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By Jefferson Lisboa Lelis, Marcos Roberto Soares da Silva, Maiara Rodrigues Gouveia

Nowadays, due the development of new hot rolled strips at USIMINAS, established the necessity of realizing studies to define new parameters for the welding machine of new pickling line, in order to improve mechanical and metallurgical properties of these materials. The aim of this study was to evaluate the weldability of high strength low-alloy steel with low boron content with tensile strength above 600MPa.The influence of energy input and preheating temperature on the mechanical properties of hot rolled strips were analyzed at three distinct thickness (2, 4 and 6 mm). To perform these evaluations were used tensile test, micro-hardness, metallography (micro and macro examination) and scanning electron microscopy analysis. In resume, a good welding performance was achieved, increasing preheating temperature and the welding energy higher than 60%.

Oct 13, 2019

By John Anthony Vasquez

During the last years Riva Acciaio Verona has taken the decision to invest in the route of a fully automated meltshop. The aim is to reduce at the minimum the operator's intervention from the bucket preparation till the ladle transfer to the continuous casting bay. The foundation for achieving the goal is the introduction of innovative technological solutions (fully automated cranes for bucket charge in the EAF, robots for sampling, etc. The paper underlines how the different solutions are based on the best practices to improve operator's safety and describes the different steps of the project, the different solutions adopted and the results in terms of production, energy savings, cost reduction and improved safety. Details are presented for: scrap yard management and bucket preparation, EAFs centralized controls and related robots for auxiliary operations (sampling, EBT cleaning, scraper for slag door automation, complete mass & energy balance based on process control), LFs centralized controls and process integration.

Aug 16, 2017

By H. A. Doerner

"Statistics show3 that in 1927 the United States consumed 60 per cent of the world's production of chromite and produced none. The uses of chromium are rapidly expanding, and a dependable supply is essential to our industries. Since the political and commercial control of our supply of chromite is now in foreign hands it is prudent to determine how this nation can best prepare to supply its need for chromium if the imports were cut off or restricted and whether it is now possible and desirable to stimulate production of chromium from domestic deposits. We have only small amounts of chrome ore of high enough grade to meet present trade requirements. Therefore the Bureau of Mines is making a study of methods for beneficiating our low-grade ores.Chromite (Cr203.Fe0), is the only commercial source of chromium. For refractories, a minimum of 40 per cent Cr203 and a low silica content (5 to 8 per cent) is usually specified. In most instances bricks or lumps having a physical structure that will not crack when heated are required. The only way an inferior ore could be adapted to this use world be to concentrate it and develop a satisfactory binder to make bricks out of the concentrates.For making ferrochrome the requirements are a minimum of 45 per cent Cr203 and an iron content not exceeding one-third of the chromic oxide. On some low-grade ores gravity concentration will give a product meeting these requirements; other ores yield concentrates containing too much iron or other impurities to be saleable."

Jun 1, 1930

This document is Volume II of a two-volume report on underground and surface metal and nonmetal mine fires occurring between 1950 and 1979. Two surface fires from 1980 are included. Volume I discusses the methods of data acquisition, data analysis procedures, and results and conclusions. This volume contains (1) a master list of all fire incidents obtained from MSHA reports, (2) an annotated bibliography of all MSHA reports, journal articles on selected incidents, and non-reportable fires (appendix), and (3) indexes to be used in accessing incidents in the master list and annotated bibliography. These three types of information provide the reader with a complete summary of metal and nonmetal mine fires during the period from 1950 through 1979 and a convenient means to locate incidents of specific interest. The body of this volume is organized around two tables and a series of indexes. The two tables are master lists of underground and surface fire incidents. They are followed by 15 indexes keyed to the master list and annotated bibliography. The Appendix contains three different parts: ? The annotated bibliography of MSHA fire reports (one section each for underground and surface mine fires). ? The annotated bibliography of journal and other periodical articles about selected fires from the MSHA bibliography. ? A listing of non-reportable fires (one section each for underground and surface mine fires). Descriptions of the contents and use of each of the three major components of this volume (i.e., master list, indexes, and appendix) are presented in Section 2.0.

Jan 1, 1980

By R. L. Grant

[p(,ton~to'rs 'ar-IV uscG.. to explode 9crnli .... sible c}:plosivcs, dynamites, or other hiGh uxplosives. This ?,...!xplosion or detr)nation is brought about by th\.:J energy which i liberated as a cOl":"Lb' nation of concusBion and heat wl1en the ? detonator is fired. 'm Ot:18t? I'l(jrds~ liThe detonator is the key VI: ich unlocks the enerGY of a llgh? explosIve""? (8) :1/. Being sensitive nd latently dangerous, detonators ITl.ust lTIeet t\V0 primary requirerDentr: They must be ..;.afe to handle and IT. list? detonate' when (l,esired, the ... eby iIr.parting deton:l.tion to the explo8ivc cJ.1Cire-e.]

Jan 1, 1941

By Rolph Linder

It is generally known and accepted that the efficiency of the blast furnace process, expressed by the symbols specific production and coke consumption, is influenced by a large number of variables connected to the type of burden, the alloy contents of the produced iron and the conditions of production as composition and preheating of the blast, the furnace heat losses and the possible use of fuels added on the tuyere level. It is furthermore obvious, that the coke consumption of the process will be influenced by specific production which could be said to be the result of two counter-acting influences. With high production, realized through intensive blowing, the passage time of the ore through the furnace is shortened leading to a decrease of the indirect reduction taking place in the upper part of the shaft within the temperature range of 300 to 1000°C. Simultaneously the external heat losses (constant in time) will be smaller calculated on each ton of iron and the resulting change in coke consumption will be the effect of both those influences. It is certainly of interest to be able to predetermine the effect of those variables before a change in the production practice is carried out.

Jan 1, 1964

By J. P. Hansen

Reducibility tests were run by the Bureau of Mines on an open hearth lump ore and four groups of pellets whose smelting characteristics had been deter-mined previously in the Bureau's experimental blast furnace. When reduction data from various tests were plotted on specially prepared paper l-(l-percent reduction/100)1/3 against time, the plots were linear. The iron-wustite inter-face therefore advances at a constant rate. The rate of the interface advance in mm/min was used as a reducibility index. The reducibility index measured at 900° C, using 0.45 cu ft hydrogen per minute varied inversely with the surface area of the sample. Even with carefully controlled surface areas, how-ever, duplicate reducibility indices varied considerably. When enough tests were run to give a stable mean, the mean reducibility index did correlate with blast furnace production for the four pellet groups. Results indicated that if the interface speed itself were to be used for correlation with blast furnace production, a sample size of about 180 grams of minus 0.742-plus 0.525-inch particles should be used with a test temperature of 900° C and a flow of 0.45 cu ft hydrogen per minute.

Jan 1, 1966

By AIME AIME

IF the observation of our British friends is true that Americans put new records in bigness above everything else then the 150th meeting of the Institute was not the grand success it seemed to be. Just why the attendance slumped a little this year is anyone's guess, but the favourite explanation seemed to be that half the country is planning to come to the New York World's Fair this summer and that two trips from the hinterland to the me- tropolis, with another to San Francisco of course, can hardly be justified with the present condition of the stock market and the prices of the products of our mines. Certainly, some were pre- vented from coming too by the epidemic of respiratory afflictions that was rampant in February. Unfortunately. several succumbed after they had reached New York.

Jan 1, 1939

By M I. Pownceby, S Hapugoda, H Han, E Donskoi, L Lu

Iron ore sinter mineralogy and its associated macro-/micro – structure has a strong impact on sinter quality. At a macroscopic scale, sinter ideally consists of a strong, porous matrix which bonds relict ore nuclei together. Microscopically, the sinter matrix (solidified from the melt part of the initial sinter mix) generally consists of complex calcium ferrites known as SFCA, secondary magnetite and hematite grains (precipitated from the primary sinter melt), glass and silicates. Depending on the conditions under which the sinter structure is formed, two major forms of SFCA with different morphologies are generally recognised, ie fine micro-platy SFCA (usually termed SFCA-I) and coarse columnar/prismatic SFCA. Detailed optical microscope observations of several pot grate and compact sinter samples revealed the presence of a variety of fine, coarse and dense forms of both types of SFCA. The controlled cooling tests revealed that cooling rate has an impact on the form and size of SFCA crystals. In this work, EPMA analysis of SFCA compositions from a variety of pot grate and compact sinter samples are presented. Results show that the SFCA types exhibit a broad range of complex compositions within the system Fe2O3/CaO/SiO2/Al2O3/MgO/TiO2/MnO2. Although SFCA-I and SFCA are known to be crystallographically distinct and with different, well-defined ranges in composition, there was considerable overlap in compositions of the experimental sinter samples. The development of SFCA textures depend on several parameters including the local chemistry and conditions including the maximum temperature attained and the cooling rate, within the sinter bed, thereby suggesting that SFCA identification based on morphology alone may be erroneous.

Nov 8, 2021

By W. W. Albrecht

I. Introduction Refractory metals like tungsten, molybdenum, rhenium, tantalum and niobium and their compounds are essential ingredients of our modern technology. Especially in purified form, they are used in special alloys, electronics, optics and ceramics. The processing route from raw material to high purity refractory metals and their compounds includes, as a prime option, the following steps: - dissolution of raw materials. - liquid liquid extraction. - precipitation of high purity intermediate compounds. - calcination/reduction to high purity oxides/metals. Especially in the first three steps, major amounts of chemicals like acids or sodium hydroxide are used and, as by-products, substantial quantities of residues and effluents are generated. The impact of environmental regulations on these by-products and the attempt to reduce or minimize the amount of residues and effluents produced will be discussed in this presentation using Ta/Nb chemistry as the example. The basis of our considerations will be the way these by-products are handled at HCST, a major, and in some cases, the biggest producer of refractory metals (tungsten, molybdenum, rhenium, tantalum, and niobium).

Jan 1, 1992

By Robert P. Dufresne

Electrolytic cells are used in electrowinning (EW) and electrorefining (ER) of non-ferrous metals such as zinc and copper, and are a critical part of the purification process. The cell is a large basin and has an electrolyte or aqueous solution, an anode and a cathode, an insulator, and incoming high amperage. Cells are exposed to unfavourable internal and external factors that have a direct impact on their lifespan. Their deterioration can be caused by incorrect polarity, insufficient magnitude, their construction, tension stress, thermal shock, corrosion and other, and their maintenance and replacement can be time-consuming, costly, difficult and environmentally unsafe. Occupational health hazards and dangers posed by the maintenance and removal of the cell should also be taken into consideration. Modifying the design and fabrication method of the cell, using chemical-resistant reinforcement, and increasing tensile and mechanical strength will defer maintenance for a very long time. This can be achieved by a double hull system that comprises full-length composite reinforcement, polymer concrete reinforced with fiberglass pultruded rods and rebars, fiberglass structural layers, and special resin matrices. This will provide protection against thermal shocks, corrosion, leakage, cracks. The design of this cell incorporates a lifting system that will afford quick and easy install without having to move a great number of cells in close proximity, since it is strong enough to stand on its own and not have to be bonded to adjacent cells. As well, the cell can be anchored with ease as it remains stable. This is especially important because space is limited to lift and manoeuver between the cell and the double-girder overhead travelling cranes. The lifting system can also prevent electrocution and loss in product quality, while increasing efficiency and safety in the workplace. Considerable savings in terms of production downtime are also part of the equation. INTRODUCTION Maintenance and replacement of electrolytic cells in electrowinning and electrorefining are operations that pose many challenges, health and safety concerns, and give rise to substantial operational costs. These problems have existed since time immemorial. Electrolytic cells are made of conventional concrete or polymer concrete, and because of the very nature of their composition and their exposure to severe and environmental conditions, their lifespan is short. Although polymer concrete is composed of high-quality materials, and has good thermal stability and resistance to chemicals, nonetheless, maintenance is frequently required in order to maintain the integrity of the cell and to ensure the quality of refined metals. Repairing concrete is a non-permanent solution as cracks will reappear, and every repair weakens the integrity of the cell a bit more, until it reaches a knock- down point and the structure is compromised. The cell needs to be replaced, otherwise the cell will collapse.

Jan 1, 2019

By R. W. Diamond

Low-grade ores can be designated by two main classifications: (1) simple low-grade ores, and (2) complex low-grade ores. As a rule the first type has a relatively small metal content, although low- grade iron ores contain a rather high percentage of metal. As the simple type is the one that is ordinarily in mind when the term "low-grade ore" is used, the paper will be devoted mainly to ores in this general category. Cheap treatment is the prime requirement in utilizing low-grade ores of the simple type, although in some cases the value of nonmetallic by-products, such as limestone for fer- tilizer and silica for flux, allows a little more lati- tude than in the usual situation. When the costs are divided under the three headings-mining, milling, and smelting-it is apparent that the last group will not constitute an important factor as a rule because the high concentrating ratio makes the smelting cost per ton of ore fairly low.

Jan 1, 1949

By Richard L. Profio

A practical analysis of the three basic elements of a mining shovel's productive capacity. Payload Speed Reliability Improved dipper fill factor is explored referring to the latest generation of wide dippers combined with higher "bank horsepower" capabilities of modern drive systems. Cycle time improvement is reviewed including overall attachment geometry and coordination of motions. A specific case study is detailed. Basic reliability of welded structures, machinery components, and electrical systems are related to operating costs. Three basic elements determine a mining shovel's long term productive capacity: 1) Average payload per cycle. 2) Average cycle time; and 3) Reliability. This paper deals with productivity gains that are possible with existing shovels as well as new equipment.

Jan 1, 1984

By M. Kawahata

Methane sensors using principle of catalytic oxidation of methane are employed for determination of methane content in ambient air of coal mines. Certain foreign gases or vapors in the air poison the catalyst of the sensor effecting the sensor's response. After literature search of poison compounds of Pt and Pd oxidation catalyst, experimental studies of catalyst poison kinetics were made for three siloxane compounds, tributyl-phosphate, monobromotrifluoromethane, and hydrogen sulfide, selected as poison vapors. Concentration range of the poison vapors was varied in a range from 3000 to 0.1 ppb (v/v). Three siloxane vapors produced strong catalyst poison effect, followed by tributylphosphate, hydrogen sulfide and monobromotrifluoromethane for the high concentration level of the poison vapors. The poison effects are influenced significantly by concentration of the vapors. Threshold poison vapor concentrations where effect of the poison vapors on the sensor is minimal were determined experimentally. Experimental studies were made further for prevention method of catalyst poison by adsorption techniques. Use of activated carbon cloth inserted on the sensor's head prevented catalyst poisoning efficiently.

Jan 1, 1981

By Ting Ren, Jon Roberts, Zhongbei Li, Ming Qiao, Jianming Wu

Spontaneous heating of coal continues to present a health and safety hazard in underground coal mines. The influence of seam gas composition on gas flow dynamics and distribution characteristics in the active longwall goaf has not been studied in-depth, and corresponding effective proactive goaf inertization strategies for preventing potential spontaneous heating from occurring have limited investigation. To advance this knowledge, an 80-m-height goaf model was constructed and developed based on specific conditions of an Australian underground coal mine, and onsite gas monitoring data was collated to verify base model results, which allowed for various scenarios of seam gas composition to be simulated and investigated with confidence. This study involved modeling five different gas composition scenarios for the goaf atmosphere, namely, 100% CO2 (case 1), 80% CO2 and 20% CH4 (case 2), 50% CO2 and 50% CH4 (case 3), 20% CO2 and 80% CH4 (case 4), and 100% CH4 (case 5). Simulation results show that O2 is primarily distributed at the middle and upper part of the CO2- dominant goaf model, while it is mainly layered at the floor level of the CH4- dominant goaf model. N2 is superior to CO2 in the goaf inertization for the CO2- dominant goaf model, whereas CO2 performs better than N2 for the CH4- dominant goaf model. The optimal inert gas flowrates for case 1 to case 5 are 1.5, 1.75, 0.75, 0.5, and 1.0 m3/ s, and the oxidation zone area is reduced by 55.76%, 67.21%, 58.04%, 78.17%, and 81.82%, respectively. The simulation results allow for increased insight and understanding of the gas distribution patterns in the active goaf with different seam gas composition and the development of corresponding proactive goaf inertization practices, thus minimizing potential spontaneous-heating-related hazards and improving mining safety.

Sep 26, 2023

By S. J. Pearce

The need for a simple, very sensitive, and accurate method for the determination of benzene in blood and urine was evident throughout a recent study of chronic benzene (C6H6) poisoning conducted cooperatively by the United States Bureau of Mines, The Barrett Company, and the producers of benzene. A combustion method which will be described in a later publication, end a previously described5/ adaptation of Smyth's method were developed and used during that investigation. The adaptation of Smyth's method gave satisfactory results when dealing with exposure conditions that produced chronic poisoning in a comparatively few days, but it was time-consuming and lacked the accuracy necessary for a study of the absorption, distribution, and fate of benzene in the body during exposure to threshold concentrations of benzene vapor in air. The combustion procedure was satisfactory from the standpoint of sensitivity but was cumbersome, intricate, time-consuming, and required the use of special and somewhat expensive physical and. chemical apparatus. Following the termination of this study of chronic poisoning, possibilities for developing better methods occurred, and these have been investigated by the Bureau of Mines with the aid of Relief Works Division personnel. A microcolorimetric method for the determination of benzene in air has been described recently.6/ The present report deals with the adaptation of this new colorimetric method to the determination

Jan 1, 1936

By J. A. Organiscak

Enclosed cabs are a primary means of reducing the silica dust exposure of equipment operators at surface mines. The National Institute for Occupational Safety and Health (NIOSH) has investigated various factor effects on enclosed cab air filtration system performance. Factors experimen­tally investigated were intake filter efficiency, intake air leakage, intake filter loading (filter flow resistance), recirculation filter use and wind velocity effects on cab penetra­tion (inside to outside cab concentration ratio). Adding an intake pressurizer fan to the filtration system was also investigated. Results indicate that the intake filter efficiency and recirculation filter were the two most influential factors on cab penetration. Use of a recirculation filter significantly reduced cab penetration over the intake air filter by itself due to the multiplicable filtration of the cab interior air. Cab penetration was also affected to a lesser extent by intake filter loading and air leakage. Adding an intake pressurizer fan notably increased intake airflow and cab pressure while providing only minor changes to cab penetration.

Jan 1, 2008

By J. J. Jonas, G. R. Stewart, A. M. Elwazri

Two important parameters for dynamic recrystallization can be derived from the changes in the strain hardening rate: the critical strain for initiation of dynamic recrystallization and the point of maximum softening. In this work, these values are determined from the flow stress-strain data obtained in continuous compression testing in the range 900-1100°C. The resulting strains are used to calculate a kinetic model of dynamic recrystallization for two materials: 304 austenitic stainless steel and a hypereutectoid plain carbon steel. The mechanical parameters used to define the proposed model are confirmed with quantitative metallographic analysis of the recrystallized microstructure.

Jan 1, 2004

By Dipankar Gorain, A K. Vishwakarma, Vivek K. Himanshu, Murari P. Roy, Shubham Singh, R S. Yadav

The industrial establishments of a power plant consist of many important structures viz. cooling tower, wagon tippler, track hopper, plants and offices. The leveled foundation is the utmost need for erecting these structures. The leveling of the foundation is done by rock excavation, when the establishments have to be setup in hilly/rocky areas. Drilling and blasting is the cheapest and most dominant method of rock excavation. However, this method has associated hazards in terms of blast induced ground vibration, air overpressure, flyrocks etc. The foundation work and erection of the industrial buildings are done in parallel to achieve the faster construction of the establishment. The challenges to reduce the induced hazards in such cases are more. This paper presents a case study on the controlled blasting method devised for the rock excavation for construction of 2 × 660 MW Obra-C thermal power plant. The foundation work for this power plant was made by excavation of Dolomitic rock. The excavation work was performed in the proximity of the existing residence of the local people and Obra market. With the advancement of project, the excavation was also performed in the proximity to the ongoing construction work of various industrial buildings. Accordingly, the controlled blasting pattern was devised suitable to the specific sites. The pattern consisted of variations in blasthole diameter, burden-spacing, maximum explosive charge per delay, total explosive in a blasting round, initiation system and direction of initiation. The suitable muffling arrangements were also used, when the blast was conducted in the close proximity to the structures. The initial blasting pattern was established by analysis of blast vibration wave propagation characteristics. Thereafter, the final pattern was adopted for the safe excavation at the site. The safe excavation for the foundation work of this power plant has been completed successfully based on the devised controlled blasting pattern.

Feb 6, 2023

By O. P. Sinha, Biswajit Mishra, A. K. Mandal, Raj Kumar Dishwar, G. S. Mahobia, Ram ji Omar

Most of the mineral deposits found in North-East India remain unexploited due to inadequate knowledge on their status, economic viability, and requisite mining technologies. The aimof this study is to characterize the multimetallic magnetite mineral deposit from the Nagaland area in India. The quality of iron ore was evaluated to establish its suitability as a raw material for iron production. Detailed studies were conducted to establish the composition and properties of the samples. X-ray diffraction (XRD), X-ray fluorescence (XRF), electron probe micro-analyzer (EPMA), and petrographic microscopy techniques were employed in the investigation. Shatter and tumbler test was performed for analyzing the mechanical properties of the ore. XRD studies indicated that magnetite is the major mineral with low amounts of martite, maghemite, and quartz. XRF/EPMA results indicated that magnetite contains 35–65 wt.% of iron and 1–5 wt.% of chromium. It also confirms the presence of Ni and Al up to 1 wt.% and Si up to 6 wt.%. Chromite-rich ore contains up to 30 wt.% Cr and 15–20 wt.% of Fe.

May 10, 2021