, Wolfdietrich Skala, René Prissang

Operational grade modelling is a technique that uses production data to run daily updates of property models. It will enable mining engineers to use property predictions based on the most recently acquired data as support for quality control and decision making. The approach necessitates that the properties of the run- of-mine material can always be attributed to individual mining blocks or charges. The software employed must be highly reliable, because a system failure or the loss of data could seriously affect the mine's quality management. An operational grade modelling system has been developed for the Breitenau magnesite mine. It makes use of the Linear Octree Based Property Modelling system which was conceived and realised at the Free University of Berlin. This paper describes the system design and gives an account of the experiences during the first six months since system start-up.

Jan 1, 1996

By J. Litsenberger, T. E. Marshall, P. R. Coyle, L. J. Prosser, A. T. Iannacchione

For the first time in an underground stone mine, the relationship between roof movement and microseismic emissions was examined in conjunction with two distinct roof fall areas. As roof monitoring increases in acceptance and monitoring technology advances, the goal of providing reliable roof fall detection systems to enhance the safety of underground mine workers moves closer to reality. Instrumental to reaching that goal is the ability to interpret accurately and completely roof movement and microseismic emissions, which can serve as precursors to roof falls. This paper examines the capabilities of convergence and microseismic monitoring systems to better understand roof rock failure mechanics and to anticipate roof falls. An understanding of how these techniques are used and how they interact with each other is critical in developing the most effective ground control strategy for our nation’s mines.

Jan 1, 2004

By W. I. Enderlin, P. O. Jackson, J. A. Glissmeyer, K. B. Olsen

A reliable estimate of radon emissions to the environment from underground uranium mines was obtained through measurements of radon in ventilation air at 24 mines and from estimates of radon release from other mine sources. The total production of U308 from the mines sampled represents about 63% of the total U.S. production from underground mines (1978 statistics). Wide variation in the radon emission rate per unit of production was found from mine to mine. Using the total radon emitted and U308 produced by all mines sampled, an average of 26.7 Ci of radon was emitted per ton of U309 produced. The investigation includes a brief study of the sources of variation of the emission rates. A statistically significant relationship was found between the measured radon release rate and the cumulative ore production at several mines.

Jan 1, 1981

By Robert Sutton, Milan Sjaus

Conveyor pulleys are an important and integral component of a conveyor. Conveyors work in sequence to make up conveyor systems. Each conveyor system is only as reliable as its crudest component. If the pulley fails, then the whole material handling system stops. So what is the effect of this downtime? What are the costs of repair? How much are we willing to pay to solve the problem? What should we spend to prevent an unscheduled shutdown? Do we use the technological improvements at our disposal or do we ignore them to satisfy immediate cost savings? This study will focus on the cost of pulleys relative to the total conveyor cost, the cost of downtime, the maintenance costs and the costs for resolution of the problem. Some philosophic and design concepts are injected for illustration and discussion.

Jan 1, 2000

By Maurice Bottiau

When dealing with displacement auger piling, some general and fundamental issues have to be considered, irrespective of the system. More than with other pile types, the interplay between the soil conditions and the design and execution is of outstanding importance. This paper intends to address these issues and to summarize some critical matters in terms of design, execution and control such as : ? Importance of a reliable soil investigation ; ? Summary of the design as it is addressed in Europe for this category of piles ; ? Criteria for a good choice and control of the correct asset of the piles ; ? Importance of the concreting phase; ? Relation between the power and the engine characteristics of the drilling equipment with the final bearing capacity. For each of these issues detailed examples will be given as well as results of load tests and in-situ control during execution.

Jan 1, 2003

By George E. Niewiadomski

The exposure of miners to radon gas and its airborne daughter products is a serious health problem which has long been recognized in the uranium mining industry. The association of high exposure to alpha particle emitters with incidence of lung cancer is well established. There continues to be a pressing need to reduce and eventually eliminate the high incidence of occupational lung cancer among uranium miners through the development of new and improved measurement and control technologies. This paper highlights the current efforts of the Bureau of Mines radiation hazards research program. It is aimed at obtaining a fundamental understanding of the behavior and transport of radon and radon daughters, developing more accurate and reliable instruments and measurement methods and developing cost-effective control techniques. Also discussed are the most recent accomplishments and the future research plans of the program.

Jan 1, 1981

A large scale distributed process con-trol system has been successfully applied to the automatic control of aluminium reduction cells at Boyne Smelters. A three stage hierarchy of minicomputers and microcomputers is used to continuously monitor and control conditions in each cell and to manage the data generated during the process.The automation hardware was purchased on the basis of low cost, high reliability, prior use in the aluminium industry and a high level of backup under failure conditions. The hardware has met performance criteria to date.The process control strategies have continually been updated to minimise the energy and raw material consumptions in each cell. A major change to systems software has recently been made to decrease the development time for-future changes. Various low energy potline retrofit alterations are currently being investigated requiring significant changes to the process control strategies.

Jan 1, 1985