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By Anthony William Deller

MAJOR battles in the present war have been fought in American research laboratories. Without the outstanding contributions made by our scientists, engineers, and technologists in mining and metallurgy, many of our achievements in the present war would have been impossible. All recognize the fact that modern research has found the answer to problems which seemed insuperable. For the duration, many of these inventions must be maintained as war secrets. But aside from these, the record of accomplishment in peace and war, especially in the past few decades, known to all, demonstrates what scientific and industrial research can accomplish. It may be regarded as axiomatic that the development of modern industry is based principally upon research devoted to making inventions and discoveries. We have come a long way from the sixteenth century, when Agricola published his classical "De Re Metallica:" With our vastly increased knowledge we are now commercially producing dozens of metals entirely unknown at that time. Further, with our modern methods of research and development, a large number of invaluable alloy compositions have been produced. These include numerous age-hardenable alloys, cupronickels, "Everbrite", "Everdur", "Duralumin", "Elinvar", "Hastelloy", "Inconel", "Invar", "Monel", "Ni-chrome", "Ni-Hard", "Ni-Resist", "Permaloy", "Silcrome", stainless steels and irons and other alloy steels, "Stellite", and zinc die-casting alloys.

Jan 1, 1945

By Akihiko Nishiyama

Unmanned construction technology used for remote control operation of construction machines has some problems to solve compared with manned operation of construction machines, such as fatigue due to long-term operation or decreases in operational efficiency. To solve these problems, we recorded the viewpoints of operators in both manned and remote control operation and analyzed the differences. This paper reports on our discussion of improving the operability of remote control operation based on the analysis results.

Aug 1, 2013

By B. Hohenstein, B. McBain, B. de Jong

"The automated fire assay system (Fast In-line Fire Assay or FIFA) has not found acceptance in the Au mining industry as the lower measurable limit of 0.20 ppm did not allow Au tailings to be measured with confidence. The development of arrested cupellation has overcome this hurdle which was a limiting factor in the FIFA 1 process. In the new automated fire assay process, automated sample preparation, fluxing, fusion and separation of a Pb button are essentially similar to the FIFA 1 process, albeit with some improvements. However, the game-changer is the development and incorporation of arrested cupellation into the automated system, now called FIFA 2. The purpose of arrested cupellation is to reduce the 50 g Pb button to a 5 g Pb button by partial cupellation in a specially developed arrested cupellation system thereby concentrating the Au in the Pb by a factor of 10 and in so doing moving them into higher concentration ranges in the mini-button where they can be read on the spark spectrometer. Results show that concentrations down to 0.02 ppm Au in geological materials can now be determined using arrested cupellation in the FIFA 2 process, an order of magnitude improvement over FIFA 1.INTRODUCTION Traditional fire assay for Au has remained virtually unchanged for 3000 years. It has survived for so long because it is accurate, has relatively low detection limits and is relatively inexpensive. However, it is labour intensive, has a long turn-around time (typically at least 7 hours), is environmentally unfriendly and exposes assay operators to potentially unsafe conditions (toxic fumes, toxic dust and extreme heat from furnaces). The NiS collection method is not as effective for the assay of Au as it is for the PGEs. A rapid, accurate, cost-effective method for the determination of Au and the Platinum Group Elements (PGEs) in geological materials would be a tremendous benefit to mining companies. Many of these objectives have been met by the FIFA 1 (Fast In-line Fire Assay) developed some 15 years ago in which automated methods have replaced the manual procedures which are part and parcel of conventional fire assay. However, concentrations below 0.2 ppm have been very difficult to achieve with sufficient reliability."

Jan 1, 2017

By J. M. Simard, S. Morissette, P. Coursol, P. Mackey

A new, powerful model is presented that focuses on plant logistics and scheduling aspects of the smelting, converting, fire refining and casting operations at the Horne smelter. This plant complex is the largest custom copper smelter in North America. It handles a wide range of feeds and utilizes a number of proprietary continuous and batch technologies that require good scheduling in order to maximize plant capacity and efficiency. The present model was developed by Xstrata Process Support, in collaboration with the Horne smelter, and uses the Arena® software to evaluate the impact of a number of plant variables on the annual copper capacity of the plant. Model development was carried out by Xstrata Process Support, in collaboration with the Horne smelter, through the effective combination of process chemistry knowledge and detailed knowledge of the plant operation (including all material flows and transfers, as well as information such as operating on-line times, plant stoppages and also scheduled and unscheduled maintenance activities). A number of case studies were then examined, including the impact of anode furnace and casting cycle times on annual copper capacity and the impact of a one-crane mode of operation in the converter aisle, which normally operates with two cranes in service. The model predictions were found to match actual plant results very well. The present modelling of plant logistics and the scheduling aspects were found to add important dimensions at the plant with regard to projections of the real-life plant capacity. As demonstrated in the present case, this type of model and application can have a significant impact on optimizing operations at a given plant. This impact is particularly important in the current market environment, where emphasis is on maximizing plant output and lowering costs. These models can help yield the easily obtained gains that are clearly desirable in these times. Xstrata Process Support has developed Arena models for other operations and is available to explore new applications for a win-win situation at other plants, including mines and concentrator operations.

Jan 1, 2009

By Thomas W. Scott, Manh N. Tran

Marine environments present a range of challenges for pile construction. This paper contains a discussion on the design and construction of marine piles for a recent Toll Shipping wharf upgrade in Burnie, Tasmania. The project involved several new structures including mooring, berthing and ramp dolphins supported by driven tubular piles with rock sockets, and an onshore mooring dolphin and ramp abutment supported by bored piles. Through the project, a range of construction challenges were experienced, including availability of tubular piles, the different penetration depths of driven piles into rock, the ability to drill out sockets when the piles were raked, the difficulty in verifying the design intent, latent conditions and ship impacts. The paper will present a summary of the different factors that influenced design concepts for the structures involved in the upgrade, and the challenges involved in the design of the structures. Following this, the paper will describe the methodology used to verify the design (including a pullout test), observations made during pile construction and lessons learned on how to limit risk throughout construction.

Nov 1, 2022

By Justin Kolster, Donald Benjamin, Kyle White

Expansion of the Plum Island Wastewater Treatment Plant requires interconnection of three operating pump stations using only two existing 10-ft diameter shafts for access. These two existing shafts require additional support to allow access 130 feet below grade. Interconnection requires rehabilitation of an existing tunnel, excavation of two new tunnels, and abandonment of additional existing tunnels. Construction has discovered unexpected conditions at all three connection points. The CMAR contracting method has effectively accommodated project team discussion, value engineering decisions, and allocation of risk during preconstruction and construction phase services.

Dec 1, 2022

By Monique Nykamp

"INTRODUCTIONTerminal 46 is located just south of downtown Seattle, and is one of the Port of Seattle’s busiest container terminals. The Terminal 46 Redevelopment Project was undertaken to replace the existing 15-m-wide (50 ft) cranes along the apron with 30-m-wide (100 ft) cranes, which can unload larger, post- Panamax ships. The project included upgrading the existing waterside crane rail with new piles and constructing a new land-side rail behind the sheetpile bulkhead. The new piles had to be installed adjacent to the existing apron without causing damage, which was a signifi cant geotechnical challenge due to the soft soil conditions at the site. An instrumentation program performed during the test pile program evaluated this challenge and allowed for the development of specifi c production pile installation procedures that had the least possible effect on construction costs and schedule.SITE HISTORYThe site lies along the west side of Elliott Bay, north of the mouth of the Duwamish Waterway. Prior to development, this area was part of the tide fl ats where the Duwamish River drained into Elliott Bay. Prior to 1970, there were several existing timber piers and structures in the area. In the 1970s, the Port of Seattle constructed a 900-m-long (3,000 ft), 30- m-wide (100 ft) apron to support fi ve, 15-m-wide (50 ft) container cranes. The contained backland area was then fi lled with dredged spoils (sand and silt with organics) and the upper 5 to 20 m (16 to 65 ft) backfi lled with sand and gravel.The existing apron was constructed using 0.4 m (16 in) octagonal prestressed concrete piles to support the precast concrete deck and crane rails. The pile-supported bents were spaced at 6.1 m (20 ft), center-to-center, along the longitudinal direction. Pile lengths typically varied from about 20 to 40 m (65 to 130 ft) with 15 to 26 m penetration below mudline (50 to 85 ft penetration). The slope below the apron was constructed at about 1.75 horizontal to 1 vertical to allow for suffi cient water depth for cargo ships. In most areas, a riprap buttress was placed at the toe of the slope. A typical cross section of the apron is shown on Figure 2.Several stability, settlement and pile driving issues arose during the original construction of T-46 (Pita, 1983). Reportedly, movement of the submarine slope occurred during pile driving, resulting in settlement behind the bulkhead. Pile driving reportedly caused settlement of adjacent piles. In addition, some piles were “running” (dropping quickly under one hammer blow) during installation."

Jan 1, 2007

By J. Y. Xu

A mutant of Phanerochaete chrysosporium, which is capable of degrading lignin, was bred by ul-traviolet ray irradiation and this mutant strain shows high capability of degrading of lignite. The degradation ratio of original Yima lignite and nitric acid treated Yima lignite by this mutant are 37.6% and 51.62%respectively, whereas those by the original strain are 31.84% and 32.55% respectively. XRD and FTIR analyses of the lignite converted product show that its polymerization degree and average molecular weight are both greatly reduced. The content of the functional groups is also been altered.

Jan 1, 2014

By A Wanninayake, E Novello, I Gillani

A residue storage facility (RSF) was designed to cater for Davidson Creek Area and Robertson Range Area operations under the FerrAus Pilbara iron ore development project in the Pilbara Region, Western Australia. Annual ore production was about 15 million tonnes over a period of up to 15 years. The RSF was designed to handle a tailings production rate of 2.2 Mt/a over the project life with ability to be expanded at a later date. The composition of tailings was predominantly -45 ¦ material with some spiral reject material. The fraction of solids was expected to be between 40 per cent and 50 per cent solids by weight.The RSF was designed as an above ground storage facility, integrating with a mine waste dump planned close to the selected RSF site. This integration helped to increase the stability of the RSF embankment and to reduce the construction cost. The main source of construction material for the remaining part of the RSF embankment was selected to be mine waste. The RSF was designed to be constructed in stages by considering the availability of mine waste according to the mining schedule. The use of mine waste for construction of RSF embankments has several benefits over use of borrowed material. These include less construction costs and less disturbances to the environment, by minimising borrowed areas and waste dump footprints.CITATION:Wanninayake, A, Novello, E and Gillani, I, 2013. Effective use of mine waste in the design of a residue storage facility, Pilbara region, Western Australia, in Proceedings Iron Ore 2013 , pp 39-44 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By R Bertuzzi

Permanent rock bolts in civil engineering are taken as having to serve their design purpose for at least 50 years. In many projects the design life is specified as greater than 100 years. A review of recent Australian tunnelling projects shows that substantial differences exist in the level of corrosion protection provided for permanent steel shafted rock bolts. This paper reviews the current state of practice and sets out what the authors consider to be appropriate requirements for corrosion protection.

Jan 1, 1999

By H. Stigzelius

FINLAND'S recent mining history is both dramatic and pitiful in its shifting fortunes, dominated as it has been, by the country's proximity to the border zone of opposing dictatorships and social traditions; Fascism to the south, Communism to the east, and Democracy to the west. After 108 years under Russia's more or less harsh rule, Finland gained its democratic independence during the 1917 revolutionary strife in Russia with the official help of Germany and spontaneous help of other neighbors. The young nation was attacked by Russia in 1939 and again in 1941. It is common knowledge how the Finns fought with everything they had and everything they could get against their overwhelming adversary, and how by force of circumstances they landed in the Axis camp in 1941. Finland has never been known as a mining country in the same way as near-by Sweden, whose abundant iron and copper smelters during long periods so greatly contributed to the nation's welfare. Its largely barren, Archaean-granite geology long seemed forbidding. Some mining was done, to be sure; copper and tin at Pitkaranta near the Russian border, and lead and copper at Orijarvi. But towards the end of the last century the absence of a single producing mine cast a pessimistic shadow of truth over the Finnish poet Runeberg's words, that

Jan 1, 1946

By Seong-Ho Ha, Shae K. Kim, Young-Ok Yoon

In the this study, surface segregation of Mg and Ca with Mg addition range from 5 to 10wt% in Al-Mg alloys with Mg+Al2Ca master alloy and its effect on the oxidation resistance were investigated. The addition of Mg+Al2Ca master alloy as the Mg alloying element led to the surface enrichment of Mg and Ca during high temperature oxidation. As a result of the oxidation test by TGA, the oxidation resistance of all the examined alloys was significantly improved with increasing Al2Ca content. The weight change of Al2Ca added Al-5Mg and Al-7.5Mg alloys indicated the complete oxidation resistance during the whole oxidation test time, while a slight weight increase was shown in the case of Al-Mg alloys even with Al2Ca addition. The improvement of the oxidation resistance in Al2Ca added alloys may be attributed to the formation of the protective oxide layer mixed with CaO and MgO on the surface.

Jan 1, 2015

By D Michaelsen, S Miller

The Grasberg Mine is a copper and gold open pit mine operated by PT Freeport Indonesia (PTFI) and located in the high equatorial mountains of the Indonesian province of Papua. The climate is alpine/subalpine with little seasonal variation in temperature or rainfall. The daily average temperature ranges from about 2¦C to 14¦C and the annual rainfall in the vicinity of the mine and overburden stockpiles is about 4000 mm to 5000 mm. Mining of the Grasberg open pit will continue until 2014 at which time approximately 2750 Mt of overburden will have been produced. Current overburden production rates are 200 Mt per annum. The current mill rate is 230 000 t/day from the Grasberg pit (190 000 t/day) and the underground operations (40 000 t/day). The acid rock drainage (ARD) issues associated with overburden from the Grasberg operations were identified early in the mining operation. Almost all overburden placed to date has been Potentially Acid Forming (PAF). Laboratory testing has identified four main overburden types: limestone and non-acid forming (Green waste), PAF low capacity (Blue waste) and PAF high capacity (Red waste), and Heavy Sulfide Zone (HSZ), which contains greater than 20 per cent pyrite. Waste type block modelling indicates that at least 30 per cent of the overburden production from 2003 to the end of Grasberg pit operations will be limestone. Strategies are being developed to maximise the beneficial use of limestone through strategic blending and placement for ARD mitigation and control.

Jan 1, 2003

By Francis B. Gularte

The Dalles Dam is located 192 miles upstream from the Columbia River?s mouth. As part of an effort to increase survival rates for young salmon migrating downstream to the Pacific Ocean, a river spillwall was constructed to guide the young salmon into the thalway and out of the reach of predators. The spillwall consisted of 43 large precast concrete cells constructed onsite. The 120-ton cells are positioned on the bedrock riverbed to form the 830-foot-long spillwall. Large capacity post-tensioned strand anchors extend through ducts in the precast units, anchoring the wall to the basalt. One hundred seventy-eight tie-down anchors consisting of 30, 32, or 40 strands were installed and post-tensioned to secure the cells. The logistic and technical challenges presented by positioning, installing, and stressing the precast cells in the tailrace of a large dam required a high level of cooperation and planning between the owner, general contractor, subcontractors, and suppliers in order to finish the project within the allotted in-water work windows to minimize impacts on seasonal salmon migration.

Jan 1, 2010

To produce high quality castings, one must monitor the melt quality by evaluating such parameters as the grain refinement and silicon inoculation and modification during the production of the commercial casting. Thermal analysis is a tool one can use for both monitoring and providing input to the process control of the operation. The current technique of performing thermal analysis in commercial foundries is to pour a relatively small quantity of the molten aluminum alloy into a sampling cup and to then acquire the cooling curve. This approach is somewhat simplistic in that one has limited control of the cooling rate and hence the solidification rate of the sample. Moreover, this process requires a fair amount of user intervention and effort. In the past, studies have been conducted in an attempt to develop a system for conducting thermal analysis in-situ. In a study at McGill University, an alkali based heat pipe system was developed for conducting thermal analysis in-situ. While the concept was deemed as very desirable, the complexity of the equipment and procedure was a substantial negative component. In order to improve the technique of accomplishing real-time thermal analysis with an in-situ probe, a new method that is based on McGill heat pipe technology was developed. In the new system, a controllable and flexible water based heat pipe probe is used to solidify a small quantity of metal while residing in the melt. The solidified aluminum is remelted after completing the thermal analysis. This is a key feature of the probe. It resides permanently in the melt yet it is able to both solidify a sample of the melt and then to subsequently remelt it. Various solidification rates encountered in commercial castings are attainable by adjusting the heat extraction rate of the unit.

Jan 1, 2004

By M. Kamyab

The Deep Exploration Technology project, as part of the Australian Cooperative Research Centre, is developing technologies to drill deep boreholes for mineral exploration purposes. The aim of the initiative is to transfer drilling technologies from oil and gas into mining applications. Several modifications have to be pondered due to this technology exchange: smaller cuttings sizes because of using impregnated diamond bits; narrower annulus space; higher drilling fluid velocity and likelihood of turbulent flow regime in the annulus; and higher pressure loss. In particular the results of our lab experiments have shown that the increase in concentration of small size cuttings can significantly change the rheology of the mud when drilling in hard rocks. This, in return, could have a noticeable increase in the pressure loss encountered along the annulus space. As a continuation of the above study, numerical simulations were conducted to investigate the cuttings transport behaviour in small size annulus space. Fluid velocity, annulus size, cuttings concentration, cuttings density, and cuttings size were some of the parameters that were varied to see their effects on cuttings transportation and the pressure loss along the annulus space. The results indicate that, due to the differences between oil and gas and mining drilling, conventional oil well planning is not applicable for mineral exploration drilling and numerical simulation would help in this matter.

Aug 1, 2013

By Samara Sâmid Aguiar Correia

A crescente necessidade por resultados de análises laboratoriais dentro das indústrias são cada vez mais exigentes em termos de tempo de resposta e precisão. Aliado a isso, a elevação do volume de minério de ferro exportado e o aumento da variabilidade desses produtos requerem processos cada vez mais rigorosos e tomados de decisões mais rápidas. Nesse contexto, os analisadores on-line têm um papel fundamental, pois atendem tais exigências, além de preservarem a segurança operacional. Este trabalho tem por objetivo mostrar o desenvolvimento da implantação de analisadores de umidade on line na descarga dos vagões da Vale no Terminal Ponta da Madeira. A metodologia utilizada na medição de umidade dos analisadores usa o princípio de transmissão de micro-ondas, que é a melhor tecnologia disponível no mercado para este fim. Dentre as etapas de implantação, que abrange desde a aquisição dos equipamentos até a avaliação dos controles e ajustes operacionais, é mostrado o período de cada etapa, os problemas encontrados e as soluções adotadas. Em suma, atualmente há medição de umidade on line na descarga deste site e está em fase de implantação a análise durante o carregamento do embarque para controle de processo.

Aug 1, 2018

By Phil Allen

A synthetic fiber manufactured by one chemical company has been treated by another chemical company to produce a cloth fabric capable of performing ion-exchange functions. Only a few delimiting parameters have been established. This paper will discuss briefly the highlights of a functioning ion-exchange cloth. Throughout the paper this fabric will be referred to as "Fabric Z".

Jan 1, 1970

By Charles Hardy, George D. Cremer

POWDER metallurgy has been established for some time as a novel method for manufacturing a great variety of articles generally specialties that could not be made conveniently by any other method. In this category are such parts as porous hearings cutting tools of sintered carbides, and electrical contacts in which the metallic constituents do not tend to alloy in the proportions employed. The industry, however, is now at a stage where it has begun to manufacture articles that can and have been made by other methods. Thus, powder metallurgy is now preferred technique for the production of numerous machine parts characterized by high strength, accuracy of configuration, and substantial lack of porosity. Manufacture of such machine parts from metal powders has no doubt been stimulated by the war, although the trend in this direction has been apparent for several years. In any case, quantity production of high-density precision pieces by ponder metallurgy is now in full suing in the United States, and such production can and should continue to expand during and after the war.

Jan 1, 1942

By Ken-ichiro Uemura

"The DIOS process has been developed for eight years since 1988. The research project was started with the element studies carried out by each of the five integrated steel making companies in Japan, the final two and half years were spent for the pilot plant studies. Operation were conducted in the entirely closed and pressurized system successfully as planned. From the result, the DIOS process was proved to be viable as a future iron-making process substitutable for the conventional blast furnace. In addition, a lot of findings were obtained. Hot metal productivity was primarily determined by a oxygen flow rate, and a coal consumption varied depending on the productivity. The post combustion ratio was a little lower than expected from the result of the element study. It was supposed to relate the gas-reforming with coal or volatile matter in the free space of the furnace. Hot metal carbon content seemed to depend on the char content in slag.INTRODUCTIONThe JISF's DIOS pilot plant (DIOS=Direct Iron Ore Smelting Reduction Process) has finished its last campaign of the operations in January 1996. The project was started in 1988 as a joint research of the Center for Coal Utilization, Japan and the Japan Iron and Steel Federation (JISF) with a subsidy for promoting coal productions and utilization technologies from the Agency of National Resources and Energy, the Ministry of International Trade and Industry(MITI). Throughout the pilot plant test, a total of over 20,000 tons of hot metal was produced for more than 2,000 hours of the operation. Recorded production rate was 538 ton/day for 3 days at a specific coal consumption of approx. 1,000kg/hmt. Long-term operation was carried out in the fifth campaign for 18 days, which has proved that the entirely closed and pressurized DIOS process works well as planned. In Figure 1 is shown the representative operational performance obtained in the first five campaigns. The project is going to be finished by the end of March this year after investigating the technical viability and economic potential of the process, and completing the conceptual design of the DIOS commercial plant. In this paper, the system and facilities of the DIOS process are first introduced and some of the results of the pilot plant test are detailed later."

Jan 1, 1996