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By Frank Rausche

Without doubt, driven piles are the most economical deep foundation element for a nearshore environment, providing for high bearing capacities and stiffness, quick installation times, assured quality by simple monitoring and inexpensive dynamic load testing during restrike testing. However, when the pile top elevation is several meters below water surface, questions often arise as to the most reliable and economical pile installation method. Frequently encountered, yet relatively expensive, solutions include driving inside a dewatered cofferdam, driving long piles that are later cut off below water surface, or using an underwater hammer. Arguably, the most economical solution is driving the piles with a follower or chaser. However, many foundation engineers shy away from this solution because of the uncertainty associated with the transfer of energy through the interface between follower and pile, the associated potential driveability problems and maybe the limited fatigue life of the follower. This paper will demonstrate how the driveability of a hammer-follower-pile-soil system should be analyzed prior to installation and how to model the pile-follower interface both for steel and concrete piles. As an example, results will be presented which were obtained for both steel pipe piles and precast concrete piles, driven by a single-acting diesel hammer through a steel follower for a pre-construction test pile program in Venice, Italy. While analysis of the steel pile-follower system was straightforward, for the concrete piles, the presence of a soft cushion material whose material properties changed continuously posed some difficulty. Pile Driving Analyzer® measurements and CAPWAP® analysis yielded not only realistic stresses and transferred energy values in the pile, but also reasonable model parameters for further use in a pure wave equation analysis. As a side note for clarity, the dynamic measurements and analysis results herein presented are based on the GRLWEAP and CAPWAP software. GRLWEAP is commonly used all around the world for the preparation of pile driving jobs. The program either yields a bearing graph that relates bearing capacity and pile stresses to blow count or set per blow or it predicts blow counts and pile stresses as a function of pile penetration. These results allow the contractor to estimate driving time and select an economical hammer and driving system for a safe and efficient installation. CAPWAP on the other hand is the analysis of choice once a pile has been installed and records of pile top force and velocity have been acquired during installation or during a restrike test. CAPWAP is a signal matching program which calculates for one particular impact (for example at the end of driving) the static and dynamic soil parameters. Its final results include the calculated resistance distribution, the complete stress history in the pile and also a simulated load set curve. The CAPWAP calculated dynamic soil parameters can also be used in a Refined GRLWEAP analysis to generate a calibrated bearing graph."

Jan 1, 2006

By H. Y. Sohn, Joshua E. Ramos, Moo Eob Choi

"A new technology for ironmaking based on direct gaseous reduction of iron ore concentrate is under development. This technology would drastically lower CO2 emission and reduce energy consumption by nearly 38% of the blast furnace requirements. Experiments were performed using iron oxide concentrate at 1150oC in a bench-scale facility, which was the highest temperature that could be reached in the facility. The reduction extent was determined at residence times of 3.5 - 5.5 seconds in which the reduction extent approached 43% with 0% excess H2 and 95% with 860% excess H2. Separate kinetics measurements showed that the rate is much faster at 1200 - 1400 oC. Experiments were also carried out using syngas (mixtures of H2 + CO). About 90% reduction in 3.5 seconds with 860% excess hydrogen contained in the syngas demonstrated sufficiently fast reduction for a suspension process and the feasibility of usingsyngas instead of pure hydrogen.IntroductionDespite the improvements in the modern blast furnace (BF) process, it suffers from many drawbacks. The process requires the feed in the form of sinters or pellets and high-grade coking coal. Thus, BF iron production is projected to decrease gradually [1]. The main factors for this are the environmental regulations [2] and the high capital investment cost.A large number of new ironmaking technologies have been developed or are under development [3]. Most of these processes, however, are not sufficiently intensive to replace the blast furnace because they cannot be operated at high temperatures due to the sticking and fusion of particles. Therefore, a new technology is under development for producing iron directly from fine concentrates by a gas-solid suspension technology, which would reduce energy consumption by about 38% of the amount required by the blast furnace and drastically lower environmental pollution, especially CO2 emission, from the steel industry."

Jan 1, 2009

By Jaroslav Horskoý, Miroslav Raudenský, Bogdan Filipic, Božidar Sader

This paper describes main elements and practical use of the computational system for automated setting of optimized casting conditions in the continuous casting of steel. The system consists of the heat transfer model of the process, empirical metallurgical criteria, and optimization algorithm. The physical model of the, strand temperature distribution relies on the classical Bennon-Incropera mixture continuum formulation for the convective-diffusive heat transport. Fluid flow effects are considered through enhanced thermal conductivity of the liquid phase. The model is solved by the operator-splitting Crank-Nicolson finite volume version of the Voller-Swaminathan scheme. The solution procedure is coupled with the IDS solidification analysis package. Boundary conditions for the strand cooling rely on combination of the generic and plant-specific mold, spray, and roll heat transfer coefficients ' by coping the effects of the casting speed, casting temperature, casting powder, mold oscillation mode, steel grade, water or air-mist spray type, running water, trapped water on the rolls, and radiation. The caster safety and productivity and the quality of the strand are related to nine empirical metallurgical criteria. The criteria ensure the caster safety and economy as well limit the internal, longitudinal, and transversal surface cracking possibility. The problem of finding optimum casting parameter values is stated as a minimization problem based on the analytical form of the cooling criteria evaluated from the steady-state temperature distribution of the strand. To solve the optimization problem, a genetic algorithm is employed. The algorithm explores process parameters settings heuristically by applying the principles of biological evolution. It starts with a random set of solutions and iteratively improves them through selection and variation. Solutions are evaluated by running the heat transfer model of the process and extracting the values of the empirical metallurgical criteria.

Jan 1, 2000

By Muhammad Tawalbeh

The calculated temperature history of a single particle of MgCl2 hydrates when it came in contact with fused salt electrolyte at 650 °C was determined using the measured heat transfer coefficient for the molten salt bath at 650 °C. The calculations revealed that the entire interior of the particle reached the temperature required for the formation of MgOHCI from hydrated MgCl2 in less than 2 seconds. This was much less than the time required for dissolution of the prills as observed in experiments. It is very likely that the formation of MgOHCI during prill dehydration and dissolution is a result of hydrolysis in the interior of the prills.

Jan 1, 2004

By Y. Faitakis

In the mining industry, maintenance is a key priority and a major expense. As mining equipment is large in scale, high in cost, and difficult to tow, it is key to maintain equipment on a timely basis. Breakdown in -40°C or away from a maintenance station can cause great costs in repair as well as lost production. It has often been quoted that about 5% of the North American production is lost every year due to unscheduled downtime. About one-third of the downtime is attributable to equipment failures. From this fact alone, it is evident that proper equipment maintenance can add tremendous value to the bottom line. As organizations and equipment become more sophisticated, maintenance expectations begin to evolve. This evolution can be traced through three generations: The first generation (1940?1950): A ?fix it when it broke? attitude prevailed during that time, mostly because the industry was not highly automated. The second generation (1950?1980): Automation and mechanization of the industry increased. The industry now was dependent on machines performing the majority of the work. Preventive maintenance (overhauls at fixed intervals) appeared as the first maintenance practice. Maintenance costs started to rise rapidly. The third generation (1980?): Assets become more complex. Failure modes are better understood and computerized maintenance methods are becoming mainstream. Condition-based maintenance (CBM) starts to gain ground as a cost-effective alternative, replacing the fixed interval overhauls. As corporations amalgamate and market places are becoming more complex, multi-functional teams become responsible for maintenance. At the beginning of the third generation, maintenance organizations began embracing technology to provide efficiencies in maintenance management. A strong push was made to transition from reactive maintenance to proactive maintenance. At the forefront of this push is condition-based maintenance.

Jan 1, 2004

By Y. Faitakis, G. J. Powley, C. Mackenzie

"In the mining industry, maintenance is a key priority and a major expense. As mining equipment is large in scale, high in cost, and difficult to tow, it is key to maintain equipment on a timely basis. Breakdown in -40°C or away from a maintenance station can cause great costs in repair as well as lost production.It has often been quoted that about 5% of the North American production is lost every year due to unscheduled downtime. About onethird of the downtime is attributable to equipment failures. From this fact alone, it is evident that proper equipment maintenance can add tremendous value to the bottom line. As organizations and equipment become more sophisticated, maintenance expectations begin to evolve. This evolution can be traced through three generations:The first generation (1940–1950): A “fix it when it broke” attitude prevailed during that time, mostly because the industry was not highly automated.The second generation (1950–1980): Automation and mechanization of the industry increased. The industry now was dependent on machines performing the majority of the work. Preventive maintenance (overhauls at fixed intervals) appeared as the first maintenance practice. Maintenance costs started to rise rapidly.The third generation (1980–): Assets become more complex. Failure modes are better understood and computerized maintenance methods are becoming mainstream. Condition-based maintenance (CBM) starts to gain ground as a cost-effective alternative, replacing the fixed interval overhauls. As corporations amalgamate and market places are becoming more complex multi-functional teams become responsible for maintenance.At the beginning of the third generation, maintenance organizations began embracing technology to provide efficiencies in maintenance management. A strong push was made to transition from reactive maintenance to proactive maintenance. At the forefront of this push is condition-based maintenance."

Jan 1, 2004

By David A. Monaghan, Kenneth R. Maser, Adi R. Gurdar, D. Randolph Berry

RECOMMENDATIONS FOR FURTHER WORK Based on the development effort and full-scale tests conducted during this program, a number of technical areas for future research and development have been identified. Further work in these areas would help to improve the reliability, speed of operation and efficiency of the remote sealing system. Recommendations for future work are summarized as follows 1. Development of an Inert Gas Generator For the sake of expediency in conducting the field test program, fresh air was used as the fluidizing medium for the fly ash. However, in an actual mine fire application the use of fresh air is likely to be prohibited. An inert gas, such as nitrogen, carbon dioxide or air containing less than 8 percent oxygen would be required. Using combustion as a means of reducing the oxygen content of air appears to be an attractive solution to the generation of the high flow rates of gas required (2500 to 5000 scfm). Such an inert gas generator would serve a dual purpose for the overall fire extinguishing operation. First, it would provide the inert gas for fluidizing the fly ash. Second, it could be used for inerting the fire area after the seals had been placed, thereby reducing the time required to extinguish the fire. It is recommended that the Bureau undertake a program to develop a field-operable, inert gas generator to satisfy these two requirements. 2. Development of a Field-Operable Sonar Initial Probing System A first stage prototype of a sonar initial probing system was developed during this present program. The results obtained with

Jan 1, 1973

By E. Barsky

"Theoretical notions of mass transfer processes in cascade separation of bulk materials have not been adequately developed as yet (Barsky M.D. 1980). In this paper we have derived linear difference equation of the second order for a cascade with initial feeding top any stage proceeding from mass exchange regularities. The solution of these equations has allowed us to determine quantitative dependences of the material distribution over the cascade stages, which serve the basis of the method of predictive estimate of the process results. We have also examined the model of the material distribution coefficient formation at individual cascade stages.We have checked the adequacy of this model to experimental data. It is noteworthy that the obtained theoretical results are phenomenological, i.e. they can be applied to the processes of separation of different physical nature, e.g. of isotopes, liquid media, gases, etc.INTRODUCTIONRecently, the processes of cascade separation of bulk materials have found broad application in various industries. They ensure a high separation efficiency and high-quality composition of final products. Although specialized literature gives serious attention to cascade processes [1], their theory is not sufficiently developed yet. To achieve optimal organization of this process, we examine mass transfer in a cascade gravitational classifier with stages of identical design."

Jan 1, 2016

By Marilia S. de Magalhaes

Keywords: sinter, characterization, agglomeration, iron ore Iron ore sinters are the main burden of blast furnaces for pig iron production. The evaluation of these agglomerates is very important due to their properties affect indirectly the productivity and costs of production of the steel industry. In the sintering plants, the standard procedure of sinter assessment has been carried out by particle size control, bulk chemical analyses, tumbler and/or shatter tests and determination of reduction degradation and reducibility indexes. Microscopy techniques have just been applied to characterize sinters produced in pilot conditions, however, these techniques, the classical ones and the less traditional, allow enhancing the industrial sintering process assessment. For investigation of the phases, microstructures and fabric, reflected-light and scanning electron microscopy(backscattered electrons images) were used; for micro analytical chemical examination, energy-dispersive X-ray spectrometry; for Kikuchi patterns registers, electron backscattering diffraction. In addition to the microscopy techniques, the magnetic behavior was depicted by means of magnetic susceptibility measurements. Iron ore sinters are made up by hematite, magnetite, silicoferrite of calcium and aluminium and silicates. These phases develop either during sintering or, in some proportion, represent remnants of ores and fluxes; this is the case of some hematite and Mg-bearing silicate, respectively. From the magnetic susceptibility results, three different behaviors were determined, which are directly related to the magnetiteproportion in the samples. The phase association and proportion, the sintering conditions andthe quality assessment are some features appraised by such procedures, which reveal themagnitude of this proposal in sintering plants.

Jan 1, 2005

By THOMAS J. CLIFFORD

IN 1926, finer grinding began to be a feature of the milling practice of the Southeast Missouri lead district. Nothing since the adoption of flotation has caused greater changes and greater improvement in results. The trend toward finer grinding, with the consequent discarding of tailing at finer sizes, and consequent lower assays in lead, continued to progress until 1931, when the abnormally low price of lead brought a halt: that is, the better metallurgical results obtained would not offset the increased costs due to higher power and necessary maintenance. Since 1931 a slight tendency toward the discard of coarser tailing has taken place. , In 1926, larger rod mills i.12 ft. 1 in. by 6 ft. 6 in.) than any previously used in the district were installed in cue plant, and a new primary crushing plant, of greater capacity was built. This combination demonstrated immediately the better metallurgical results obtainable by finer grinding and all the mills now running have adopted the practice.

Jan 1, 1934

By H Askari-Nasab, E Torkamani, M M. Badiozamani, S P. Upadhyay, M Tabesh

"Decision-making in mining is a challenging task. Optimal decisions regarding shovel and truck allocations, aligned with the optimal short-term production schedules, are crucial in keeping the operations in line with the company’s long-term objectives. In this paper, we present two main modelling components as the means to achieve near-optimal operational plans: a mixed integer linear goal programming model to allocate trucks and shovels to mining faces over a shift-by-shift basis so that operating costs are minimised and resource utilisations are maximised through the planning horizon a discrete-event simulation model to investigate the behaviour of a truck-and-shovel haulage system in the presence of uncertainty within mining operations. The goals integrated into the mathematical model are to: maximise production minimise deviations from the target head grade minimise deviations in tonnage feed to the processing plants from the desired feed minimise operating cost.The mathematical model provides shovel assignments and the target productions as an input to the discrete event simulation model while meeting the desired goals and constraints of the mining operation. We illustrate the applications of the discrete event simulation model by presenting a large-scale oil sands case study. The main contribution of this work thus far is the development, implementation and verification of a simulation model with a link to optimal short-term mine schedule and extraction sequence of mining faces, which assists in achieving a high level of mine plan compliance across short-term planning and operational planning time horizons.CITATION:Askari-Nasab, H, Upadhyay, S P, Torkamani, E, Tabesh, M and Badiozamani, M M, 2014. Simulation optimisation of mine operational plans, in Proceedings Orebody Modelling and Strategic Mine Planning Symposium 2014, pp 299–312 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Nov 24, 2014

By Francis P. Sinn

IN the zinc smelting industry the year 1947 seems to have been one of putting one's house in order rather than one of any material technical development or radical change in operating conditions. Labor generally has been in better supply but several plants report a scarcity of skilled workmen. Some plants continue to operate on the basis of a six-day week and will probably continue to do so until labor is more plentiful. Only one plant is known to have operated on a curtailed basis because of labor shortage, but here the difficulty was lack of proper housing facilities. Necessary materials and equipment for much-needed maintenance and modernization have been in short supply so these programs have often been delayed. Laborsaving devices of the "Payloader" type have been more generally used for handling materials. Slab zinc production was discontinued during the last months of the year at Danville, 111. and at Langeloth, Pa. Both of these plants used the Hegeler type of furnaces fired with producer gas. It is understood that the rolling mill and possibly the acid plant at Danville will continue to operate. At Langeloth acid will be produced from

Jan 1, 1948

By Ö. Genç

In this paper, full-scale mill data collected from three different circuit configurations in cement plants demonstrated the size reduction performance of dry ball mills in relation with the ball size classification achieved by the classifying liners used in the grinding compartments. Findings indicated that, breakage rates at the last 2 ~ 4 meters of the mill are not sufficient to give reasonable size reduction ratios for the production of fines. Application of only damming rings without classifying liners resulted in inverse ball size classification which lead to reduction in size reduction performance thus specific breakage rates.

Jan 1, 2014

By M. Melih Demirkan, Juan J. Gutierrez, Raghav Ramanathan

"As the capital of the United Arab Emirates (UAE), Abu Dhabi is one of the world’s fastest-developing cities. To sustain its significant growth rate, Abu Dhabi must surmount challenging engineering problems in the most efficient manner. One of the challenges facing Abu Dhabi is ground settlement caused by poor groundwater control practices in inherently difficult subsurface conditions. For construction projects in Abu Dhabi located near the Arabian Gulf, groundwater is frequently encountered and must be accounted for and addressed during design and construction. Abu Dhabi City CenterRecently, the Abu Dhabi government developed a geodatabase by digitizing, processing and qualifying an extensive amount of existing information (i.e., more than 26,000 borehole logs). Because of the evaluation and processing of the geodatabase, detailed maps of geotechnical and hydrogeological surface features were generated using 3D modeling. Ultimately, the geodatabase was used to develop risk maps indicating geohazards, such as sabhka (or salt flats), uncontrolled fill and cavities. This information identifies the location and extent of the areas vulnerable to surface subsidence. Dewatering can change pore water pressure, which, in turn, alters the effective vertical stress in a soil mass and can affect groundwater chemistry. Changes in pore water pressure and groundwater chemistry can significantly affect soil and rock. The potential effects of dewatering include:• Change in effective stresses and shear strengths in soils• Increase in seepage velocities and pressures• Erosion or transport of soil particles and piping• Settlement• Collapse of subsurface cavities or voids• Transport of groundwater containing contaminants• Dissolution of soluble materials, such as rock salt or gypsum"

Jan 1, 2017

By Mizraim Uriel Flores, Elia Guadalupe Palacios, Sayra Ordoñez, Iván Alejandro Reyes, Ister Mireles, Martín Reyes, Francisco Patiño, Hernán Islas, Víctor Hugo Flores

This paper presents the characterization of a sample of mercury jarosite that was synthesized by slowly adding Hg(NO3)2H2O into a Fe2(SO4)3nH2O solution. X-ray diffraction (XRD) analysis performed on the sample confirmed that the compound presents a crystal phase corresponding to mercury jarosite. Analysis through Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM-EDS) determined that the precipitate is composed of mercury, sulfur, iron and oxygen. It is made up of spherical particles with an average size of 38 μm; these particles are made of rhombohedral micro-crystals with sizes ranging between 1 and 2 μm. Chemical characterization was performed through dichromatometry analysis, gravimetry and atomic absorption spectroscopy (AAS), thus obtaining the following composition: 27% Fe3+, 37% SO4 2− 14% Hg2+, 22% OH− + H3O+ + H2O. The following approximate formula of the compound was determined from chemical analysis: [Hg0.39(H3O)0.22]Fe2.71(SO4)2.17(OH)4.79 (H2O)2.09.

Mar 1, 2017

By Arel B. McMahan

The U.S. Bureau of Mines investigated 21 mines, prospects, and mineralized sites in and adjacent to a 38,713-acre portion of the 255,058-acre Kingston Range Wilderness Study Area in 1983. The study area is 35 miles north of Baker, CA in the Mojave Desert. Mineral deposits in and adjacent to the study area are in altered carbonate rocks intruded by diabase sills near monzonite porphyry contacts. Monzonite porphyry forms the core of the Kingston Range and underlies about 70 percent of the study area. Sedimentary carbonate rocks are exposed in bands on the north and east boundaries and as isolated roof pendants in the southeastern portion of the study area.

Jan 1, 1986

Jan 1, 1924

Jan 1, 1924

By Shaohua Ju

Siderite ore is abundant around the world, due to its inert properties of low grade, mudding when milling and low magnetic, and it is very hard to be beneficiated. Nowadays, decomposition by roasting becomes the main process for utilization of the siderite ore. The methods of energy input for roasting are normally electrical heating, coal or gas combustion. Because traditional roasting methods owns some disadvantiges, such as low energy utilization, high cost and/or large exhaust pollution, only about 10% of the siderite ores in China were used as iron concentrate. In this work, the possibility of roasting siderite ore with microwave energy is studied by both laboratory and pilot experiments. The result of laboratory experiments showed that the optimized condition is roasting for 20 min with a power density of 3 W/g, and the Fe content of the final sample obtained is about 59.12%. The pilot experiments result showed that the decomposition is thoroughly, and the main phases of the roasted material are magnetite and wustite, and the energy consumption of the roasting process is 695.8 KWh/t.

Jan 1, 2014

By P Holtham, K Duffy, B, W Valery, E Tabosa, rade

Pre-concentration has potential to significantly improve Mineral Resource efficiency by removing gangue early in the process, before energy intensive and expensive comminution and fine processing. However, there are numerous options for pre-concentration and the performance and benefits of these are very case specific. To determine the best option for a particular deposit and to successfully integrate it into the overall mining and processing operations requires comprehensive evaluation. This needs to consider orebody suitability, technology capability and economic viability. The in-situ variability of a deposit and how it is influenced by mining methods and the liberation size of gangue are key factors which are generally not well understood. Geostatistical methods provide an insight into orebody variability, and the overall selection of any pre-concentration solution must be an integrated approach between geology, mining and processing. Many pre-concentration evaluations investigate the potential of just one option. Technology selection should start wide and may include: selective mining, pre-screening (with or without selective blasting), sorting (bulk and or particle), coarse gravity separation (e.g. jigging, DMS), coarse particle flotation, magnetic separation, etc. The upgrade performance of these processes is very ore specific and should be determined from testing, with detailed multi-component modelling used to determine the overall process performance. Many of these pre-concentration processes require significant ancillary equipment, feed preparation and materials handling. It is important to realistically estimate all costs to understand overall economics and select the best option. Some examples showing evaluation and comparison of pre-concentration options are presented in this paper. These include assessments of in-situ variability using geostatistical tools, process modelling of pre-concentration options and overall performance, preliminary layouts and cost estimates, and economic evaluations.

Nov 10, 2020