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By Mohamed Ahmed, A. Kawy

"Smelting of scrap copper and residual anodes and cathodes carried out in a reverberatory type furnace. In this, deoxidation process is carried out by wood, which acts as a resource of reduction gases such carbon monoxide, hydrogen and methane. Use of wood causes the formation of soot pollutants and efficiency of oxygen removal from copper is low leading to added costs in removing contaminants. This expensive problem was solved by using of reformed natural gas as a source of reduction gases (CO+ H2).IntroductionThree reverberatory furnaces were used for smelting of scrap copper and residual anodes and cathodes. Each furnace had a 7tpd capacity and was operated at 1183 °C.In this furnace, Step1-compressed air supplied by tubes from the side of the furnace to remove sulfur from copper matte by oxidation .The copper is also oxidized to copper oxide .[1]Step 2- copper from matte is deoxidized by a reductant. Typically deoxidation process is carried out using wood as a resource of carbon monoxide, hydrogen and methane which are the reduction gases. Use of wood causes the following:1- Forms soot pollutants2- Oxygen removal efficiency from copper is low; more contamination in copper matte increased energy in deoxidation3-the process is highly expensive.In the recent trends, this problem has been solved by using reformed natural gas as a source of reduction gases (CO+ H) .This results in 1-Reduced pollution during smelting.2- High efficiency in the removal of oxygen from copper to produce oxygen free copper. The surface of copper produced from this method is smooth which helps in forming and machining.3- Low cost and natural gas is more readily available in Egypt than wood."

Jan 1, 2010

By Anne Lemnitzer

Full-Scale cyclic field testing was performed on a 3x3 pile group consisting of nine cast-in-drilled-hole (CIDH) reinforced concrete shafts and a comparable single-shaft in order to investigate group interaction effects. Both specimens were constructed with pile diameters of d = 0.61m (2 ft), fixed head boundary conditions, and placed in stiff clayey soil at a test site near the LAX Airport in Southern California. Internal instrumentation was installed in the single pile as well as in three piles within the pile group to obtain pile curvatures. External instrumentation controlled the lateral displacement of the specimens. A combination of experimentally and analytically obtained p-y curves for the single pile was used to simulate results for piles located in the group when field data were not available. All test specimens were tested to structural failure and excavated after test completion to investigate pile damage and plastic hinge formations. Calculated group interaction factors ranged between 1.0 at very small displacement levels of <2.5 mm (0.1 in), 0.8 at the initiation of the pile-soil-pile interaction, i.e. between 4 mm - 15 mm (0.16-0.6 in), and increased towards 0.9 near structural failure (displacement >25 mm or 1 in). A literature set of p-multipliers was found to reproduce an accurate fit to the available load displacement test data from the group.

Jan 1, 2010

By Xiaobing Yang, Animesh Jha, Greg Doughty

"Successful use of inert anodes should reduce the CO2 footprint in aluminum production. The search for a “holy grail” inert anode for metal electro-winning from constituent oxides using molten salt bath as an electrolytic medium is continuing. In this article we demonstrate the engineering approaches for the fabrication of intermetallic anodes, based on a quaternary Al-Ti-Cu-M (M:Ni, Fe) system for primary aluminium production. In particular, we examine the microstructural and electrochemical properties of alloys, based on the quaternary compositions. We explain the aspects of phase stability under anodic potential, which leads to the loss of anodic materials in the temperature range of 850-1050oC. The results are analysed in the context of oxidation reaction and formation of oxide layers which readily dissolve in the cryolite melt and prevent passivation. The paper also describes the conditions under which the reduction of aluminium at the graphite cathode occurs which also strongly depends on the molten salt chemistry for the nucleation of molten aluminium at the cathode.1. IntroductionOxygen-evolving inert anodes are an alternative to the conventional consumable carbon anodes for the production of primary aluminium. In this paper the materials selection criteria chosen for the engineering of anode is based on the understanding of the thermodynamic stabilities of aluminide intermetallic phases, some of which are formed and remained stable in fluoride melts. For example, the formation Al3Ti dispersed in aluminium metal via molten-fluoride flux reaction is well known in the context of aluminium casting and grain refining [1-3]. It is for this reason in our research we concentrated on the engineering of stable intermetallic phase mixture in the Al-Ti-Cu ternary system, shown in Figure 1 [4]. In this figure two compositions in the Al3-0.5zTi1-0.5zCuz family are shown with the substitution of 7 atomic % and 11 atomic % copper. However initial investigations showed that these two compositions were unsuitable due to the formation of low-temperature liquid (~540oC) and intermetallic phase, Al2Cu along the Al-Cu binary edge during solidification. The Al2Cu phase segregated along the boundaries of Al3Ti and Al5Ti2Cu, and dissolved away when electrolysis was carried out using these anodes above 800oC. The presence of consequential porosity in the anode material increased the corrosion of the alloy through local heating due to high current density at 0.8 A cm-2. The early tests were carried out with cryolite melts, shown in Figure 2, having 3 weight percent of Al2O3 in the bath at 850oC."

Jan 1, 2010

By E. Spencer

Overexposure to hazardous noise has been found in most mining sectors, with up to 100% of the surveyed workforce experiencing a noise dose over the Mine Safety and Health Administration (MSHA) permissible exposure level (PEL). As a result, miners show elevated rates of hearing impairment of 70-90% by retirement age. To help manage noise exposures, the National Institute for Occupational Safety and Health (NIOSH) developed the Determination of Sound Exposures (DOSES) software and implementation guide for use by mine management and safety personnel. The software relies on a time-motion study that profiles the worker?s daily activities. Observations about the worker?s location and tasks or other activities are recorded along with the start and end time, to determine the duration of the tasks, so they can later be matched up with the noise data. The software gives the user the option of assessing dose relative to the MSHA PEL, the Action Level or the NIOSH Recommended Exposure Limit. The software generates a variety of interactive onscreen displays showing where, when, and how the worker?s noise dose accumulated. It also can generate customizable printed reports. These outputs can be used to highlight the tasks, locations, and times that are associated with the greatest amount of the worker?s noise exposure. DOSES simplifies the record keeping and analysis associated with time-motion studies and worker noise exposures, so mine management can make engineering noise control or administrative control decisions to limit the noise over-exposure of their workers.

Jan 1, 2010

By S. Ahmed

Critical factors of selection, fabrication, installation, and splicing of prestressed concrete piles are discussed based on experiences with coastal subsurface conditions of the United States of America (USA), and the People&apos;s Republic of China (PRC). Segmented Prestressed Concrete piles are economical when compared with other pile types of comparable capacity. However, strict quality control measures are required.

Jan 1, 2010

By J. R. Rodda

Stainless steels are widely used to handle concentrated sulphuric acid (H2SO4) solutions produced in the manufacturing process, The majority of corrosion rate data published for stainless steel in product acid conditions is typically complied in tables or in iso-corrosion diagrams (iso-corrosion rates plotted as a function of temperature and H2SO4 concentration), without any reported consideration as to the accuracy and relevance of the method used to obtain the data, Given the characteristic potential cycling associated with the active-passive corrosion behaviour exhibited by stainless steel in hot, concentrated H2SO4, weight loss is considered to be a more reliable method than electrochemical measurements to measure corrosion rates, Consequently, an effort is made herein to demonstrate the accuracy and relevance of weight loss to determine laboratory corrosion rates in product acid conditions.

Jan 1, 2010

By M. Kamali

In this research, in order to predict the peak particle velocity (PPV)(as vibration indicator) caused by blasting projects in the excavations of the Karoun III power plant and dam, three techniques including statistical, empirical, and neural network were used and their results were interpreted and compared. First, multivariate regression analysis (MVRA) was used as statistical approach. Next, PPV was predicted using some widely used empirical models. Lastly, an artificial neural network was used. In the ANN model, maximum charge per delay, total charge per round, distance from blast site, direction of firing, blasthole length, number of blastholes, total delay in milliseconds, number of delay intervals, and average specific charge were taken into consideration as input parameters and consequently the PPV as output parameter. The results of the techniques were interpreted from two points of view. Firstly, the correlation between the observed data and predicted ones, secondly the total error between observed data and predicted ones. The MVRA had a satisfactory correlation but its error of estimation was comparatively very high. The empirical model had reliable correlation and a small error of estimation; in total the results of empirical method were more reliable than those of MVRA. Generally, the ANN approach showed very high correlation and a very small error. The results of this research indicated that the ANN model is the best predicting model for PPV in comparison with other approaches.

Jan 1, 2010

By Mike de Wit

Of the approximately 6,500 kimberlites known to date, less than 3% are diamondiferous and less than half of those are economically viable. Admittedly, this is a global figure and varies from area to area much depending on geological, logistical, and political circumstances. The number of diamond-bearing kimberlites is an important geobarometer, and an age-frequency profile has been compiled in order to identify diamond metallogenic epochs and provinces. Four primary diamond clusters have been recognized: Siberia (332-370Ma), Kaapvaal South(114-144Ma), Kaapvaal Southwest(84-95Ma), and Slave (52-55Ma). In addition, three secondary clusters are the Kaapvaal Central (S06-S38Ma), the Man Craton (139-lS3Ma) and the Kasai Craton (120-130Ma). The Kaapvaal is the only area where kimberlites with diamonds were discovered between 1870 and 1925, except for the Prairie Creek discovery in North America in 1906 and Colossus in Zimbabwe in 1907. Between 1906 and 1940 no major diamondiferous kimberlites were discovered, but many of Africa&apos;s alluvial deposits were found and exploited in that period. Advances in scientific prospecting in the 1940&apos;s rapidly accelerated the discovery rate that peaked in the 1990&apos;s; 39 diamondiferous occurrences were found in the 1980&apos;s, of which 8 became mines and 5 are in feasibility, and nearly 450ha of kimberlite was added to the global resource base. Despite the accelerated exploration expenditure, the last decade (e.g. 2000-2009) has been the leanest since the 1940&apos;s. The most important reason for this decline in exploration success is that any undiscovered deposits are largely buried by younger cover. Understanding complex and geophysical noisy basement geology, as well as decomposition of path-finder minerals are major challenges to further exploration success. Major investments in basic geological expertise and field research will have to be made in order to secure future diamond resources. Integrated geophysical studies, geochemistry diamond forensics, and improved imaging of Earth&apos;s upper mantle are perhaps foremost in this requirement, but the costs of these activities are such that government support will be required if countries are to sustain their diamond mining industry.

Jan 1, 2010

By Jeongbok Seo

The Dulles Corridor Metrorail Project (DCMP) involves the design and construction of a 23.1-mile extension of the Washington Metropolitan Area Transit Authority (WMATA) rail system. The initial 11.7-mile extension, with five transit stations and a new service and inspection yard, is to be constructed. The construction plan for the initial 11.7-mile extension includes installation of a total of an estimated 4,250 or 160,000 linear feet of driven 12x53 steel H-Piles at more than 80 different locations. At the time of this paper, approximately 40 percent of the piles have been installed and the remainder of piles will be installed by the end of 2010. This paper describes: 1) subsurface investigation program, 2) application of existing Codes and impact on the design of H-Pile, 3) design methods to determine geotechnical bearing capacity and pile tip elevation, 4) verification of capacity including PDA and Static Load Tests, 5) project specific pile load tests, and 6) QA/QC during pile driving.

Jan 1, 2010

By Linruo Zhao, Qi Yang, Akihiro Sato

TiN coating has a wide range of tribological applications from wear reduction of cutting tools to erosion protection of gas turbine engine compressor components. The performance of TiN coating depends on its microstructure, mechanical properties and adhesion strength which are influenced by the coating deposition process. In this study the effects of cathodic arc deposition conditions on the microstructure, hardness, adhesion and erosion resistance of TiN coating were investigated experimentally. It was found that varying deposition temperature, substrate bias and N2 pressure could derive a processing window in which TiN coating with superior erosion performance can be fabricated.

Jan 1, 2010

By Robert J. Timko

In early June 1986, an underground fire of unknown origin erupted in one of several entries of a coal mine located in southwestern Colorado. For a time, mine personnel aggressively fought the fire. However, control of the fire was later lost. To prevent further damage and reduce the possibility of an explosion, all portals and shafts to the mine were sealed. The mine operator requested the U.S. Bureau of Mines&apos; assistance in obtaining and analyzing mine fire gases taken from sampling ports placed through the mine seals, as well as down boreholes drilled after the fire. This report recounts activities within the first 2 years of the mine being sealed. It includes a description of gases analyzed and mine atmosphere status equations generated from the analyzed gases. The gases were analyzed by chromatography and included standard atmospheric gases as well as higher hydrocarbons that are found in postfire atmospheres. Nine equations were used to evaluate what was occurring within the sealed mine. Following a description of the rationale behind each equation, the 2-year trend is briefly analyzed.

Jan 1, 2010

By G. M. Cresswell

The 2 360 t/h two module Phola coal preparation plant represents anew era of large plant in the Witbank coalfield designed to extend its life to 2020 and beyond. The plant uses the optimum processing model for Witbank coals, receiving a feed coal size of -50 mm, wet screening it into coarse and small coal fractions 50 x12 and 12 x0.63 mm before processing them in parallel through two primary DM cyclone sections, in order to make a 27.5 MJ/kg export floats product. The sinks are processed through a common high density DM cyclone section to produce a 21.5?23 MJ/kg thermal coal middlings product. The plant design incorporates the largest size DMS equipment used to date in South African coal preparation plants, i.e. 1 150 mm large diameter pump fed DM cyclones and 4.2 m width banana screens. The fine coal is conventionally processed by spirals, whereas the raw coal slimes are filtered using automated plate and frame filter presses and added to either the middlings or discards depending on its quality. The paper describes the database, innovative design concepts, construction, and commissioning.

Jan 1, 2010

By J. R. Bartels

The U.S. Bureau of Mines has established a wire rope research laboratory to examine the factors that affect the life of wire rope. Two sin-diameter 6x25 fiber core (FC) ropes were degraded on a bending fatigue machine, These were the second and third ropes in a series of tests on this construction and size rope. Tensile and nondestructive tests were performed on samples of the rope to determine the relationship between rope deterioration and rope breaking strength. The tests indicated that once a wire rope nears the end of its service life, both deterioration and the consequent loss of rope strength begin to increase at an accelerated rate.

Jan 1, 2010

By William J. Wuest

The technical analysis of parameters that can influence roof and rib reinforcement is important to the operation of safe and profitable underground mines. One such parameter, studied in this U.S. Bureau of Mines investigation, is the effect of time on untensioned, resin-grouted bolt anchorage characteristics. A group of seventy-three 4-ft-long bolts with three different grout column lengths were I installed in a stable coal mine roof. The bolts were then subjected to standardized pull tests at various intervals throughout a 37-month period. For each test, load-deformation data were reduced to determine axial stiffness and yield point. The magnitudes of these two anchorage characteristics at the time of installation were compared with results from subsequent pull tests to determine if anchorage capacity deteriorated. Bolts with 18-in grout columns were studied over 9 months, and no measurable loss occurred. Bolts with 48-and 24-in grout columns were studied over 37 months and also exhibited no measurable loss.

Jan 1, 2010

By Jay F. Colinet

Longwall mining in lower seam heights may necessitate the use of single-drum shearers to overcome size constraints associated with standard double-drum shearers. To avoid the operational problem of clearance in the tailgate entry with one single-drum shearer, two single-drum machines can be operated on the same face, with each shearer responsible for mining a predefined portion of the face. However, utilization of two shearers on the same face necessitates the positioning of one shearer operator and a jacksetter in the return air of the upwind shearer, thus complicating respirable dust control on the longwall. In an effort to evaluate the unique dust control problems associated with this type of mining, the U.S. Bureau of Mines conducted dust surveys on two multiple-machine longwall operations. Sampling was done to quantify major sources of respirable dust and to identify potential solutions to problem areas. Sampling results indicate that the cutting sequences utilized on multiple-machine faces may have to be designed to minimize dust exposure, as opposed to optimizing productivity or facilitating operational requirements. Also, state-of-the-art dust control techniques typically found on double-drum shearer longwalls must be employed to help minimize the exposure of all face personnel to traditional dust sources.

Jan 1, 2010

By Lance A. Roberts

Expansive soil formations can be found throughout the United States. When subjected to wetting, these formations have the potential to swell and exert large uplift forces on buildings and foundations. Lightly loaded structures, such as single family residences founded in areas of expansive soils, can be significantly damaged due to uplift movement from swelling actions. Designing an economical deep foundation that can resist uplift forces is critical to prevent damage to these structures. The current solutions to control uplift due to swelling soils, such as over-excavation and replacement of the expansive material or the use of drilled shafts can be costly. Piles made from recycled polymer materials could provide a solution. Due to a lower coefficient of friction along the interface of the soil-pile interface compared to traditional pile materials, solid recycled plastic piles can allow expansive soils to move nearly independently from the pile when wetted. This results in a much smaller magnitude of uplift force being transferred to the structure, which minimizes the risk of significant structural damage from excessive movements. This paper presents the results of research conducted on the use of recycled plastic piles in an expansive shale environment. The preliminary phase of the project involved the installation of six recycled plastic piles at a test site on the South Dakota School of Mines and Technology campus. Two of the piles were subjected to a full-scale compression load test in order to determine ultimate capacity. The remaining four piles were subjected to long-term monitoring of uplift movement during the course of the project. A concrete anchor was also installed at the test site for uplift monitoring. Data gathered during the field and laboratory testing was utilized in a non-linear soil-structure interaction model to predict the displacement behavior and internal stresses within a plastic pile and concrete anchor subjected to uplift forces from the swelling shale. While more research is needed to further understand the application for recycled plastic piles, the results from this research indicate that their use is a viable alternative for support of lightly loaded structures in expansive soil environments.

Jan 1, 2010

By C. -J. Rick

The ferroalloy market is characterized by a very long communication distance between the consumer and the producer. This has created a situation where it has been difficult to change ferroalloy properties. In this paper different FeNi and FeCr-compositions are discussed and their merits for stainless steel-makers in different situations are compared using the process models applied at Outokumpus Avesta works and Acerinox&apos;s Columbus operation Keywords Ferroalloy design, ferrochrome, ferronickel, stainless steel making, UTCAS software.

Jan 1, 2010

By Braden Lusk

The problem of predicting damage in densely developed areas due to incidental or malicious explosions is one of considerable importance to local, state, and federal governmental bodies. The difficulty of making such a prediction is confounded by the urban canyon phenomenon as the shock wave intensifies or rarefies depending upon the particular arrangement of buildings. The specific method detailed herein used a Computational Fluid Dynamics solver, ANSYS AUTODYN, to operate on Geographic Information Systems data, ArcGIS, which captured the geospatial relationship between the various buildings in downtown Oklahoma City, prior to the Murrah Building bombing. The model of Oklahoma City was first developed using the building footprints and elevations provided by the ArcGIS database. Due to the sheer size of the problem, the model was then subdivided into annular zones of increasing distance from the center of the blast. Each subsection was then solved using an Euler model in a cascading fashion with the output of the preceding model forming the input of the present model. To further reduce computational time, the size of the Euler nodes was increased at each stage as the section area increased. Due to the loss of precision in capturing peak pressure values when using larger size nodes, it was necessary to perform a transformation on the results using one dimensional wedge calculations with higher precision. The Murrah Building bombing event was an excellent case study due to its available ArcGIS data and the level of documentation of damage to surrounding structures due to the blast. The results from the staged CFD calculation were then used to develop a damage potential contour map. The documented incidents of damage in the area surrounding the Murrah building were then compared to the model generated damage potential contour map. Copyright ©

Jan 1, 2010

Caissons hand dug to a depth of about 100 feet were used to underpin three important structures at an industrial site in the State of Utah. The caisson shafts extended through 30 to 40 feet of coarse, granular soils and 25 to 60 feet of sands and clays to bear on a very dense, coarse gravel and cobble stratum near the water table. The shafts were belled to 12 feet square at their bearing elevation. Bearing pressures of 20 ksf were assigned. The shafts were lagged with timber. The use of hand-dug caissons allowed continuous operation of the facility during underpinning. Settlements after underpinning have been minor and well within the estimated magnitudes. Instrumentation was placed in two of the caissons with varying degrees of success.

Jan 1, 2010

By Tetsuo Yamazaki

Seafloor massive sulfides have been a subject of interest for profitable commercial mining these ten years. Because of the higher Au, Ag, and Cu contents, they have received much attention as immediate commercial mining targets by private companies and nations. Some of them already proposed the technologies necessary for the commercial mining. However, the technologies for survey, excavation, lifting, and ore dressing have not yet well been examined from viewpoint of the economy. In this presentation, the authors present some key factors and improvements for better economy in the mining.

Jan 1, 2010